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Founded in 1968, METALSISTEM commenced itsactivities specialising in the design and produc-tion of machinery for the cold profiling of metals.The experience gathered, numerous highly inno-vative patents resulting from intense research anddevelopment and the considerable market successof the first range of cold form zinc coated profilesquickly channelled METALSISTEM into the pro-duction of the latter of its activities.Today the METALSISTEM Group is an articu-lated network of companies with its head officeand main production facility in Rovereto, Italy. TheGroup has consolidated its position as one of themajor industries within the Material HandlingSector.Through products and services aimed at provid-ing complete assistance for all warehousing, prod-uct showcasing and sales outlet requirements, thecompanies of the METALSISTEM Group are ableto offer their customers a wide range of productsof the highest quality, highly competitively priced,with very rapid delivery times and a first class backup service, as well as tailor made solutions pro-viding efficient and rational use of internal stor-age areas and material handling environments.Lightness, strength and modular form, coupledwith the ease of integrating and expanding alreadyexisting structures are but a few of the successfulfeatures of the METALSISTEM storage and shelv-ing systems.The success of the METALSISTEM Group is theresult of a precise managerial choice based on re-search of new production technologies and con-tinuous development and innovation of its prod-uct range. A direction which has produced numer-ous international patents (testament to the unique-ness of the METALSISTEM product), continuingimprovements in safety, quality and versatility.

METALSISTEM’s company strategy is to offerproducts of the highest quality, very competitivelypriced, with rapid delivery times backed up by afirst class service.The numerous product lines are conceived and de-signed by METALSISTEM’s internal Researchand Development Centre, as are the profiling linesand equipment required for their manufacture.The automated production facilities for the coldprofiling of metals have enabled METALSISTEMto achieve one of the highest levels of productiv-ity in the world, today. Rigorous laboratory testsare conducted on the prime material entering pro-duction, and on the final product, thus ensuringthe continuing evolution of efficiency and qualitystandards.All products have elevated structural characteris-tics and ensure high quality standards recognisedby the most important European certification bod-ies, such as Germany’s TÜV Product ServiceGmbH, Austria’s Ö-NORM, Rome’s I.S.P.E.S.L.,ACAI/CISI (Associazione Costruttori AcciaioItaliani - Sezione Costruttori Italiani di ScaffalaturaIndustriale), the latter of which METALSISTEMhas membership, and others. The company’s ISO9001 quality assurance system is certified by IGQ.With an annual turnover of exceeding 260 MillionEuro, the METALSISTEM Group premises oc-cupy a total area of 200.000 m², 120.000 of whichare dedicated to production. The METALSISTEMGroup affiliated companies and distributors pro-vide a world wide commercial network coveringthe domestic market and the industrialised nationsof the world, able to satisfy the most demandingneeds.We value greatly the high level of trust that isplaced in us by our customers and feel that it isproof of the quality and reliability of our products.

THE GROUP

SAFETY STANDARDSAND CALCULATIONASSUMPTIONSThe correct use of a product, distinguishesboth the Customer and the Manufacturer.METALSISTEM recommends that Custom-ers make use of their product in strict conform-ity with the design characteristics given andstandards of best practice.The design and assembly of the racking sys-tems must be carried out by qualified person-nel.METALSISTEM is not responsible for any im-proper or inappropriate use of its product.

a) Floor slab loading.Prior to installation of the product, check that thefloor slab is of adequate load capacity.b) Site installation.The site installation of racking systems must becarried out by expert personnel following the as-sembly criteria and specifications tabled in thiscatalogue and in the SUPERBUILD TechnicalReference Book. Site personnel must ensure thatall frame bolts have been tightened and all safetyelements have been installed.c) Rack alignment.While assembling the racking system, the verti-cality of the frames must be checked for both the“X” and “Z” directions. Unless more restrictivestandards have been specified, the deviation ofboth the “X” and”Z” planes must not exceed ±

