Given the limitations on gross vehicle weight, one of the top priorities for any racking manufacturer is to minimise the weight of racking components to maximise load capacity. Lightweight racking means lower fuel consumption, a greater load capacity and reduced stress on the vehicle’s mechanical systems. Syncro System has adopted two strategies to achieve this objective:

SOPHISTICATED MATERIALS LIKE ALUMINIUM AND HIGH-STRENGTH STEEL and WEIGHT-REDUCING CUTOUTS. THIS SMART COMBINATION OF MATERIALS AND DESIGN HAS PERMITTED AN OVERALL REDUCTION IN WEIGHT OF UP TO 30%

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Syncro System van racking components are designed and made to satisfy two fundamental requirements:

• STRENGTH = Racking components must be able to support heavy loads and must also be able to withstand the stress generated by movement, torsion, impact and vibration when the van is moving. Syncro racking guarantees customers many years of trouble-free use.

• LIGHT WEIGHT = The racking must weigh as little as possible to permit the van to carry a useful load. Lightweight racking means greater load capacity as well as lower fuel consumption, improved handling and safety, and less wear on mechanical components.

To guarantee both strength and lightness, Syncro racking is made from two types of metal:

• ALUMINIUM ALLOY = Space dividers for drawers and shelves and other non-load-bearing parts (e.g. locker doors, bottom profiles for floor-level compartments) are made from anodised or painted aluminium alloy.

• HIGH-STRENGTH STEEL = Research in recent years has led to the development of a new type of high-strength steel that is easier to work and weld than older types and about 25% stronger. Depending on the part concerned, use of this advanced material has allowed Syncro to reduce thickness and weight, or to increase component strength.

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These simulations clearly show how, for the same applied load, a part in high-strength steel bends far less than the same part made from conventional steel.

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To make floor, wheel arch and bulkhead liners, Syncro System uses aluminium tread plate with a base thickness of 2 mm + a relief pattern of 1.8 mm. Syncro tread plate is made from an annealed aluminium alloy that is far stronger and harder than untreated aluminium. These liners therefore offer excellent strength and protection for exceptionally low weight.

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Syncro uses 1.5 mm thick sheets of hard aluminium alloy, anodised on both sides for complete protection. This tough aluminium alloy offers greater mechanical strength than conventional aluminium for the same thickness of material. Anodisation also makes the surface attractive and extremely easy to clean. Syncro uses anodised aluminium for all shelf and drawer space dividers. The Syncro System catalogue also contains bodywork liners in non-anodised aluminium and in aluminium chequer plate.

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Many Syncro System components are made from a mix of aluminium and steel. In Syncro Ultra lockers, for example, the rear panel is made from anodised aluminium. In such cases, the use of aluminium instead of steel gives a weight saving of 10% to 20% with no significant loss in strength.

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Aluminium is also used to make various accessories, including cable holders, storage pockets, spray can racks, silicone cartridge racks etc..

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Wherever possible, sheet metal parts are designed with cutouts to save weight. Put simply, all unnecessary material is cut away. This design solution reduces weight by 30%.

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Thanks to large cutouts, Syncro’s plastic container shelves have seen a weight saving of 60%.

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Syncro floor, wheel arch and bulkhead liners, worktops and vice benches are made from birch plywood, a material formed by gluing thin sheets of wood together with non-hygroscopic, phenolic resin adhesive. This is the same type of adhesive that boat builders use. It makes plywood waterproof and resistant to spillages of oil, petrol, etc.. Birch wood has a particularly low specific weight. Syncro plywood floor liners are available with a high-grip rubber or marble-look resin surface. Marble-look floor liners also have a film of resin on the underside. Syncro’s resin and rubber coatings are non-toxic, provide a certain degree of fire protection and are extremely easy to clean. And because they are more wear-resistant than uncoated plywood, they greatly improve the strength of the material.

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The two surfaces compared.

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Worktops with raised side and rear edges are made from 25 mm thick birch plywood.

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Syncro offers a wide range of plywood floor liners.

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