Numerical characterisation of reaction forces’ contribution to initial stiffness in speed-lock beam-to-upright connections

Abstract

This article presents a detailed numerical model of speed-lock (boltless) beam-to-upright connections in steel storage pallet rack systems. The model is capable of predicting initial stiffness and characterising the reaction forces of connector-to-upright interactions. The study examines nine configurations, combining three types of uprights and three types of beams with a common connector. Initially, experimental tests were conducted using the monotonic cantilever test method according to EN 15512 standard, with initial stiffness calculated using a standardised version of the initial stiffness method. Subsequently, a numerical analysis was developed through a finite element model based on the experimental setup. The model introduces new geometric details, evaluating each impact on behaviour, particularly on initial stiffness. Results show that numerical accuracy improves with detailed components such as inclined tabs, more detailed perforations, and 3D weld modelling. The contribution of reaction forces of connector-to-upright interactions to initial stiffness was analysed, considering the impact of the rotation centre’s position. It was found that a lower rotation centre position reduces the connector-to-upright lateral contact contribution while increasing tab-to-slot interaction contributions. The impact of beam height and beam weld position on initial stiffness was also analysed, with results showing that increasing these variables consistently led to increased initial stiffness. Finally, the rotation centre’s position was shown to evolve throughout the test, redefining the contribution of interactions. It clarified that connector-to-upright lateral interaction and tab1-to-slot1 and tab2-to-slot2 interactions have the highest contributions. This information is valuable for rack manufacturers to improve, optimise, and ensure the safety of their designs.