Instruction 09.2014

special page | 09/14
Rev. 2
Assembly instructions
BERNECKER ModularSteel is extremely versatile and
easy to assemble thanks to its relatively small number
of system components. There are a number of important
rules that must be followed, however:
The system components are completely hot-dip galvanized and all necessary holes are predrilled at our factory. Drilling or welding on the components affects their
load bearing capacity and should be avoided.
Assembly in general
The bolts* must be used as shown in the sketch and tightened with the prescribed torque (Tab.1).
We recommend to mark the bolts after fixing.
Tab. 1
ModularSteel 120
ModularSteel 80
120 Nm (90 lb-ft) 80 Nm (60 lb-ft)
Torque
* Always tightened bolts with prescribed tool
ModularSteel 120:
Washer plates* STB-U-016-F
must be fitted on the flange
side in all 90 connections (see
sketch).
ModularSteel 80:
Screw connections with long
holes must be fitted by the
screw fastening* STL-SU012x035-F. In all other cases
the screw fastening* STL-S012x030-F is used.
Adapter plate assembly

Position the system beams and bolt them with the provided bolt fastners* in the adapter plate.
Adapter plate for clamp connection

Slacken the connection kit STL-AS-F / STB-AS-F supplied, align to desired beam and clamp tight.
Adapter plate for plug connection

Please refer to table 2 for the types of chosen anchors which
our stress calculations are based upon. Other manufactures
can be used if their load bearing capacity is proven and if
they apply to the clearance hole. The anchors must be set
according to the instructions and building cotes of the anchor
manufacturer.
Tab. 2
ModularSteel 120: tmax= 30mm

(1,18 inch)
ModularSteel 80: tmax= 20mm

(0,79 inch)
Adapter plate
Anchor
Caution: The bolt* must be straight

and clamps be parallel to each other.
ModularSteel 120
STB-APD-50-F
STB-APD-B-50-F
Liebig plug B
M16-25/55/15
Fischer FAZ 12/30
ModularSteel 80
STL-PD-x-F
Liebig anchor AB
M12-20/80/15
Note on the static loadings:

The loadings shown in this document have been calculated based on a static model using certain assumptions
and parameters. Despite taking every precaution and applying the accepted rules of engineering practice and the
applicable standards, we can only guarantee the loadings for the static cases illustrated in this catalogue. Under no
circumstances can we give any guarantee or warranty in the case of deviations from models, constraints and static
assumptions.
Errors and technical modifications reserved, images similar, Copyright Bernecker 2014
Rev. 2
Suffixes _P90 and _S90

Designed by smart plan tool:
If either of the Primary or Secondary System Beams is not on its default orientation with respect to the Adapter
Plate and Vertical Connector or Vertical Stay, the suffixes _P90 and _S90 will be appended on the Assembly
ID and its Name.The basis of the default orientation or configuration should be based from the Bernecker Catalog
(See Modular Assemblies section)
These suffixes are for Construction purpose. Modular Assemblies without suffixes should be assembled basing
from the Bernecker Catalog.
e.g.
UL68K_ _ _
Assembly ID:
UL68-DBA1
This has no appended suffix

since the Adapter Plates Length
(longer side) is parallel with the
Flange Side of the Primary
System Beam. The secondary
System Beam is not also rotated
since the Vertical Connector is
pointing downward.

UL68D_ _ _
Assembly ID:
UL68-DBA1_P90
_P90 is appended since the

Length of the Adapter Plate is
perpendicular to the Flange
Side of the Primary System.
Assembly ID:
UL68-DBA1_P90_S90
_P90_S90 is appended since

the Length of the Adapter Plate
is perpendicular to the Flange
Side of the Primary System and
the Vertical Connector is also
inverted.
Rev. 2
< ~ 78 inch
min. ~ 78 inch
Instructions for erection on field (SAFETY)
In access areas the construction height must be at min.

2,00 m.
Attention! If min. height is impossible warning PVC-cap

must be used to avoid injuries.
If assembled weight is more than 66 lbs do not move by

single person.
Heavy constructions only move by crane. Assemble

single items on site (not in warehouse).
Rev. 2
Instructions for erection on field
Only use torque wrench to ensure the mandatory torque

moment for final finish
Do not use screw wrench for final finish.
Tab. 1
Torque
ModularSteel 120
ModularSteel 80
120 Nm (90 lb-ft) 80 Nm (60 lb-ft)

Always tightened bolts with prescribed tool
After finished connection (final torque) we recommend to

mark the screw joint with screw varnish.
This displays if screw has moved during time.

Rev. 2
Instructions for construction (check loads with our catalogue)
Do not use this kind of construction for heavy loads.
For heavy load use 45 stay or create bridge.

