Pallet Rack Guide

Selective Pallet Racking

Selective racking, or “standard racking,” is pallet racking in its most basic, bare-bones form. At its core, a single pallet racking unit consists of two upright frames and two horizontal beams, creating a shelf level (see more on these components below). The height, depth, width, capacity rating, and number of beam levels are entirely customizable for a selective pallet rack system.

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There are two types of selective pallet racking – roll-formed and structural. Roll-formed racking typically comprises selective rack systems. Steel is cold-rolled into the correct shape making roll-formed racking easy to assemble. Roll-formed racking is for lower capacity applications than structural rack.

Structural racking uses hot, raw iron that is hot-rolled into steel channels and bolted together. Structural racking is heavy-duty and can withstand a much higher impact than roll-formed racking.

A pallet rack beam, sometimes called a cross beam, connects to pallet rack frames to form the shelf level of a pallet rack system.

These heavy-duty steel rails have a standard 1 5/8” step, which makes them compatible with wire decking, pallet supports or wood supports.

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The right pallet racking cross beams are a must-have item for your warehouse racking system. They provide support for the products you place on the pallet racking.

To keep your products safe from falling and breaking, you’ll want to make sure that your pallet racks have adequate support.  Make sure you build your pallet racks with beams that are sturdy enough to handle the job.

Pallet Rack Beam Dimensions

Length: Pallet rack beams typically range in length from 4 feet to 12 feet. The length chosen depends on the width of the pallets being stored and the overall configuration of the rack system.

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Height: The height of pallet rack beams can vary depending on the load capacity required and the vertical space available in the warehouse. Standard heights range from 3 inches to 6 inches.

Width: The width of pallet rack beams is often standardized to accommodate standard pallet sizes. Common widths include 3 inches, 3.5 inches, 4 inches, and 5 inches. The width chosen should match the depth of the pallets being stored and provide sufficient support.

Thickness: The thickness of pallet rack beams influences their load-bearing capacity and durability. Common thicknesses range from 1.5 inches to 3 inches, with heavier-duty applications typically requiring thicker beams.

Capacity: Pallet rack beams are designed to support specific weight capacities per pair. These capacities can vary widely depending on factors such as beam length, thickness, and material. Standard load capacities typically range from 2,000 pounds to 10,000 pounds per pair.

Calculating Necessary Cross Beam Capacity

In order to know the size of the beam that you need, you’ll need to calculate the beam capacity required per beam level. Since you will always need two beams per level, you need to know that capacities are listed per pair, not for an individual beam.

Calculating the beam capacity that you need isn’t too difficult once you know the proper way to do it: First, determine the weight of the heaviest pallet that you have and multiply it by the number of pallet positions you want per beam level. This will provide your required beam capacity. The most common configurations have two pallet positions on 8ft, 9ft, or 10ft beams. Typically three pallet positions will fit on a 12ft beam level.

Pallet Rack Beam Types

1. Step Beams: These are the most common type of pallet rack beams. They have a step or recessed section that allows for the placement of wire decking or other support structures. Step beams are versatile and can accommodate various pallet sizes.
2. Box Beams: Box beams have a square or rectangular shape, providing enhanced strength and load-bearing capacity compared to other beam types. They are often used for heavy-duty applications or where extra durability is required.
3. Structural Beams: Structural beams are made of heavier gauge steel and offer superior strength and durability compared to roll-formed beams. They are ideal for high-traffic areas or environments with heavy loads.
4. Wire Decking Beams: These beams are designed specifically to support wire mesh decking, which provides a flat and stable surface for storing non-palletized items or partial pallet loads. Wire decking beams enhance safety by preventing items from falling through the rack levels.
5. Channel Beams: Channel beams have a U-shaped channel profile, providing additional support and stability for pallets. They are often used in applications where pallets need to be slid into place rather than lifted.
6. Box Channel Beams: Similar to channel beams, box channel beams have a box-shaped cross-section, offering increased strength and rigidity. They are suitable for heavy-duty storage applications and can withstand significant loads.
7. Tubular Beams: Tubular beams feature a hollow tubular design, which reduces weight while maintaining strength. They are commonly used in warehouses where weight restrictions or seismic considerations are a concern.

Beam Height / Face Size

Once you calculate your desired beam capacity, that number will be your guide for determining the height (or face size) of beam you purchase. The length, height, and gauge of steel all affect the capacity of the beam. The chart on this page is a helpful guide to the measurements and weight capacity of each size of pallet rack beam.

Keep in mind that beam capacities are based on uniformly distributed static loads. If you are in an area with seismic concerns (i.e. California, Oregon, Washington, etc.) give us a call for a seismic review of your rack configuration.

To be sure about the load capacity of your pallet rack system, contact us and ask one of our industrial shelving experts. We can help ensure that you select the correct beam size for your required capacity.

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