SAFERAK
® 32P INDUSTRIAL
POWERED MOBILE RACKING

Maximize the efficiency and minimize the costs of your warehouse storage space with Montel’s powered mobile racking designed for industrial environments. The load capacity of the SAFERAK® 32P is 32,000 lb (14,514 kg) per double rack sections.

Standard Embedded Industrial Rail RACK&ROLL 8MA, 8P – SAFERAK 32P

Montel’s Industrial Rail consists of a steel rail recessed in a concrete slab. It is designed to withstand the loads applied by the mobile system and to perform under heavy long-term cyclic stress. The use of a self-leveling mortar provides the means to meet the levelness requirements for the tracks.

FEATURES:

A. Industrial Rail
B. Rail Profile With Narrow Channels
C. Anchoring Screw
D. Concrete Slab (New Or Existing)
E. Track Profile And Mortar

BENEFITS:

A. Heavy-Duty Powder Paint acts as a barrier against corrosion caused by direct contact with concrete.

B. Narrow channels reduce debris accumulation, ease the cleaning and reduce tripping hazards.

C. Permanent floor anchors are staggered to insure proper alignment of the rails in the floor and to facilitate the installation on steel reinforced concrete.

D. Industrial rail can be installed on an existing concrete slab, which reduces the cost.

E. Application of fiber-reinforced fluid mortar provides a continuous support to the system. Self-levelling fluid mortar provides the means to meet the levelness requirements for the rails.

APPLICATION:

The heavy-duty powder painted industrial rail is a basic component of the RACK&ROLL 8MA, 8P and SAFERAK 32P industrial systems. It can be installed in a new or existing concrete slab within non-seismic areas.

TECHNICAL SPECIFICATIONS:

• Design: The rails are designed and manufactured to carry loads imposed by the They are made of cold rolled steel (CRS). Dimensions are of 3/8” (9.5 mm) in height by 3-1/2” (99 mm) in width. The rail surface of contact with the wheels is of 1-3/8” (35 mm) width.
• Finish: Rails are heavy-duty powder painted for great abrasion It serves also as a barrier against oxidation caused by the contact of steel with concrete.
• Rail Levelness: 1/8” (3.2mm) high maximum variation in 20’ 0” (6.1 m) of rail length, along any rail; 1/16” (1.6mm) maximum variation between adjacent rails, perpendicular to rail direction; 1/64” (0.4mm) maximum variation of the center-to-center alignment between two rail sections at any given junction.
• Floor Levelness: A maximum variation of 1/4” (6.4 mm) from true level within any 20’ (6.1 m) of any system.
• Anchors: Anchors are 1/4″ (6.35 mm) X 2 1/4″ (57 mm) flat head concrete screws. There is no anti-tip device provided with this rail.

DESIGN AND CAPABILITIES:

Montel’s Industrial Rail is designed to be embedded and anchored in a structural concrete floor. It provide a smooth transition for material handling equipment and movement. Being in direct contact with concrete, the rails are protected against oxidation by the use of heavy-duty powder paint after machining. It is delivered in 12 to 47 inches (305 to 1194mm) long pieces for easy handling. For more information concerning the mortar, please refer to the technical data sheet M01.162.106.

Industrial Seismic Rail RACK&ROLL 8MA, 8P – SAFERAK 32P

Montel’s Industrial Seismic Rail consists of a 3-component rail recessed in a concrete slab. It is designed to withstand the loads applied by the mobile system and to perform under heavy long-term cyclic stress while the seismic bracket is designed to prevent the mobile carriages from tipping. The use of a self-leveling mortar provides the means to meet the levelness requirements for the tracks.