10 mm or 1/350 of the height (ie max.deviation =H/350), whichever is greater (figure 1).d) Load bearing capacity plate.Load bearing capacity plates must be fastened ina clearly visible position nominating the modeltype, year of assembly, load bearing capacity ofthe frames, load bearing capacity per pair of beamsor per shelf (expressed as a uniformly distributedload), the load unit applied, the height of the firstlevel from ground and the number of levels (fig-ure 2).e) Rack safety standard.Rack structures must be fastened to the floor slabvia two anchor bolts for every upright.In cases where the height of the frame is:- more than 5 times the depth, for single-sidedracking;- or, more than 10 times the depth, for double-sided racking;that structure must be connected via top ties.The racking structure must also be supplied com-plete with column and/or frame protectors.f) Reference Standards.The theoretical calculation is based on the follow-ing reference standards:- C.N.R. 10011/88- C.N.R. 10022/84Reference standards for the materials are:- EN 10142- EN 10147- EN 10204g) Software references.The theoretical calculations of finished elementswere elaborated with the SICS program. Guidelines followed as the basis for the calculations arethose of the organisation CISI (Association of Ital-ian Manufacturers of Industrial Shelving).h) Frame load bearing capacity.The load bearing capacity graph (Graph 1) in theSUPERBUILD Technical Reference Book showsthe load bearing capacity of frames used for palletracking systems. These are expressed as a func-tion of the height, from ground, of the first pair ofbeams. The following underlying assumptionsapply when interpreting the graph. The rackinghas:- a minimum of 4 consecutive bays of equal length;- a minimum of 3 levels divided equally in height;- an equal and uniformly distributed load has beenapplied to all levels.Given that the load bearing capacity of the rackmay depend on other elements such as, thenumber of levels, the proportion between heightand depth, installation in seismic areas, etc., con-tact the METALSISTEM Technical Departmentfor consultation should there be doubts about anyaspects of the installation.i) Load bearing capacity of beam pairs.The load bearing capacity of the beam pairs werecalculated with the following assumptions:- loads are uniformly distributed;- admissible tensile stress of the material;- deflection 1/200.It is mandatory to place beam retaining securityclips on either side of all beams.l) Custom built applicationsThe METALSISTEM Technical Department is atthe disposal of its customers for any specific cal-culations or custom built applications.

METALSISTEM reserves the right to modify thetechnical characteristics of its products at any timeas it sees fit.Technical data, dimensions and characteristicsgiven in this document are indicative only.

fig. 1

Ref. no:

System:

Year of Construction:

Frame Load Capacity:

Load Capacity of Beams:

Weight of Load Unit:

Distance betweenN° levels:

ground and first level:

2

fig. 2

height

n° of spacer bars

SUPERBUILD 1451998

12500 Kg

2500 kg

800 kg

m.1 5

To achieve the stated frame load bearing capacities, frames should be built in strict accordance with the assembly diagram above. Three bolts 8x20 mmshould be placed opposite to the short diagonal crossings, respectively at the height of 528, 928 and 1328 mm, as shown on the left.

DIAGRAM FOR ASSEMBLINGBRACING OF SUPERBUILDFRAMES

SUPERBUILD systems are made

from high tensile steel, certified

according to EN 10204 3.1B and

carry the approval mark of TÜV

PRODUCT SERVICE GmbH.

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THE COMPANY TODAYMETALSISTEM products are now in use ina great many installations throughout theworld, and after more than 30 years produc-tion, we value greatly the high level of trustthat is placed in us by our customers andfeel that it is proof of the quality of our prod-ucts. The shelving components are pro-duced on fully automated production lines.The folding and cold processing tech-niques developped by METALSISTEMare designed to obtain light and extremelystrong components. Ligthness, strengthand modular form, coupled with the easeof integrating and expanding already ex-isting structures are but a few of the suc-cessful features of the METALSISTEMIndustrial Storage Systems. Ideal stor-age solutions for a whole host of prod-ucts supplied worldwide are createdhere thanks to a total commitment toresearch and development.The METALSISTEM Technical De-partment is at the complete disposal of itscustomers, to study their individual needsand to propose the most effective solutions.

