Long Span Shelving with Butterfly Hole Uprights
Modular Storage Built for Heavy Manual Loading
The Long Span Shelving system with Butterfly Hole Uprights engineered by StahlRack Intralogistics GmbH provides a versatile, cost-efficient storage solution tailored for fulfillment centers, spare parts depots, workshops, and commercial logistics hubs across Germany and the DACH region.
By replacing rigid, fully welded frames with an engineered knock-down bolt-assembled upright structure, this system optimizes container loading space—slashing international ocean freight volume by up to 30% while eliminating transport deflection damage.
- 30% Freight Savings: Flat-pack packaging minimizes cubic meter volume for bulk global exports.
- Tool-Free Butterfly Keyhole Lock: Beam pendants drop smoothly into butterfly hole channels for instantaneous installation.
- Reinforced Decking Understructure: Spot-welded stiffening ribs prevent steel panel sagging under concentrated loads.
- DIN EN Structural Compliance: Manufactured under ISO 9001 quality management adhering to FEM safety margins.
Key Engineering Advantages of Butterfly Hole Shelving
Every profile, bend, and connection point is structurally optimized by StahlRack engineers to combine high load-bearing safety with minimal total cost of ownership (TCO).
1. Bolt-Assembled Upright Frames
Unlike traditional welded frames that lock in dead space during shipping, our uprights feature precision-punched cold-rolled steel profiles connected via heavy-duty hex bolts and diagonal bracing.
- Drastically reduces shipping volume and container freight costs
- Lowers risk of bent frames or surface scratching during transit
- Enables easy single-component replacement on site during maintenance
- Provides superior structural adaptability for long-term expansion
2. Butterfly Hole Upright Pitch
The signature butterfly keyhole pattern is stamped with micro-tolerances along the column face, accommodating step-beam end clips and safety locking pins seamlessly.
- Enables fast, tool-free beam adjustment in 50mm height steps
- Creates a rigid wedge-action joint that strengthens under load
- Eliminates lateral sway under dynamic manual picking operations
- Supports fast shelf level reconfigurations as SKU sizes change
3. Under-Deck Stiffening Ribs
Steel shelf panels feature precision-formed perimeter edges and continuous spot-welded hat channel stiffeners underneath the loading surface.
- Prevents panel deflection when carrying heavy totes or metal castings
- Increases uniform distributed load (UDL) ratings up to 500kg per level
- Extends operational lifespan in demanding industrial warehouse environments
- Maintains smooth flat surface for easy slide-in parcel handling
4. Diagonal & Horizontal Truss Bracing
Integrated C-section bracing bars are triangulated across the depth of each frame to absorb side forces and impact vibrations.
- Distributes vertical load forces evenly down to floor baseplates
- Increases overall rack stability without adding excessive deadweight
- Ensures full compliance with industrial warehouse safety guidelines
- Supports multi-tier mezzanine shelf configurations
Engineering Specifications & Load Capacities
Select standard duty types or request customized height, width, and depth parameters designed for your exact storage requirements.
| Duty Level | Capacity / Tier (UDL) | Upright Profile (mm) | Beam Profile (mm) | Panel Thickness (mm) | Standard Colors |
|---|---|---|---|---|---|
| Light Duty | 100 kg – 150 kg | 50 × 30 × 0.5 mm | 50 × 30 × 0.4 mm | 0.25 mm | RAL 5015 Blue / RAL 9003 White / Black |
| Medium Duty (Type A) | 200 kg – 250 kg | 80 × 40 × 0.6 mm | 60 × 40 × 0.5 mm | 0.30 mm | RAL 5015 Blue / RAL 7035 Grey / Black |
| Medium Duty (Type B) | 300 kg – 350 kg | 80 × 40 × 0.8 mm | 60 × 40 × 0.8 mm | 0.40 mm | RAL 5015 Blue / Orange / Black |
| Heavy Duty | 400 kg – 500+ kg | 80 × 40 × 1.0 mm | 70 × 40 × 1.0 mm | 0.50 mm (Reinforced) | Custom Powder Coating Available |
* Custom dimensions (Height: 1,500–4,000mm, Width: 1,200–2,500mm, Depth: 400–1,200mm) and custom RAL colors available upon engineering request.
Ideal Applications for Long Span Shelving
StahlRack longspan shelving systems are deployed across diverse commercial and industrial operations requiring flexible, un-palletized hand loading.
E-Commerce & Parcel Fulfillment
Provides fast open-access shelf pick locations for fast-moving consumer goods, carton picking, and automated tote handling lines.
Automotive & Spare Parts Depots
Accommodates heavy motor components, machine parts, and hardware bins with high structural integrity and high layer weight limits.
Industrial Workshops & Factories
Organizes maintenance tooling, raw materials, and sub-assemblies directly adjacent to production assembly lines.
Archive & Document Storage
Maximizes vertical clearance for dense document storage boxes, binder bins, and long-term record archives.
Hardware & Retail Stockrooms
Presents a clean, powder-coated aesthetic suitable for retail backrooms, DIY centers, and wholesale trade stores.
Multi-Tier Shelving Mezzanines
Serves as the structural support posts for multi-level walk-way mezzanine floors, multiplying usable floor area exponentially.
Frequently Asked Questions
Common technical inquiries evaluated by procurement managers and logistics architects prior to order placement.
Butterfly hole uprights utilize a tapered keyhole pattern. Beam end connectors slip into place effortlessly and lock downward under gravity. This tool-free design eliminates time-consuming nut-and-bolt alignment on every beam level, reducing on-site installation labor costs by up to 50%.
Welded upright frames create large empty voids during transport. By shipping upright columns, bracing bars, and baseplates disassembled in flat-pack bundles, we maximize container density, fitting up to 30% more material per shipping container and reducing per-unit ocean freight charges.
Yes. Our engineering department prepares customized 2D CAD layout drawings and structural 3D models free of charge within 24 hours of receiving your floor plan, room height, and load specifications.
All steel components undergo automated multi-stage washing, iron-phosphating, and electro-static thermosetting epoxy powder coating. Standard colors include RAL 5015 Blue, RAL 7035 Light Grey, RAL 9003 White, and Jet Black. Custom RAL shades are produced upon request.
Request a Custom Long Span Shelving Layout & Factory Quote
Contact the engineering project team at StahlRack Intralogistics GmbH today. Send your hall dimensions and load requirements directly to [email protected] or launch our interactive inquiry chat.