FEATURES:

A. Welded Steel Bar

B. Angle

C. Seismic Hook

D. Screw Anchor

E. Powder Coating

F. Concrete Slab (New or Existing)

G. Fiber-Reinforced Self-Levelling Mortar

BENEFITS:

A. The load bearing part of the rail consists of a cold-rolled steel bar welded to a steel

B. The angle prevents the mortar or concrete from entering the rail channel during the

C. The seismic hook holds the carriage to the ground to prevent any tipping that could result from an heavy impact or a seismic

D. Floor anchors are staggered to insure proper alignment of the rails in the floor and to facilitate the installation on steel reinforced Standard anchors used are 3/8” x 3” screw anchors. *Anchors must be approved by a local engineer for seismic applications.

E. Heavy-Duty Powder Coating acts as a barrier against corrosion caused by direct contact with

F.The industrial seismic rail can be installed in an existing concrete slab, which reduces the

G.The application of a fiber-reinforced fluid mortar provides a continuous support to the system and its self-levelling properties provide the means to meet the levelness requirements for the

 

APPLICATION:

The industrial seismic rail is used for Rack&Roll 8MA, 8P and SAFERAK 32P systems that have a high height-to-depth ratio and for seismic areas. All tracks within the system must then be of the seismic type, i.e. every standard rail is substituted for a seismic rail.

TECHNICAL SPECIFICATIONS:

• Design: The rails are designed and manufactured to carry the loads imposed by the mobiles. They are made of 3 The load bearing part is made of a 1” high x 1 3/8” wide (25.4mm x 34.9mm) cold-rolled steel bar welded to a 3/16” thick x 7” wide (4.8mm x 178mm) structural steel plate. The seismic hook is made of 3/16” (4.8mm) structural steel and formed into a “Z” shape 1” high (25.4mm). The other side angle is made of 3/16” (4.8mm) structural steel and formed into a “L” shape 1” high (25.4mm).

 

• Anchors: Anchors are 3/8” x 3” concrete screws anchors. They secure the three components of the rail together to the concrete *Anchors must be approved by a local engineer for seismic applications.

 

• Finish: Rails are heavy-duty powder painted for great abrasion It serves also as a barrier against oxidation caused by the contact of steel with concrete.

 

• Rail Levelness: 1/8” (3.2mm) high maximum variation in 20’ 0” (6.1 m) of rail length, along any rail; 1/16” (1.6mm) maximum variation between adjacent rails, perpendicular to rail direction; 1/64” (0.4mm) maximum variation of the center-to-center alignment between two rail sections at any given

 

• Floor Levelness: A maximum variation of 1/4” (6.4 mm) from true level within any 20’ (6.1 m) of any system.

DESIGN AND CAPABILITIES:

Montel’s Industrial Seismic Rail is designed to be embedded and anchored in a structural concrete floor. It provides an ideal solution for applications requiring an seismic device. Being in direct contact with concrete, the rails are protected against oxidation by the use of heavy-duty powder. It is delivered in 12 to 48 inches (305 to 1220 mm) long pieces for easy handling. For more information concerning the mortar, please refer to the technical data sheet M01.162.106.

Carriage

SAFERAK 32P

With its heavy-duty base, Montel’s SAFERAK 32P mobile storage system carriage is able to withstand a weight of 32,000 lbs per tandem bay of racking (14 500kg) and its accelerations. It provides practical, efficient and sturdy storage solutions to various industrial-duty applications.

FEATURES:

A. WheelChannels
B. Dual Flange Wheels
C. Full-Length DriveShafts

D. FlangeBearings
E. Side Members
F. FrontandRearBumpers

G. Side Member Bumpers
H. 1/2 HP AC Gearmotors
I. Custom Anchor Plate

BENEFITS:

A. Structural steel wheel channels designed to support 16,000 lbs each.
B. Dual Flange wheels for continuous rail guidance.
C. Full-length drive shafts eliminate distortion and provides greater traction.
D. Flange sealed ball bearings for superior longevity and protection against dust.
E. Side members are constructed of “C” shaped 50W steel profiles and corner braced for
excellent carriage stiffness.
F. Front and rear bumpers for aesthetic look and carriage protection against forklifts.
G. Side member bumpers for additional end stop protection.
H. High reliability and powerful AC gearmotors.
I. Custom anchor plates for specific racking dimensions.