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THE PRODUCT

SUPERBUILD is interchangeable with the UNIBUILDheavy duty pallet racking and has been designed tosatisfy all the requirements of medium to heavy dutypallet storage.It is available in three different frame load options,varying from 7.5 up to 15 tons.The closed design of the frame upright provides astronger section than that of the standard open “C”profiles used by other manufacturers.The frames are made from prime quality, certified, hightensile hot dipped galvanised steel (procedureSENDZIMIR) , thus ensuring a high level of durability.All the structural components are made from hightensile steel, certified according to EN 10204 3.1B.The beams are profiled sections with quadruple flangethickness at points of maximum stress for high loadingcapability. The grooves on top of the beams are used tolocate modular heavy duty steel shelf panels, palletsupport bars and drum cradles for the storage of nonpalletised or special goods.The welded beam end connector has five anchor points,three of them operating in tension and two incompression, providing a better connection to theupright with increased load capability.The adjustment of beams at intervals of 50 mmfacilitates optimum use of space available.The beams are painted in yellow RAL 1004 (standardcolour) according to the following procedure:• hot wash degreasing and iron phosphate

pretreatment;• application of thermosetting powder paint.• curing at a temperature of approx. 240°C in a force

ventilated air circulation oven.

The design of the various components is the result ofrigorous technical testing and the highly specialisedknowledge developed over years of experience in thefield of metal processing.This experience has enabled METALSISTEM to offerinnovative products of the highest quality, highlycompetitively priced, and to produce a highly technicalsolution to the most important shelving problems, suchas rapid assembly, stability, low cost and load bearingcapacity.

connection of beams

bracing of

SUPERBUILD frames

assembly of

security pins

TENSIONCOMPRESSION

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MAIN STRUCTURALCOMPONENTSThe design of the various components is theresult of rigorous technical testing and thehighly specialised knowledge developedover years of experience in the field of metalprocessing.The components are subjected to regular andrigorous technical tests.The safety and the quality of the producthave always been a primary aim of METAL-SISTEM and are recognised by TÜV PROD-UCT SERVICE in Munich, one of the mostrigorous E.C. commissions in the field ofquality and safety certification.The versatility of METALSISTEM installa-tions makes them suitable for a wide rangeof applications not illustrated here. METAL-SISTEM offers innovative products of thehighest quality, providing highly technical so-lutions to the most important racking prob-lems, such as rapid assembly, extreme sta-bility and strength and utmost cost efficiency.

Heavy duty steelshelf panels H25/H29with flanged tops

Beams used for palletracking or for heavyduty steel shelfpanels to be inset

Heavy duty metalbase plate

Locking pinsfor beams

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Regarding technical data, characteristicsand dimensions, customers should referto the Technical Reference Book of theSUPERBUILD series. Column

protector

Wooden insert forSUPERBUILD upright

ACCESSORIESRegarding technical data, characteristicsand dimensions, customers should referto the Technical Reference Book of theSUPERBUILD series.

Row spacers

Double frame protector

Double frame protector(detail)

Loaddistribution plate

Pallet backstopbeam

Floor mountedguide rail(single and double-sided)

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Bin cradle

Drum cradleDrum wedges

Combined palletsupport bars

Raised palletsupport bar

Lightened secondary beamsFor use in installations equipped withsprinkler systems (shelf surfacewith coverage< 50%)

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DRIVE - INThe DRIVE-IN racking system allows themaximum use of space, and volume dueto the elimination of access aisles.The storage volume is therefore more thandoubled compared with standard palletracking.Two kinds of installation are possible:DRIVE-IN or DRIVE-THROUGH.

Entrance crescentfor DRIVE IN guide rail

Pallet located on theDRIVE-IN guide rail

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For a correct assembly of DRIVE-IN structures,customers should always refer to the DRIVE-INAssembly Instructions.

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DRIVE-IN guide raillocated on a double bracket

Entrance crescentfor DRIVE-INguide rail (detail)

Double sided DRIVE-IN guiderails located on single brackets.

DRIVE-IN guide raillocated on a single bracket

SUPERBUILDNew.Strong.SUPER!

METALSISTEM...we don’t speak aboutthe future...we make it.

NR. EDIZIONE DATA EDIZIONE NR. REVISIONE DATA REVISIONE DATA STAMPA01 1999 03 10/2002 5/2004

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SISTEMI E STRUTTURE PER IL MAGAZZINO

METALSISTEM S.p.A.38068 Rovereto (TN) - Italy - Viale dell’Industria, 2Tel. +39 0464 30 30 30 - Fax +39 0464 30 30 31info@metalsistem.com - www.metalsistem.com