Pallet Rack: Structural vs Roll Form
This article explores the pros and cons of different types of warehouse racking.
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
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