RACKING AND STORAGE

TECHNOLOGY

OMEGA PALLET RACKING

STORAGE TECHNOLOGY FOR EUROPE

GALLER can trace its origins back to

1917 and played an active role from
the very start in the development of
storage technology in Europe.

The GALLER works in Kulmbach

As one of our valued customers you have made GALLER one of the major companies in Europe in racking and storage
technology. We are very grateful to you and feel, at the same time, that we have also been strengthened in our efforts
to provide products of the best quality, the best possible customer orientation and the best possible price.

From our very first rack, made of wood, to the utilisation of steel components for small racks and to the best racking
technology in Europe. GALLER has always had the interests of their customers first and always been to the forefront in
the development of storage technology.

At our works in the Bavarian town of Kulmbach we manufacture our products utilising computer-controlled systems on
a large number of shape rolling mills and machines operating with welding robots, supported by interlinked automatic
handling devices: these methods ensure the greatest precision, efficiency and quality. A particular guarantee of our quality
is the cathodic dip-coating process followed by powder coating that adds the final touch to the top finish.

We are looking forward to being of service to you and can assure you that we will always do our very best for you at
all times.

Coil storage Rack: profile plant Powder coating plant in operation

THE OMEGA SYSTEM: AN OVERVIEW

1 2

5 6 4 3

1 OMEGA racking
2 Racking vertical beam
3 Cross-member, horizontal and diagonal
4 Foot plate with floor anchoring
5 IPG beam with hooks
6 Spacer

The illustrations and pictures do not indicate the actual colours,

sizes or finish. We reserve the right to make changes rendered
necessary by technical improvements.

4
Contents

Omega system overview and specifications 4-5

Omega systems 6-7

Omega multi-position system 8 - 13

Omega single-position system 14 - 17

Omega drive-in and drive-through racking 18 - 21

Standard parts and sizes 22 - 23

System accessories 24 - 27

Specifications

The best possible statics to optimise profile stability: OMEGA standard profile and SIGMA beams or IPG beams
(“I” denotes the shape, “P” denotes profile and “G” denotes Galler).

Welded standard frame constructions for heavy loads with lowest tolerances for automated storage and in racking
silo construction.

Bolted rack designs provide the alternative for standard racking up to a construction height of 12000 mm.

Correctly dimensioned accessories, e.g. corner protector and strips, wire mesh with frames and precision-made
guide rails.

A finishing unit with a cathodic dip coating plant: this finish provides adequate capacity since it measures 12000
(length) by 2200 mm (depth) by 600 mm (width). The OMEGA racking is finished in light grey (RAL 7035) after
a thorough preparatory treatment and final treatment (degreasing, cleaning, activating, zinc phosphate treatment,
dip coating and baking).

Powder coating is offered as an option for customized colouring after pre-treatment

Storage planning design and statics completed by in-house experts.

Competent advice from our sales office staff.

5
OMEGA SYSTEMS

The multi-position system

In each bay there will normally be

2, 3 or 4 pallets (or lattice boxes,
steel boxes, etc.) on one IPG pair
of beams.

With this system there is direct access

to each pallet. This is the standard
system for storage using fork-lift trucks
or high-rise trucks. Thus this system
ensures that space will be well uti-
lised with fewer racks, particularly for
lengthways storage (X access).

The single-position system

In each bay there will be only one

pallet (or lattice box Mesh box, steel
box, etc.) on one pair of deep beams
for crossways inserted pallets.

The height in each pallet bay can be

adjusted separately, if the storage
units are of different heights. The
available space can be best used
to accommodate these heights: of
course there is direct access to each
bay.

The drive-in and drive-through system

These two systems stand out in pro-

viding an excellent use of space,
because 15 pallets or more can
be stored at each level in the chan-
nels.

The drive in system operates from

one side only (First-in Last-out), but
in the case of drive-through system
goods are inserted on one side and
removed from the other (First-in First-
out).

6
Aisle widths and equipment

In this planning draft, we have shown different types of equipment, aisle widths and heights. When a silo is being con-
structed or when high pallet racking systems in a warehouse are planned (≥12000 mm), the planning module must be
rised in height by at least 200 mm to allow for bracing and, normally a sprinkler system.

Up to a construction height of 10000 mm a conventional warehouse is recommended with separately built-in racking.
With a construction height between 10000 and 15000 mm a check must be made in each case to establish whether it
would be better to plan a separate building or a roof and wall bearing racking system (silo). With a construction height
of more than 15000 mm we generally recommend a rack cladded building.

7
THE OMEGA MULTI-POSITION SYSTEM

High-rise storage with

a high-rise truck

Forwarding company storage

with drive-in high-rise truck

Furniture storage with inductively

controlled high-rise truck
8
Example
OMEGA three-bay system with high-rise truck with guide rails for flat, wooden Euro-pallets (1200 mm)
deep stored.

Longitudinal
section

Ground plan

9
THE OMEGA MULTI-POSITION SYSTEM

The system in detail

The pallet station Upper guide rail for high-rise trucks

The station is for pallets hooked in the The upper guide rail with low tolerances at the
first upright positioning. aisle bridges and at the cross-over areas mount-
ed on a cantilever designed racking.