APPLICATION:

Montel SAFERAK 32P systems are designed for industrial applications that require up to 32,000 lbs per tandem section without compromising safety. A full range of industrial machine safeties are available for SAFERAK 32P systems. For more information concerning the rails, please refer to the technical data sheets M01.152.114 and M01.152.118.

DESIGN AND
CAPABILITIES:

TECHNICAL
SPECIFICATIONS:

• Wheel Support Sections: Made of 3/16″ (4.8mm) 50W steel. Wheel support sections are welded and are 6 1/4″deep x6 3/8″ high (159mm x 162mm). Wheel support sections can support a maximum of 16,000 lbs, i.e. 32,000 lbs in tandem configuration.
• Wheels: Made of solid SAE 1045 steel for smooth operation. Wheels are precision ground and balanced. All wheels are 6 1/8″ (156mm) diameter (rolling dimension). They are dual-flanged and sloped to ensure efficient guidance.
• Torque-Resistant Tubular Drive Shaft: Tubular drive shafts are made of 1.90″ (48mm) outside diameter by 1.650″ (42mm) inside diameter steel tubing and are fastened with Grade 8 hardware.
• Direct-Drive System: Provides drive system that prevents carriage whipping, binding and excessive wheel/rail wear under normal operation. All wheels are driven on one side of carriage. Power transfer to wheels is ensured by a chain sprocket drive system. The chain and sprocket are ANSI#60.
• Bearings: Two 1 1/2“diameter flange ball bearings per wheel. Design of the carriage is such that the weight-bearing
  of the upright rests directly over the wheel channels, thus transmitting the load directly to the rail. All bearings are permanently shielded and lubricated.
• Carriages Side Members:Constructedof “C” shapedprofiles 21/2″deepx511/16″high(63.5mm x144mm), minimum 50W 11-gauge steel. Side members are not load carrying components i.e. all live load must sit on racking components.
• Bumpers: Made of 11-gauge 50W steel toprotect the carriage and distance sensors from impacts and dust with clean aesthetic look. Integrated hole to access the drive shaft for mechanical ratchet power failure solution.
• SideBumpers: Side members rubber bumpers to protect carriages and floor-level safeties.
• Motors: Industrial rated 230 VAC three-phase current limited, fractional horsepower, gear motors driven by an AC variable frequency inverter.
• Anchor plates: Made of 3/16″ (4.8mm) 50 W steel with welded studs positions customized for your specific racking.

Floor Requirements SAFERAK 32P & 60P

To perform adequately, Montel’s industrial powered mobile systems SAFERAK 32P and SAFERAK 60P require detailed analysis of not only the concrete floor into which it will be installed, but also the soil density underneath the structure. The following document serves as a guide to predetermine if a project qualifies or not for an industrial mobile system. Further analysis must be conducted by a local engineer to confirm feasibility and detailed requirements.

 

 

1 Slab dimensions have been calculated for ground bearing slabs, i.e. they do not apply to a structural slab design.

2 Soil type is for reference only. A local soil analysis must be conducted to confirm the actual soil bearing capacity.

3 SAFERAK 32P slab dimensions are for cut trench installation, as specified by Montel. For surface mounted rail with concrete pad installation, the required slab thickness may be lower. A local engineer must confirm the required slab capacity.

4 SAFERAK 60P slab dimensions are for surface mounted rail with concrete pad installation, as specified by Montel. For cut trench installation, the required slab thickness may be greater. A local engineer must confirm the required slab capacity.

