Installing new or additional rack systems can be a time consuming exercise even under ideal circumstances. Whether it’s a single unit for an office or one hundred for a complete datacentre; manhandling 42U cabinets into position can be tricky. This is why a number of manufacturers have launched flat-pack solutions into the market. However, do the savings really add up and what are the additional benefits? Alan Lewis, business development manager for Retex UK, explained the differences between some of the flat pack solutions on the market, and the savings that can be made.
Once the design and specifications for a rack system have been finalised the final question may be ready-made or flat-pack? This decision will have both short-term and long-term effects, in terms of both costs and energy consumtion, and it is important to understand the slightly less obvious advantages to the DIY option.
Initially, the space occupied by the self assembly rack is up to 75% less than that of the conventional, ready-made product. This translates into more efficient transport costs, reduced fuel use and less CO2, all of which are important to energy and cost conscious companies. In addition, the space required to store the racks before they are installed is reduced by a similar amount.
Very often, rack systems are located in areas with less than ideal access, which can make manoeuvring full sized cabinets rather difficult and time consuming. The sheer bulk of a fully assembled rack system makes it difficult to handle while also having to negotiate stairs and doorways. In comparison, the flat pack version is considerably easier to transport, however, the next question is: what exactly is inside the box?
Although the dimensions and colour will have been specified at the start, it is important to read the small print for every manufacturer since there are some considerable differences in the flat-pack designs. Some will use a lighter construction for the flat-pack models in an effort to save weight, but this may compromise the overall strength of the system when it is installed. This may also affect the total load capacity of the rack system, another important factor to bear in mind.
The strength and durability of the flat-pack system should, ideally, be the same as that of the conventional, fully assembled units. Fortunately this should not be cause for concern with premium flat-pack designs. For example, the Logic2 from Retex UK, shares the same specifications with its pre-assembled cousins, including the rated static load of over 1,500kg (over 50% more than many standard cabinets on the market).
However, even with all other variables being equal, it is the speed with which the rack can be assembled that will have the greatest impact. This is wholly dependent on the design of the rack and the number of stages and components involved in assembly. Some manufacturers will simply send an unassembled cabinet that is designed to be put together on an assembly line, by workers who use specific tools and have literally built thousands of units. In some cases this flat-pack system carries a surcharge above the assembled units as well.
The key to an efficient assembly is making it as easy as possible for the customer. So, completing some of the assembly work – such as the rack support brackets – before dispatching the system will make the task much easier. By reducing the number of components and commonising the fixings, it is possible for the customer to understand the simple instructions and complete the assembly process in under five minutes.
This has been demonstrated by the Retex Logic2 rack system, which uses precision machined aluminium corner sections to provide solid fixing points for the frame. Quarter-turn screws are used to locate the lid and adjustable feet ensure a stable installation. The front and rear doors can be hinged from either side with an opening angle of 190 degrees C, providing excellent access to the equipment.
Since Logic2 was first launched, it has been specified for use in many applications, including the extension of Barcelona’s underground railway network. Albantia, the contractors for the Barcelona project, have estimated that the Logic2 system reduced the initial installation of the racks into their position by 75%, which translated to a significant saving in time as there were over 750 individual units involved in the project.
Every manufacturer makes all the usual sizes of rack cabinet and many will offer a flat pack option, which is said to save time and effort, however, this may result in a false economy. By specifically designing a rack cabinet for self-assembly, Retex ensures that it can deliver the complete package in one box and that it can be assembled in under 5 minutes.
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