The sprinkler line

Here the sprinkler line is shown running in the
shadow of the beams (horizontally) and of the Racking in a furniture store:
supporting members (vertically). a positioning station
The first section is the receiving station for
roller containers. The racking vertical mem-
bers are separated by a T-frame from the
front so that pallets can be moved easily.

10
System accessories

Special deep beams for crossways inserted

wooden, flat Euro-pallets

Special deep beams that are flat are inserted at a

52 mm support width to hold the wooden flat Euro-pal-
lets stored crosswise.

These beams are deep drawn from one piece and can
be adjusted at the sides if necessary.

Z deep beams

These deep beams have rised edges at the sides to facil-

itate positioning and to preventing pallets from sliding off.

These beams are fixed by clamped joints. They can be

adjusted at the sides to accept different widths.

Cross Beam Support

When the beam-span is wide, each compartment has a

device to prevent tipping. The device is bolted between
the front and the rear beams. It prevents the beam from
twisting.

Drum support

This is welded on. It lies on the pallet beams and is held

firmly by angled profiles. The drum is centred by means
of angle profiles welded on in the direction of the depth.

11
THE OMEGA MULTI-POSITION SYSTEM

System accessories

Frame Spacer

For fixing the frame distance be-

tween double-sided racking.

Anti-slip protection beam

A continuous anti-slip protection

beam made of C profile steel.
When double-sided pallet racking
is being used (as shown here), this
device is fixed by supports in the
middle between the racking. This
will prevent the pallets from slip-
ping off at the rear.

When a sprinkler system is being

used, two such anti-slip devices
can be fixed parallel to each other,
separated by a clear distance of at
least 100 mm.

With single sided racking the anti-

slip device can be fixed with a
support bolted at the back.

Support member joint, inside,

U, bolted Support member joint

Beams can also be utilised at up- Members can be joined to in-

right connections. At this connec- crease height by means of welded
tion the load for the extra member joint plates using a central friction
must not exceed 6000 kg. grip bolted joint. The load can be
in excess of 6000 kg.

12
System accessories

IPG beams

With chipboard
floor and Z steel
locking device.

IPG beams

With grid floor and Walk-through aisle with ceiling

bolt fixing.

GF beams

With laid-in wood-

en or chipboard
decking. As an op-
tion flush-fitting with
beam top edge.

GF beams

With laid-in steel Drive-through with cross-over walkway

panels and flush-fit-
ting with beam top
edge.

13
THE OMEGA SINGLE-POSITION SYSTEM

pharmaceutical industry

motor vehicle industry

motor vehicle industry

14
Example
For steel box pallets, storage depth 1000 mm high-rise trucks wire guided (inductive).

Longitudinal
section

Ground plan

15
THE OMEGA SINGLE-POSITION SYSTEM

System components

Deep beam G hook

G hook with welded on deep

beam (front view).

Deep beam G hook

The deep beam is hooked into the

elongated holes at the side of the
vertical member bracing by means
of two welded hooks. The pitch of
the holes is 50:50 mm and so the
beam can be adjusted. The side
edging is at an angle of about
170° and stops the pallet when it
is positioned and stored.

There is a push-through safety de-

vice fixed at the rear to a bracket.

Deep beam G hook / DS

As above, but with a welded-on

push-through safety device.

16
System components

Deep support beams on

longitudinal beams

To ensure stability the OMEGA

single-position must be supported
top and bottom, depending on
construction height, at one or more
levels by longitudinal beams. Here
the deep beam is bolted to the
longitudinal beams. There are, in
addition, continuous push-through
safety devices at the rear.

Deep support beams on

longitudinal beams / DS

As above, but with welded push-

through safety device.

Deep support beams

bolted at the side

Deep support beam, angle profile,

bolted from the side directly on the
racking. The pitch of the holes is
50:50 mm so that the beam can
be adjusted.

17
OMEGA DRIVE-IN AND
DRIVE-THROUGH RACKING

Industrial storage
for recycling materials

Forwarding agent storage

Packaging storage

18
Example
Drive-in racking for flat, wooden Euro-pallets using a counter balance truck or a fork-lift reach
truck.

Front view

Ground plan

19
OMEGA DRIVE-IN AND
DRIVE-THROUGH RACKING

System components

Pallet beam with positioning

device

Special profile guide rail (modified

Z profile), beam width 100 mm, to-
tal profile height approx 165 mm.
Fixed at the sides so that the bolt
heads do not obstruct the surface
of the beam.

Guard

A flat steel guard at the same level

as the pallet beam fitted to the
brackets. The guard serves as a
deflector rail and guide rail.

Pallet guard

A pallet guard fixed above the pal-

let beam. This prevents damage to
the upright by the pallets that are
being stored.

20
System accessories

Top longitudinal beam

Required to maintain stability of The system is extremely variable

drive-in racking and drive-through because it can be extended, modi-
racking. In each case it is hung for fied or dismantled, because the
each channel using an OMEGA claws are fixed separately for each
claw into the vertical member pro- channel.
files above the top most pallet com-
partment and is secured by bolts.

