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What’s the Difference Between Structural Pallet Rack and Roll Formed Pallet Rack? The Ultimate Guide to Warehouse Racking Solutions
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When it comes to efficient warehouse management, the right storage solutions are crucial. Among the plethora of choices available, two types of racking systems – Structural Pallet Rack and Roll-Formed Pallet Rack – stand out for their distinctive features and benefits. Roll-formed pallet rack is made using cold-rolled sheet metal, while structural rack components are made with hot-rolled steel. Roll-formed pallet rack is generally less expensive, easier to install, and all around more convenient. Structural steel is often more expensive but is also typically stronger and more resistant to damage from forklifts and other lift equipment. Let’s explore these two very different types of racking and how their design influences their use in warehouse storage and determine which one is the right fit for your warehouse racking needs.
Understanding Roll Formed Pallet Rack: A Cost-Effective Storage Solution
Roll formed pallet racks, crafted from cold-rolled steel (typically between 12-16 gauge) are a popular choice for their affordability and adaptability. Their construction process involves cooling and coiling the steel, followed by shaping it into various components through a roll-forming machine. This method is versatile, allowing for numerous shapes perfect for engineered solutions like catwalk and mezzanine systems.
Most commonly manufactured in a “teardrop style”, roll-formed pallet rack beams are attached to uprights by inserting their teardrop-shaped connectors into the teardrop-shaped holes on the uprights and then secured with safety locks on the beams. The versatility and cost-effectiveness of roll-formed pallet rack has enabled it to become the most popular type of warehouse storage product in the world. Roll-formed pallet racks are commonly found in environments with less intense storage needs, like retail and 3PL warehouses. They have adequate strength for standard warehousing applications. Beam capacities can range from 1,700 to more than 10,000 pounds per pair. Upright frames are similarly less sturdy than a structural product.
Why Choose Roll Formed Pallet Racks?
- Economical: Cost-effective compared to structural racks, they are ideal for standard warehouse applications.
- Adaptable: The cold-roll process allows for diverse shapes, catering to various storage needs. These racks can also be easily adjusted, disassembled, and reconfigured, making them ideal for facilities with changing storage needs
- Popular Design: Commonly manufactured in a “teardrop style” these racks offer easy assembly and flexibility.
- Quick Installation: Roll formed racks are simpler to install and require less specialized labor, reducing overall setup time and cost
- Advancements in Durability: Modern steel fabrication processes enhance their dependability which makes them a reliable choice.
Limitations to Consider
- Durability Concerns: While roll-formed racks are budget-friendly, their thinner steel gauge can make them more susceptible to forklift damage. However, ongoing advancements in manufacturing techniques are steadily boosting their resilience.
- Lower Load Capacity: Properly designed roll-formed pallet rack can easily support standard pallet weights - a typical pallet load on a roll formed racking system is approximately 2,000-2,500 lbs. Even 3,000 lb pallet loads are common. Roll-formed racks may not be suitable for very heavy loads.
Exploring Structural Pallet Rack: A Robust and Durable Choice
Unlike roll-formed pallet rack that is cold-rolled, Structural Pallet Rack is fabricated using hot-rolled structural steel channels that are then welded together to form robust components. These racks are known for their exceptional strength and resistance to forklift damage, making them a suitable choice for heavy-duty storage. Structural racks are a go-to choice for warehouses that handle high-velocity, heavy pallets or operate in harsh conditions such as outdoor or freezer environments.
Structural racks offer a range of beam capacities from 3,200 to over 12,000 pounds (with a beam tie). The upright frame capacities range from 35,200 to over 51,000 pounds depending on the vertical beam spacing. The capacities also vary between manufacturer but generally tend to offer much higher capacities vs most comparable roll-form pallet racks.
The Advantages of Structural Pallet Racks
- Enhanced Durability: The thicker steel channels offer superior resistance to wear and tear.
- Higher Load Capacity: Designed to handle very heavy loads - structural rack is ideal for intensive storage needs.
