Rack End Barrier units are supplied de-assembled. Each unit comprises of:
2 Post Assemblies
1 Pre-cut Rail
2 Locking Pins
2 End Caps
8 Post floor fixings (4 per post)
A rubber mallet may be necessary to properly locate the rail onto the posts and for inserting the post/rail locking pins.
1. Position the posts into the rail through the pre-cut location holes in the rail. This may be done by placing the posts in the rail (as shown below) or if preferred by placing the rail onto the posts.
2. When the posts are positioned, stand the barrier on the post base plates. Push the rail down onto the posts (use a mallet if necessary so that the locking pin holes are fully visible on both posts.
3. Position the locking pin by placing the chamfered end of the pin over the hole in the post. Using the mallet if necessary, push the locking pin completely through the postto lock the post to the rail. Repeat for the second post assembly.
4. Locate the end cap into the end of the rail and push firmly to seat correctly. Repeat for the second end cap.
Should it be necessary to disassemble the barrier the assembly procedure described should be reversed.
Remove end caps remove locking pins. The pin may need to be gripped with a good pair of pliers or similar tool to facilitate removal.
Remove rail from posts.
Undo post fixing bolts to remove posts if necessary.
To install the Rack End Barrier the following equipment will be required:
Power Drill
12mm Masonry/Concrete drill bit, 120mm long
19mm spanner
Torque wrench, max. torque>35Nm
Hammer
Rubber Mallet
Marker pen
Suitable personal protection equipment
A rubber mallet may be necessary to properly locate the rail onto the posts and for inserting the post/rail locking pins.
1. Position the assembled unit. The distance between the rack end and the edges of the barrier base plates should be between 125mm and 150mm.
2. Using the holes in the base plates as a template mark the position for drilling the 12mm fixing holes using an easily visible marker pen.
3. With a 12mm masonry/concrete drill bit, using the marked positions, drill 8 holes to a minimum depth of 100mm for the post fixing bolts. When all the holes are drilled clean up the drilling/dust particles and reposition the rack end barrier unit so the holes in the base plates coincide with the drilled holes.
4. Place the fixings through the holes in the base plates inserting them into the drilled holes. Using a hammer, hammer the fixings into the drilled holes so that a minimum of 15mm of threaded bolt protrudes above the post base plate.
5. Using a 19mm spanner tighten the fixing bolt nuts until they start to nip down on the base plates.
6. Finally, using a torque wrench, tighten the bolt nuts to the recommended torque of 40Nm for un-cracked concrete and 35Nm for cracked concrete.
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Rack End Barrier Assembly/Installation Instructions