Guide rail

Set into a C profile fixed to the

floor. The rail runs the entire depth
of the channel. At the front there
is a positioning opening to ensure
that the channel can be entered
easily.

Anti-slip protection beam

A straight beam for normal usage.

Anti-slip protection beam

A beam bent at a right angle for

joining elements

21
 STANDARD PARTS AND SIZES

OMEGA AND OMEGA M

OMEGA OMEGA M
Welded vertical upright Bolted vertical member

Each OMEGA vertical upright as The OMEGA M vertical member

a standard part will be welded is an assembly system that is bolted
into its position with low tolerances together on site. The vertical mem-
and then finished completely by ber needs little space for storage
cathodic dip coating. and so transport costs are low.

The struts and the horizontal brac-

ing are galvanized, and the base
plates are cathodic dip coated.

Standard base plates bolted-on

foot

Standard base plate

and standard connection
for bolted vertical member
frame.

22
Standard profiles and components for the Omega systems

OMEGA vertical
member profiles

Standard profile Standard profile Standard profile

with slotes with round hole

IPG beam clearance 66

55

100
120
150
254

IPG 100 (=profile height 100 mm)

IPG 120 (=profile height 120 mm)
IPG 150 (=profile height 150 mm)

S beam clearance
55

254

100
125
150

S 100 (=profile height 100 mm)

S 125 (=profile height 125 mm)
S 150 (=profile height 150 mm)

Depending on the type of beam and the different load capacity requirements, the IPG beams and S beams are produced
with a sheet thickness from 1.75 mm to 2.50 mm.

23
SYSTEM ACCESSORIES

Special U guide rail

The special U guide rail (U35/110/55/

4 mm) is used for automatically guiding
high-rise trucks or commissioning vehicles.
The rail is set and levelled on raw concrete,
and the space between the rails where the
racking is to stand is filled with concrete.
The upper edge of the U profile will prevent
the concrete from cracking at later stages,
when the racking is being used!

The aisle between the rails is filled as

U guide rail, levelled
required with screed. If the floor has been
levelled (with screed) the guide rail will be
laid flush.

The standard procedure is for the guide rail

to be finished with cathodic dip coating
RAL 7035.

If the screed is bound with magnesium

oxychloride cement, additional protection
will be provided by powder coating.

U guide rail, not levelled

Opening (not illustrated)

At the entrance to the aisle for the high-rise trucks the opening for the guide rails is inclined at 15° at the front.

L guide rail

The L guide rail (L100/65/9 mm.,

DIN 1029) is also used for automatically
guiding high-rise trucks or commissioning
vehicles. But this rail is not levelled on the
prepared screed (or concrete). The ground
must, however, already lie on the floor side
within the tolerances required for operation.
In the case of guide rails ≤ 50 mm the beam
is not required.

When the sections that are approximately

6000 mm are being fixed, 2x2 welded
L guide rail
bolts have to be used at the joints and a
steel plate bolted on top.

24
 Corner protector

Height 400 mm, made of 4 mm

steel plate anchored to the floor
with pegs (shear connector).

Painted with black/yellow stripes

as required by safety regulations.

Vertical protector

Made of 4 mm steel plate for the

vertical member and 8 mm steel
plate anchored to the floor with
pegs (shear connector).

Surface painted with black/yellow

stripes.

The 400 mm upright strips are pro-

vided with corner upright protector
and are connected at the centre
with bolts. By using adapters in the
middle the upright protector strips
can be made to fit the racking
depths.

Anti-collision
frame protector

This is for strengthening the verti-

cal member and is slid over the
racking support and bolted on.
U111/45/5 mm, 800 mm high (or
reaching to lower pallet beam)
Light grey RAL 7035.

25
GENERAL ACCESSORIES

Rear protectiv mesh

This is a framed grid that is fixed with

special bolts to the racking.

Storage divider

This is a framed mesh that is fixed with

a foot plate plugged to the floor.

The gates can be either opening or

sliding (also available with a grid).

26
 Capacity label

(type, year built, order number, load/compartment,

max. stand load, max. compartment height).

Location description bar code

Adhesive foil for the location bar code.

Alphanumeric location description

Adhesive foil for the alphanumeric location bar code.

Main plate

(order number, stand type, level spacing, field

load, beam type, compartment width, compartment
load, and year).

Aisle indicators

Aisle indicators made of strong plastic with the

aisle numbers glued on.

27
 Our Production Programme:

Pallet racks

High-bay silos

Dynamic live storage

Tray and drawer storage

Wide span and compartment racks

Mobile racking systems

Subject to technical changes or printing errors · 12/2006 · www.kaiser - fotografie.de

Cantilever racking

Drive-Through racking

Drive-In racking

Storage platforms

sales office UA: Firma LagerService

12/3 Mate Zalky St, apt. 61, 04211 Kiev, Ukraine, Tel/Fax: +38(044)5036560 or 5036419,
E-mail: [email protected], www.lagerservice.com.ua