Remote Control SAFERAK 32P, 60P

Every Montel SAFERAK storage systems has standard built-in network connectivity to integrate into your industry 4.0 manufacturing process with the advanced Montel web-based app. System statuses and controls can be remotely accessed through Ethernet and Wi-Fi from the intuitive application that can run on any device with a web browser. All communications go through an Ewon industrial VPN device for secure remote access when required.

FEATURES:

A. Remote Control
B. Remote Monitoring
C. Alarm History

D. Automatic Movements
E. User Management
F. Remote Troubleshooting

BENEFITS:

A. Navigate through the intuitive software to control Montel SAFERAK systems remotely. No other user can move an aisle while the system is being controlled remotely. Of course, all safeties will stay active.

B, C, D. Operations such as adjusting all parameters, modifying automatic movements or accessing log data can be done remotely.

E. Manage and customize user access level through a built-in user management module.

F. Secure industrial VPN off-site remote monitoring, maintenance and troubleshooting on SAFERAK systems by a Montel technician is available upon client *Internet connection required.

APPLICATION:

Every SAFERAK 32P and SAFERAK 60P system comes with built-in remote control access and monitoring. By connecting the system to the client’s network, any device connected to the same network can be granted an authorized access to these features. A user management module is integrated to control all system access.

TECHNICAL SPECIFICATIONS:

1/2 HP – 3/4 HP Motors SAFERAK 32P, 60P

Montel’s 1/2 HP and 3/4 HP motors provide the power, flexibility and reliability needed for the following industrial systems: SAFERAK 32P and SAFERAK 60P.

FEATURES:

A. Optimized motors and gearhead combinations for maximum output power in the smallest package.
B. Variable speed, 3-phase design for operation with a wide range of inverter (AC drive) products.
C. Reliable performance under a range of operating conditions.
D. Needle bearing throughout for increased radial load capacity and lifetime.
E. Hardened steel helical gearing provides quietness and high output to size ratio.
F. Helical pinion cut on motor shaft for maximum strength and minimum noise.

 

TECHNICAL SPECIFICATIONS:

Power Requirements SAFERAK 32P, 60P

Montel’s following electrical systems (SAFERAK 32P and SAFERAK 60P) operates on a 208-240 VAC, 60 Hz dedicated circuit. Depending on the quantity of carriages per system, as well as the applied loads on carriages, a 30 A or a 60 A circuit will be used.

Connections Requiring No Transformer:

Single Phase/Split Phase 4 Wire With Ground

 Single phase 120/240 is commonly seen as the source for AC power to household cloths driers and may also be called Split Phase 240. This configuration consists of 2 voltage wires and the voltage between the two wires (called phase to phase or line to line) is 240V and the phase to neutral voltage is 120V.

 

 

Three Phase Four Wire Wye

AC power is usually distributed in a facility in a 3-phase system consisting of 5 wires. Three of the wires carry current and are called phases. The fourth wire is the neutral wire. The neutral wire will not have current flowing in it as long as the current in the three phases are matched or have a balanced load. The fifth wire consists of the ground wire.

 

 

Connections Requiring a Transformer (Not Provided by Montel):

Three Phase Four Wire Wye

Used primarily in industrial facilities, this configuration has no neutral wire, so the voltage is always a line to line measurement.

 

 

TECHNICAL SPECIFICATIONS:

Connections Requiring No Transformer:

• 240 VAC Split Phase
• 208 VAC Single-Phase

Connections Requiring a Transformer:

• 480 VAC Three-Phase
• 600 VAC Three-Phase
• etc.

Provided by Montel:

• 30A (or 60A) Power Box per SAFERAK System

 

Provided by the Client:

• 3 pole 4 wire #10 AWG (or #6 AWG) with ground from the building electrical service to every 30A (or 60A) system power
• Transformer (if required).

 

Montel does not provide any power transformers.

All electrical connections must be done by a certified electrician.

 

Please refer to technical data sheet M01.161.103 for additional information on the motor that is used.