Please refer to loads specified in our catalogues.
Avoid those long constructions as proper weight referring

to specified load forces are not useful.
Simplify construction and check orientation.
Do not fill space between support and steel construction

with shim plates.
Easy use of vertical connection plate instead of

shim plate. This enables an infinity adjustment.
Rev. 2
Avoid skewed fitting!
The bolt must be tightened straight and clamps must be

parallel to each other.
Rev. 2
Do not use bolts without plates for this connection

(STB-U-016-F).
Washer plates STB-U-016-F must be fitted on the flange

side in all 90 connections (see sketch).
Or use vertical connection plate with original attachements.
Rev. 2
Components unmounted
Components mounted
1 x STB-APK-1-50-F
120201
or
washer to
slotted hole
1 x STB-APK-2-50-F
120202
or
1 x STB-APK-4-50-F
120206
complete with
connecting kit,
bolts and nuts
1 x STB-APD-50-F
120203
or
1 x STB-APD-B-50-F
120204
complete with
bolts and nuts
Rev. 2
Components mounted
1 x STB-APV-1-F
complete with
bolts, nuts and washers
120401
washer to
drilled hole
washer to
slotted hole
1 x STB-APV-3-F
complete with
washer to
slotted hole
120402
1 x STB-TB-500-F
complete with
120601
1 x STB-HM-500-F
complete with
120602
washer to
drilled hole
washer to
slotted hole
washer to
drilled hole
washer to
slotted hole
Rev. 2
Components mounted
2 x STB-U-016-F
120301
washer to
drilled hole
1 x STB-VS-F
complete with
bolts, nuts and
washers
washer to
slotted hole
120501
washer to
slotted hole
washer to
drilled hole
1 x STB-HS-F
complete with
bolts, nuts and
washers
120502
2 x STB-U-016-F
120301
washer to
slotted hole
washer to
slotted hole
1 x STB-S45-600-F
120108
10
Rev. 2
Components mounted
1 x STB-QAS-1-F
complete with
bolts and washers
120403
Connection alternative 1
1 x STB-QAS-1-F
complete with
bolts and washers
120403
Connection alternative 2
4 x STB-016x045-F
120302
11
Rev. 2
Components mounted
washer to
slotted hole
4 x STL-S-012x030-F
080301
1 x STL-PK-1-F
080201
or
1 x STL-PK-2-F
080202
washer to
slotted hole
or
1 x STL-PK-3-F
080203
or
1 x Y-STL-PK-4-E-F
080208
with connecting kit
4 x STL-S-012x030-F
080301
washer to
slotted hole
1 x STL-PD-1-F
080204
or
1 x STL-PD-2-F
080205
or
1 x STL-PD-3-F
080206
washer to
slotted hole
4 x STL-S-012x030-F
080301
1 x Y-STL-PD-5-E-F
080209
1 x Y-STL-AS-E-F
washer to
slotted hole
washer to
slotted hole
080707
12
Rev. 2
Components mounted
4 x STL-S-012x030-F
080301
4 x STL-SU-012x035-F
080302
080302
washer to
slotted hole
1 x STL-VS-F
080501
080302
080302
washer to
slotted hole
washer to
slotted hole
washer to
slotted hole
1 x STL-HS-F
080502
to bridge horizontal gaps up to 50 mm (1,97")
080302
1 x STL-HS-2-F
080503
080302
washer to
slotted hole
washer to
slotted hole
to bridge horizontal gaps up to 160 mm (6,30")
13
Rev. 2
Components mounted
6 x STL-S-012x030-F
080301
080302
washer to
slotted hole
1 x STL-PV-1-F
080401
8 x STL-S-012x030-F
080301
080302
1 x STL-PV-2-F
080402
washer to
slotted hole
6 x STL-S-012x030-F
080301
1 x STL-PV-3-F
comprised
4 x bolts, nuts and washers
080411
14
washer to
slotted hole
Rev. 2
Components mounted
8 x STL-S-012x030-F
080301
1 x STL-PV-4-F
comprised
4 x bolts, nuts and washers
080412
washer to
slotted hole
1 x STL-TB-500-F
080621
or
080302
1 x Y-STL-TB-400-E-F
080651
or
washer to
slotted hole
1 x Y-STL-TB-610-E-F
080652
1 x STB-HM-500-F
080622
washer to
slotted hole
080302
washer to
slotted hole
080302
1 x STL-S45-F
080108
15

Instruction 09.2014

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special page | 09/14

120 Nm (90 lb-ft) 80 Nm (60 lb-ft)

* Always tightened bolts with prescribed tool

Adapter plate assembly

Adapter plate for clamp connection

Adapter plate for plug connection

Caution: The bolt* must be straight

Note on the static loadings:

special page | 09/14

Suffixes _P90 and _S90

This has no appended suffix

_P90 is appended since the

_P90_S90 is appended since

special page | 09/14

Instructions for erection on field (SAFETY)

In access areas the construction height must be at min.

Attention! If min. height is impossible warning PVC-cap

If assembled weight is more than 66 lbs do not move by

Heavy constructions only move by crane. Assemble

special page | 09/14

Instructions for erection on field

Only use torque wrench to ensure the mandatory torque

Do not use screw wrench for final finish.

120 Nm (90 lb-ft) 80 Nm (60 lb-ft)

After finished connection (final torque) we recommend to

special page | 09/14

Instructions for construction (check loads with our catalogue)

Do not use this kind of construction for heavy loads.

For heavy load use 45 stay or create bridge.

Avoid those long constructions as proper weight referring

Simplify construction and check orientation.

Do not fill space between support and steel construction

Easy use of vertical connection plate instead of

special page | 09/14

Avoid skewed fitting!

The bolt must be tightened straight and clamps must be

special page | 09/14

Do not use bolts without plates for this connection

Washer plates STB-U-016-F must be fitted on the flange

special page | 09/14

special page | 09/14

special page | 09/14

special page | 09/14

special page | 09/14

special page | 09/14

to bridge horizontal gaps up to 160 mm (6,30")

special page | 09/14

special page | 09/14

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