Roll-Formed Pallet Racking… What’s with All Those Holes?

Like most industries, material handling has its own lingo, and so knowing the lingo brings us one step closer to solving our warehousing and distribution challenges.  Here are a few words, for example, that when used together represent a significant storage medium: Teardrop, T-Bolt, Slotted or Square. So, what do you think of when you see the words?  If you guessed roll-formed pallet racking frame punching patterns… congratulations, you are correct!

Now what?  Well, since knowing the lingo helps us communicate with our customers, let’s describe these major design types of roll-formed pallet rack frame/beam connections and review some of their uses.

First a quick review … Roll-formed pallet racking describes the method of cold-rolled steel that is shaped into pallet rack posts and beams.  While the steel is flat it is punched with holes (where the beams will attach) then it is rolled into the required shape, which also gives the column its strength and desired capacity.  For many industries, roll-formed pallet racking is the economical choice for warehousing storage and distribution. It is lighter-weight, yet strong, flexible and long-lasting.

Although there are a large variety of punching patterns, a few of the more popular types include:  Tear drop, slotted, and square. While different manufacturers create proprietary variations of these punches, the basic concept of each is universal. A common feature of the three punches is that they allow for faster and easier clip-together type installation and reconfiguring than bolted structural pallet racking.

Teardrop style pallet racking is one of the most popular roll-formed pallet rack.  Columns/posts using roll-formed steel are welded to base plates for added stability. Then, beams are easily clipped into the teardrop openings on the posts to create the frame.  Columns are typically available in standard 3″ and 4” column widths with a range of heights available.

 

 

 

Slotted & Square style pallet racking features automatic beam-to-column lock connections much like tear drop style rack.  Square and slotting style pallet racking is available in a virtually unlimited selection of sizes and load capacities.

 

 

 

T-bolt is a patented system very similar to the square/slotted pallet rack connector format.  It is strong and reliable with the ability to save expensive installation time requiring only a front-end connection, thus no need to reach inside the column to connect post and beam.  The T-bolt is used in the T-bolt upright i.e. “square style” punched upright.

 

 

 

We can’t talk about frame punch styles, or any kind of pallet rack for that matter, without mentioning the Interlake-Mecalux brand; popular across a variety of warehousing sectors, this type seems to require some added clarification, especially when trying to retrofit existing systems. You may be asked whether you’re looking for old style vs. new style which also implies round pin vs. shaved pin.  In a nutshell, the older style Interlake punch uses the round style pin, or teardrop F punch (TDF) to lock in the beam.  The newer style punch is designed with a shaved pin, or teardrop U punch (TDU).  Now to make it even more complicated, the TDU new style can retrofit the older systems, however the TDF will not fit the new style frame connection.  Got it? Don’t worry if it’s still a little grey, our team will steer you in the right direction.

To help you zero-in on the right design for your warehouse, the Apex team will specify the best solution for your storage and inventory needs, working with you to define the following.

Frame Selection Considerations

• Adjustability –  How often will you need to reconfigure your beam elevations?
• Ease of Installation – ls labor time/cost a major concern?
• Flexibility – Does your frame selection retrofit other styles?
• Durability – Will the frame/beam connection hold up in tough warehouse conditions?
• Capacity – Is the systems designed for heavy applications?

If you’ve done any research into roll-formed pallet racking types, you know that this just scratches the surface in terms of the number of variations available.  For more information and pallet rack selection advice, give us a call and we can discuss your warehousing and distribution needs and budget to develop the best solution.  You can also reference the guide below.

Frame-Punch Identification Guide