SAFERAK
® 60P INDUSTRIAL
POWERED MOBILE RACKING

Maximize the efficiency and minimize the costs of your warehouse storage space with Montel’s powered mobile racking designed for industrial environments. The load capacity of the SAFERAK ® 60P is 60,000 lb (27,215 kg) per double rack sections.

Standard Rail SAFERAK 60P

Inspired by the crane rail industry, Montel’s SAFERAK 60P Standard Rail is designed to withstand the heaviest loads applied by SAFERAK 60P mobile systems and to perform under severe long-term cyclic stress. It consists of a 3-component rail recessed in concrete. The use of a high strength self-leveling mortar provides the means to meet the levelness requirements for the tracks.

FEATURES:

A. Steel Soleplate

B. Steel Rail

C. Clip and Screw Anchor

D. Concrete Nails

E. Powder Coating

F. Fiber-Reinforced Self-Levelling Mortar

G. Concrete Slab

H. Concrete Pad and Epoxy Overlay

BENEFITS:

A. The steel soleplate distributes the loads to the concrete slab and improves cyclic performance at the rail joints.

B. The 1” high steel rail is designed to withstand the heavy loads of the SAFERAK 60P and is precision machined for quick installation and accurate guidance.

C. High-strength rail clips and screw anchors secure the rail to the slab and are positioned to minimize stresses from cyclic forces.

D. As an option, concrete nails are ideal for quickly fixing the soleplates to the ground during the installation.

E. Heavy-Duty Powder Paint acts as a barrier against corrosion caused by direct contact with concrete.

F. Application of a fiber-reinforced fluid mortar provides a continuous support to the system. Self-levelling fluid mortar provides the means to meet the levelness requirements for the rails.

G. The rail is usually installed on the concrete slab and then overlaid with Floor capacities must be verified by a local engineer.

H. A concrete layer is poured to make the floor flush to the top of the An epoxy layer can be added for increased durability.

APPLICATION:

The SAFERAK 60P standard rail is designed and used exclusively for SAFERAK 60P systems. It is normally installed on new concrete slabs and is used within non-seismic areas.

TECHNICAL SPECIFICATIONS:

• Design: The rails are designed and manufactured to carry loads imposed by the mobiles. They are made of 3 components. The rail part is made of a 1” high x 4 1/2” wide (25.4mm x 114mm) cold-rolled steel bar. The soleplate, located directly under the rail component, is made of 3/16” thick x 7 1/2” wide (4.8mm x 191mm) steel plate. The rail clips secures the rail component and soleplate to the concrete floor with anchors. The rail surface of contact with the wheels is of 1 3/4” (45mm) width.
• Anchors: Anchors are 3/8” x 3” concrete screws anchors. They secure the components of the rail together to the concrete floor. There is no anti-tip device provided with this rail.
• Finish: Rails are heavy-duty powder painted for great abrasion resistance. It also serves as a barrier against oxidation caused by the contact of steel with concrete.
• Rail Installation: 1/8” (3.2mm) high maximum variation in 20’ 0” (6.1m) of rail length, along any rail; 1/16” (1.6mm) maximum variation between adjacent rails, perpendicular to rail direction; 1/64” (0.4mm) maximum variation of the center-to-center alignment between two rail sections at any given junction.
•  Floor Levelness: A maximum variation of 1/4” (6.4mm) from true level within any 20’ (6.1 m) of any system.

DESIGN AND CAPABILITIES:

Montel’s SAFERAK 60P Standard Rail is engineered to withstand the most demanding applications associated with SAFERAK 60P mobile systems. It provides a long-lasting heavy-duty rail designed to be embedded and anchored in a concrete floor. Being in direct contact with concrete, the rails are protected against oxidation by the use of heavy-duty powder coating. For more information concerning the mortar, please refer to the technical data sheet M01.162.106.

