What’s the Difference Between Structural Pallet Rack and Roll Formed Pallet Rack?


In material handling, there are two main types of racking: roll formed and structural. 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 usually stronger and much more resistant to damage. Let’s explore these two very different types of racking and how their design influences their use in warehouse storage. 

Structural vs. Roll Formed Pallet Rack Manufacturing Processes


Structural Pallet Rack
Structural pallet racking

The differences between the two types of racking begin early in production. Roll formed pallet rack is made by feeding pieces of steel through a sequence of roller dies. Each roller die bends the frame column closer to its eventual finished shape. These bends and folds give the raw sheet metal during the manufacturing process add tensile strength. Typically, the more lengthwise bends an upright frame column has, the stronger and more rigid it will be.

The pliability of roll formed racking puts it at odds with structural pallet racking. This is because structural pallet rack is manufactured by pouring molten steel into a mold, forming it with a die, and letting it cool to form the pallet rack component. Once the steel has cooled, the product is in its strongest form. Trying to bend or modify a component may compromise structural integrity. There are a number of different forms or shapes of structural steel, but a couple of the most common forms include C-Channels and I-Beams.

Beam-to-Frame Connection


Structural pallet racking also often differs from roll formed pallet rack in the way in which beams are connected to upright frames. While many modern roll formed pallet rack designs will feature a rivet-style connector, structural pallet racking features a bolt-together beam connector design, adding strength to an already strong pallet rack system. Speaking of strength, that brings us to another important difference…

Structural vs. Roll Formed Pallet Rack Capacity


Structural pallet racking is significantly stronger and often more durable than roll formed pallet rack. For many applications, this may not be an important factor. After all, roll formed pallet rack can be very strong, and most applications don’t require excessive beam capacity. Still, for those heavy-duty storage situations, structural racking is often the only available option strong enough to withstand ultra-heavy loads. Structural racking is also generally more expensive than roll formed pallet rack, adding another variable to consider when making a decision regarding roll formed versus structural pallet rack.

Not sure which one is right for you? Give us a call, and we’ll be happy to help you figure out whether roll formed or structural pallet rack is the right fit for your storage solution. Also, make sure to check out our YouTube channel for more great tips and information!