- Bolted Connections: These bolted connections of structural rack provide a high-capacity storage system suitable for harsh environments.
- Long-Term Investment: With a lifespan extending 5-10 years longer than roll-formed systems, structural racks promise a higher ROI despite their higher upfront cost.
- Longevity: Once installed structural pallet rack requires minimal maintenance and can withstand rigorous daily operations.
Challenges of Structural Pallet Racks
- Installation and Adjustability: The bolted assembly of structural racks makes installation and any future reconfigurations time-consuming and labor-intensive.
- Higher Costs: It’s important to note that the strength and durability of structural racks come with higher costs, including shipping, installation, and longer lead times due to the complexity of their design and construction which require premium materials, skilled labor, and customization.
Which Racking System Suits Your Warehouse Best?
Choosing the right racking system depends on several factors, including your budget, storage requirements, and the intensity of warehouse operations. At Storage Coordinators, our 30 years of expertise in warehouse design and material handling systems integration positions us uniquely to guide you in selecting the most suitable racking solution.
Personalized Consultation and Turnkey Solutions
- Expert Team: Our expert team consists of in-house engineers, CAD designers, project managers, systems installers, and sales and support staff who are here to help you every step of the way.
- Customized Approach: Storage Coordinators is highly knowledgeable with over 30 years of experience in designing, engineering, and installing both roll-formed pallet rack and structural pallet rack systems. As a leading material handling systems integrator, we will work with you from end-to-end to provide you with a completely turnkey solution. We can help you choose the proper racking system that fits your unique needs. Storage Coordinators has the flexibility to integrate products from various manufacturers based on the requirements you need in your racking system.
Contact Storage Coordinators Today
To dive deeper into the world of warehouse racking systems or to schedule a personalized consultation, reach out to our team of experts. We’re here to help you optimize your storage space with the right racking solution, ensuring efficiency, safety, and scalability for your warehouse operations. Call our racking experts today at (800) 436-7760 or (610) 328-7666.
FAQs About Pallet Racking Systems
When selecting pallet racking for warehouse storage, consider key factors like your budget, the type of inventory you store, and specific environmental conditions of your warehouse. Roll formed pallet racks are a cost-effective solution for standard storage needs, while structural pallet racks are designed for more demanding, heavy-duty applications. Certain types of racking systems like Drive-In/Drive-Through Rack require structural rack due to the nature of the system and the close proximity of forklifts to the frames. There are also hybrid systems with both structural and roll-formed components that can be engineered.
Roll formed pallet racks with recent advancements in steel fabrication have become increasingly reliable for various load capacities, supporting substantial weight. They are suitable for a wide range of industrial warehouse storage requirements. However, for extremely heavy loads typical in some industrial settings, structural pallet racks are recommended due to their higher load-bearing capabilities.
Yes, structural pallet racks are exceptionally suited for extreme conditions. Their robust construction makes them ideal for outdoor storage environments and freezer storage applications, offering durability and reliability under challenging conditions.
The installation process differs significantly between structural and roll formed pallet racks. Structural racks require a more time-consuming and labor-intensive setup due to their bolted connections, making them more suitable for permanent installations. In contrast, roll formed racks offer a more straightforward assembly, ideal for dynamic warehouse spaces that require flexibility. In our experience installing both systems, it’s notable that structural racks require approximately two-thirds (66%) more time to install the same number of bays of roll-form teardrop racks. This significant difference highlights the efficiency of roll-formed selective racks for quicker setup, making them a preferred choice for projects with tighter schedules.
Roll formed pallet racks may need more frequent inspections for potential damage due to their construction, whereas structural racks are known for their low maintenance and long-lasting durability. Regular maintenance checks are essential for ensuring the safety and longevity of any pallet racking system in a warehouse setting. Ask about our preventative maintenance plans!
Absolutely, at Storage Coordinators, we offer customized pallet racking solutions that are tailored to meet your specific warehouse layout and storage needs. Our team works closely with you to design a system that maximizes space efficiency and meets your operational requirements.
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