Interchangeable Pallet Rack Beams? What You Need to Know Before Clipping In
Exploring Interchangeable Pallet Rack Beams –The Dos, The Don’ts, The Cautions
Everyone would agree that life is anything but simple in today’s modern warehouse. However, it doesn’t mean we’ve given up trying to simplify tasks, processes, equipment, etc. As most facilities rely on pallet racking for inventory storage, exploring economies in system design, installation, and repairs simply makes sense. One such product is the “interchangeable” pallet rack beam. It’s an intriguing idea and certainly sounds simple, but let’s take a closer look to see how it may… or may not connect with your inventory storage needs.
What Are Interchangeable Pallet Rack Beams?
Let’s start with what interchangeable pallet rack beams are NOT. They are not universal beams that fit with any uprights to safely replace or reprofile your system. This doesn’t mean they don’t have an application; we will get to that. Still, it’s important to note that RMI (Rack Manufacture’s Institute) advises against combining components from different rack manufacturers, as they can be incompatible, increasing the risk of system failure.
An interchangeable pallet rack beam is a roll-formed beam with a uniform step size, depth, and connector style. This beam type has a built-in step on the inside face for attaching pallet supports and decking. Connector plates lock the beam in place to prevent dislodging, and each OEM uses a unique connector method. Some connector clips are built into the beam, such as the rifle slide lock; some are spring-loaded and built into the connector plate; others require a separate safety pin clip or bolt to safeguard the attachment to the upright.
 Rifle Slide Lock |
 Spring-Loaded Clips |
 Beam Safety Pins |
Front & Rear Step Beams with Pallet Supports
Standardizing step beam measurements and connector types across beam lengths and widths makes adjusting the rack for changing inventory or process needs easier. You can also save money by reusing wire decking, pallet supports, etc., sized for the beam depth and step dimensions.
Built-in connectors simplify the tool-free installation process and keep the beam secured to the uprights despite daily warehouse activity.
Interchangeable pallet rack beams offer configuration flexibility and potential cost savings, enhancing efficiency and optimizing your pallet racking space. Many OEMs manufacture beams with the same punching, enabling mixing. However, before you mix beams, understand that the capacity of the beams and frames from the standard charts will be derated due to tolerance differences from OEM to OEM.
Specifying Beams for Pallet Racking
When specifying your beams, consult an engineer well-versed in pallet rack design and construction. If inventory size or beam requirements change, consult an engineer before repositioning beams… no matter how easy they are to unclip and shift.
Your racking is carefully engineered to distribute weight evenly across the system. An engineer can modify components to create your needed stability and load-bearing capacity. Simply shifting beams to change the number or height of rack levels can overload capacity maximums and possibly make an unsupported span, compromising the system’s integrity.
Importance of Structural Calculations
When mixing interchangeable beams from different OEMs, it is crucial to run structural calculations for the configuration. As you mix OEMs, the frames and beams will be derated from standard capacity charts. This step is necessary to ensure your racking system’s safety and structural integrity. Differences in manufacturing tolerances can lead to variations in load capacities, and failing to account for these differences can increase the risk of system failure.
Unsupported Span
Unsupported Span
An unsupported span refers to the horizontal distance between two upright frames (vertical columns) without the support of beams or other structural elements. If you remove beams to allow for new load heights (think double-stacked pallets, for example), your rack structure may no longer support the design spec and capacity requirements. An unsupported span that exceeds the rack system’s specified capacity poses a safety risk.
Beam Deflection
Additionally, under-specifying your beam size can create beam deflection, i.e., excessive bending or sagging. Beams must have sufficient capacity to support the intended load weight, and the front and rear beams should be identical. Pairing a larger and smaller beam can lead to bowing. Also, be cautious that long beams are adequately supported as they are vulnerable to deflection.
Beam deflection puts pressure on the localized storage bay and the uprights. The RMI allowable amount of deflection in either uprights or beams is approximately ½”.
Upright deflection is determined by measuring the gap at the widest point. Calculate beam deflection by dividing the beam length by 180 –e.g., a 96” beam divided by 180 allows for .53” of deflection, which falls within the approximate ½” allowance.
 Upright Deflection |
 Beam Deflection |
Shopping for Pallet Rack Beams
The type, shape, and thickness of steel influence the weight-bearing capacity of your pallet rack cross beams. Since you can’t identify steel specifications visually, you need to rely on the original engineering plans and adhere to those specifications when shopping for new or replacement components.
Check out the Apex Punching Guide if you need help determining your original manufacturer. Using our guide, you can hone in on your racking type by the punch type and locking mechanism.
If you’re shopping for roll-formed rack beams, uprights, and accessories, you can also visit our New & Used Pallet Rack Inventory page to find quality components in the sizes you need.
Design, Engineering, Installation –We Got This!
Contact Apex to simplify your warehouse tasks and optimize storage with the best pallet rack equipment for your needs. We provide full-service support, from design and engineering to sourcing quality products and professional installation—it doesn’t get any simpler than that!
