News

Customer Challenge:

A major data center faced a logistical challenge. They need to maneuver and install a long, heavy server rack into a tight space. The rack has to be positioned precisely underneath its designated installation point and then lifted to a height of 16 feet. Traditional methods, such as forklifts and cranes, were impractical due to space constraints, the need for precise positioning, and utilities under the concrete floor, which made point loading using other methods not a viable option.

Solution Overview:

To address this challenge, an innovative solution was developed involving the use of two scissor lift tables mounted on Aerofilm air pallets. This setup provides both mobility and lifting capability, ensuring the rack can be moved into position easily and then elevated to the required height without damaging the utilities beneath the floor. Each air pallet is capable of handling the combined weight of the lift table and the server rack.

Detailed Solution:

1. Scissor Lift Tables:
   • Two robust scissor lift tables were selected for their stability and lifting capacity. These tables are capable of raising the heavy server rack to a height of 16 feet.
2. Air Pallets with Guide Wheels:
   • Each scissor lift table was mounted on an air pallet equipped with two guide wheels. These guide wheels were oriented in different directions, allowing for straight tracking while the air casters were in use. The air pallets, utilize air casters mounted underneath, use a thin film of air to lift and float heavy objects. Each air pallet had a capacity of 20,000 pounds, sufficient to handle the combined weight of the lift table and the server rack. This allows for smooth and effortless movement of the load across flat surfaces without causing point loading that could damage the utilities under the concrete floor.
3. Connecting the Lifts:
   • The two scissor lift tables with mounted air pallets can be operated individually or connected with a single air hose to allow both to be used simultaneously. This connection is crucial for maintaining stability and preventing any misalignment during the lifting process.
4. Positioning the Rack:
   • With the server rack securely placed on the connected scissor lifts, the air pallets are activated. The floating capability of the air pallets, combined with the guide wheels, allow the team to maneuver the long rack precisely into position underneath the installation point, ensuring straight and controlled movement.
5. Lifting the Rack:
   • Once the rack is correctly positioned, the air pallets are shut off, grounding the scissor lifts. The lifts are then operated to raise the server rack to the required height of 16 feet.
6. Installation:
   • At the desired height, the rack is secured in place. The scissor lifts and air pallets are then removed, leaving the server rack installed as required.

Benefits:

• Precision: The air pallets with guide wheels provided exceptional maneuverability and straight tracking, allowing the team to position the rack with high precision.
• Stability: The use of two connected scissor lifts ensured the rack was lifted evenly and securely.
• Space Efficiency: This solution is particularly effective in the constrained space of the data center, where larger equipment would have been impractical.
• Protection of Utilities: The air pallets eliminated point loading on the floor, protecting the underlying utilities from potential damage.
• Weight Handling: Each air pallet’s capacity of 20,000 pounds ensures that the combined weight of the lift table and the server rack can be safely managed.
• Safety: The method minimized the risk of damage to the rack and surrounding equipment, as well as reducing potential safety hazards to personnel.

Conclusion:

The combination of scissor lift tables and air pallets with guide wheels provided an innovative and effective solution for maneuvering and installing a long server rack in a challenging environment. This case demonstrates the importance of tailored solutions in complex logistical scenarios and highlights the potential for creative thinking in overcoming spatial and operational constraints, including the protection of utilities under the floor and the ability to handle significant weight.

Challenge

Our client seeks a comprehensive resolution for effortlessly transporting an unconventional load through a 150-foot corridor that encompasses multiple turns. Notably, the load incorporates a bottom valve that necessitates special consideration. Presently, the client contends with suboptimal equipment mobility within the corridor, resorting to the deployment of two different pieces of equipment—one for lifting and another for the subsequent movement of the load. Moreover, due to the environment’s potentially explosive nature, the requirement for all stainless-steel components and air-powered mechanisms has become imperative.

Resolution

The proposed remedy entails the development of a custom air pallet system, designed to address the intricate demands of the situation using air casters (or air bearings). The system showcases a strategically crafted notch to seamlessly accommodate the load, valve and all. Effectively combining both lifting and transportation functionalities. This design eliminates the use of multiple pieces of equipment, streamlining the entire process, and enables a lone operator to deftly navigate and direct an impressive 16,000 lbs. load with ease.

This air caster solution emerges as a less expensive and more efficient alternative to a conventional wheeled transporter, boasting a substantially reduced cost profile. Furthermore, the implementation integrates stainless-steel components, ensuring enduring reliability and resilience. Importantly, the chosen air-powered design addresses the potentially hazardous setting, aligning perfectly with safety standards.