 

Carriage SAFERAK 60P

With its heavy-duty base, Montel’s SAFERAK 60P mobile storage system carriage is able to withstand a weight of 60,000 lbs per tandem bay of racking (27 200 kg) and its accelerations. It provides a practical, efficient and sturdy storage solution to the most demanding industrial-duty applications.

FEATURES:

A. Wheel Channels
B. Dual Flange Wheels
C. Full-Length Drive Shafts

D. Flange Bearings
E. Side Members
F. Front and Rear Bumpers

G. Side Member Bumpers
H. 3/4 HP AC Gearmotors
I. Custom Anchor Plate

 

BENEFITS:

A. Structural steel wheel channels are designed for heavy-duty applications and support up to 30,000 lbs each.
B. 10” diameter dual flange wheels for proper rail alignment.
C. Drive shafts are made of mechanical steel tubing for unparalleled strength and joined with clamping couplings for virtually no play. Full-length drive shafts eliminate distortion and provide greater traction.
D. High capacity square flange sealed ball bearings for superior longevity and protection against dust.
E. Side members are constructed of “C” shaped structural steel profiles and corner braced for excellent carriage stiffness.
F. Front and rear bumpers for aesthetic look and carriage protection against forklifts.
G. Side member bumpers for additional end stop protection.
H. High reliability and powerful AC gearmotors.
I. Customized anchor plates for specific racking dimensions.

APPLICATION:

For heavy industrial applications that require more capacity than the SAFERAK 32P, Montel’s SAFERAK 60P systems can carry up to 60,000 lbs per tandem section without compromising safety. A full range of industrial machine safeties are available for SAFERAK 60P systems. For more information concerning the rail, please refer to the technical data sheet
M01.152.115.

 

DESIGN AND CAPABILITIES:

 

TECHNICAL SPECIFICATIONS:

• Wheel Support Sections: Made of 3/16″ (4.8mm) 50W steel. Wheel support sections are welded and are 8” deep x 10″ high (203mm x 254mm). Wheel support sections can support a maximum of 30,000 lbs (13 600 kg), i.e. 60,000 lbs (27 200 kg) in tandem configuration.
• Wheels: Made of solid SAE 1045 steel for smooth operation. Wheels are precision ground and balanced. All wheels are 10″ (254mm) in diameter (rolling dimension). They are dual-flanged and sloped to ensure efficient guidance.
• Torque-Resistant Mechanical Tubular Drive Shaft: Tubular drive shafts are made of steel mechanical tubing of 2 3/8” (60.3mm) outside diameter with a 3/16” wall (4.8mm). A solid steel shaft is welded at each end to link the Drive Shaft to the Wheel Support shaft with keyed clamping shaft couplings.
• Direct-Drive System: Provides drive system that prevents carriage whipping, binding and excessive wheel/rail wear under normal operation. All wheels are driven on one side of carriage. Power transfer to wheels is ensured by a chain sprocket drive system. The chain and sprocket are ANSI #80.
• Bearings: Two 2“ diameter square flange ball bearings per wheel. Design of the carriage is such that the weight- bearing of the upright rests directly over the wheel channels, thus transmitting the load directly to the rail. All bearings are permanently shielded and lubricated.
• Carriages Side Members: Constructed of “C” shaped profiles 2 1/2″ deep x 9 3/4″ high (63.5mm x 248mm) and are made of 11-gauge 50W steel. Side members are not load carrying components i.e. all live load must sit on racking components.
• Bumpers: Made of 11-gauge 50W steel to protect the carriage and distance sensors from impacts and dust with clean aesthetic look. Integrated hole to access the drive shaft for mechanical ratchet power failure solution.
• Side Bumpers: Side members rubber bumpers to protect carriages and floor-level safeties.
• Motors: Industrial rated 230 VAC three-phase current limited, fractional horsepower, gearmotors driven by an AC variable frequency inverter.
• Anchor Plates: Made of 3/16″ (4.8mm) 50W steel with welded studs positions customized for your specific racking.