Structural Pallet Rack vs. Roll Formed Pallet Rack

When designing a pallet racking system, both structural pallet racking and roll-formed pallet racking seem like good choices, but which type is better suited for your warehouse facility?

In this article, you’ll find out!

• What is structural pallet racking and its advantages and disadvantages
• what is roll-formed pallet racking and its advantages and disadvantages
• The differences between the two and their uses

Guidance for businesses or warehouses on choosing the best option for their storage needs.

What is a Structural Pallet Rack?

Structural pallet racking is made from cast iron hot rolled into high-quality C-channel steel components. They are ideal for storing heavy pallets or in warehouses with a risk of forklift impacts. Each level can hold between 500 kg and 25,000 kg, offering durability and strength far superior to standard pallet racks.

These racks are made by cutting, punching, and welding high-strength steel, with beams bolted to the uprights for easy assembly and disassembly, which is why they are called structural racks.

The racks feature a galvanized coating that resists rust and corrosion, and their open-back design makes them suitable for extreme weather conditions, whether cold or hot. This makes them a top choice for outdoor use.

Advantages of Structural pallet rack:

1. High Strength and Durability: Welded hot-rolled C-channel steel enhances structural integrity, offering superior strength and durability.
2. Strong Load Capacity: Each beam level can support up to 25,000 kg, easily accommodating heavy pallet loads.
3. Long Service Life: Resistant to wear and tear, structural racks last 5-10 years longer than similar racks.
4. Suitable for Harsh Conditions: The galvanized surface makes these racks ideal for outdoor and freezing environments.
5. Impact Resistance: Bolted connections and welded designs improve resistance to forklift impacts, reducing maintenance frequency.
6. Open-Back Design: The C-channel’s open back makes cleaning easier, especially for food storage applications.
7. Versatile Applications: The robust structure allows these racks to perform well in harsh environments and refrigerated facilities.

Disadvantages of Structural pallet rack:

1. Higher Cost: Structural racks require higher-quality materials and precise design and installation, making them more expensive.
2. Complex Installation: The use of welding and bolted connections means installation takes more time and labor.
3. Limited Adjustability: Adjusting beams or uprights requires replacing bolts, reducing flexibility. These racks are not ideal for frequently changing inventory needs.

What is a Roll Formed Pallet Rack?

Roll formed pallet racking using a cold rolling process, the steel into the “rolling” molding machine, cold rolled into thin and light, different shapes of high-specification steel parts, and then use the safety locks to fix the beams on the uprights, forming a whole system.

Roll-formed pallet rack has a boltless design, which improves the overall assembly and adjustment of efficiency, because of the lighter weight of steel, and higher specifications, but also limits its unsuitable for storing heavy goods characteristics, can only be stored in light or medium-sized items, but also a lot of warehouses to choose the ideal choice of storage applications.

Advantages of Roll-Formed Pallet Rack:

1. Low Cost: Roll-formed racks use thinner steel, making them more cost-effective and efficient.
2. Easy Assembly: Boltless design simplifies installation, saving time and labor costs.
3. High Adjustability: Components can be easily replaced to meet different storage needs, offering greater flexibility.
4. Versatile Use: An ideal choice for a variety of storage configurations.

Disadvantages of Roll Formed Pallet Rack:

1. Easily Damaged: Thinner steel makes the structure less robust and more prone to damage from forklift impacts.
2. Lower Load Capacity: Typical roll-formed racks can hold 900-1200 kg. When loads approach or exceed 1500 kg, the racks may fail.
3. Shorter Lifespan: With a lighter structure, these racks have a shorter lifespan and require frequent maintenance or replacement.

How to Choose the Right Choice for You?

Both structural pallet racking and roll-formed pallet racking can be used for a variety of racking including selective pallet racking, drive-in racking, push-back racking, gravity flow racking, and cantilever racking!

If you are looking at budgetary constraints, roll-formed racking is your best choice because of its low price and quick turnaround;

If you are looking at load requirements and operating environment, structural pallet racking is heavier and more robust than roll-formed racking, and structural racking is preferred in warehouses with heavy loads and forklift traffic;

If you are looking at adapting to changing inventory and storage needs, roll-forming pallet racking is more flexible than structural pallet racking.

If you consider the ability to adapt to changing inventory and storage needs, compared with structural pallet racks, roll-formed pallet racks have greater flexibility and adjustability.

Considering all the immediate costs, start by evaluating whether your storage products are light or heavy if there are budget limitations, and the need for flexibility. However, it’s also important to take a long-term view. While structural pallet racks require a higher initial investment, their durability gives them a lifespan of nearly 20 years, far exceeding the 5-7 years of roll-formed racks.

Still unsure which is right for you? Contact OKE! With a team of experts with 20 years of experience, we’re happy to help you find the best solution for your warehouse. We’ll provide you with a tailored plan and a quick quote.

Stay updated by following us on YouTube, LinkedIn, and Facebook to learn more about our rack systems!