Pallet Rack: Structural vs Roll Form

Which is better: Structural or Roll Formed Racking?

Roll Form Rack vs. Structural Rack

Pallet shelving, often referred to as warehouse rack, comes in two main types: Roll Form and Structural Steel.

Definition: Rack manufacturers commonly use the terms cold-rolled (Roll Form Rack) or hot-rolled (Structural Steel).

Roll Formed Rack

Roll Formed Rack starts as a steel coil. While flat, the steel is processed through a punch that creates holes for attaching the beams. After punching, the steel is rolled to shape it for added strength.

Types of Roll Form Pallet Rack

Connections: Roll Form Rack can be assembled using bolts or welds, depending on the manufacturer.

Paint: Most manufacturers powder coat the beams and uprights, giving them long-lasting durability. Some manufacturers opt to dip the components in paint, which reduces initial costs but leads to faster wear and rusting.

Pros and Cons

• Lightweight and easy to move and install
• Uses less steel, which lowers the cost significantly
• Available in various configurations (single selective, double deep, push back, pallet flow, etc.)
• Can reach great heights despite being lightweight
• Simple beam replacement
• Comes in many colors and styles

Cons

• Damage requires immediate replacement
• Like a soda can, it's strong due to its shape but weakens when deformed, requiring unloading and replacement of compromised parts
• Easily damaged without upright protectors
• Replacing parts can be time-consuming and labor-intensive
• Lower upfront cost but higher maintenance over time compared to Structural Steel

Structural Steel Pallet Rack

Structural Steel Racks are made from hot-rolled steel, shaped into I-beams and C-channels. Structural steel is one of the strongest construction materials available.

Types of Structural Steel

Connections: Structural Racks are initially welded, with beams connected using bolts.

Paint: Most Structural Steel components are dip-painted, but some manufacturers offer powder-coated options for enhanced durability.

Pros and Cons of Structural Steel Rack

• Can withstand significant abuse while retaining 90% of its load-bearing capacity
• Upright protectors are often unnecessary
• Available in multiple configurations (single selective, double deep, push back, pallet flow, etc.)
• Beam replacement is relatively straightforward
• Structural steel can often be repaired, not replaced
• More compact components with higher capacity than Roll Form, allowing for more pallet positions
• Structural Steel is usually used for the tallest racking systems

Cons

• Costs about 15% more than Roll Form Rack on average
• Heavier and more challenging to handle
• Slightly higher installation cost

For more details on different pallet rack profiles and connections, visit: Pallet Rack Design