Your Guide to Pallet Rack Columns: Design, Materials & Structural Insights

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Pallet Rack System Design - Apex Cos.

Pallet rack columns form the vertical backbone of your warehouse racking system. These columns are connected front to back by struts to create uprights, which are then joined by horizontal beams to build out the storage bays.

In high-density systems like push-back, drive-in, pallet flow , or automated storage and retrieval systems (ASRS), columns may also function independently as vertical supports, often referred to as mono-posts. The design of your pallet rack columns—along with system height, depth, weight capacity, and equipment compatibility—will influence which style is best suited for your Carolinas facility.

Structural vs Roll-Formed Rack

Pallet rack columns are typically made from either roll-formed or structural steel. Structural rack columns are created through a hot-rolling process that forms rugged, solid C-channel uprights—ideal for environments where impact resistance is key. Roll-formed columns, on the other hand, are crafted by shaping cold steel through rollers, allowing for a variety of profiles and configurations.

Roll-Formed Column & Beam

Structural Rack Column & Beam

Both options offer dependable strength, but the right choice for your Carolinas warehouse depends on factors like traffic levels, equipment compatibility, environmental conditions, seismic ratings, and budget. Structural rack is especially popular in busy, heavy-use operations—think food distribution, cold storage, or beverage handling—where extra durability matters.

Once you’ve selected the material, it’s time to consider column design, which plays a big role in long-term system performance.

Pallet Rack Column Designs – Open, Closed, or Reinforced

Column shape and reinforcement will vary depending on how the rack is manufactured and what your application demands. In roll-formed racking, common styles include open, closed, and reinforced columns. Structural rack columns typically fall under open, boxed, or reinforced designs.

Pallet Rack Column Types - Apex Cos.

Types of Roll-Formed Pallet Rack Columns

  • Open Column
  • Closed Column
  • Reinforced Column

Open Columns – These columns feature an open-back design and are enclosed on the remaining three sides. They’re easy to identify due to the open rear side. Brands like Ridg-U-Rak, Prest, Paltier, Omega, and Redirack commonly use this style. Connection holes are punched along the face and sides of the column to allow for secure beam and accessory attachments.

Closed Columns – Built as a fully enclosed steel tube, closed columns lack the open back seen in other roll-formed styles. Holes are still punched in the face and side to allow for beam connection points. A notable variation of this type is the T-post, which is named for the distinct “T” shape of its cross-section.

Reinforced Columns – This design involves welding two columns together (front to back) to enhance strength and durability. Reinforcement is typically limited to the lower portion of the upright, where damage is most likely to occur. These columns offer higher load capacity and greater resistance to impact, making them a smart option for high-traffic zones in your Carolinas warehouse.

Pallet Rack Columns - Roll Formed - Apex Cos.

Open Column

Closed Column

Reinforced Column

Types of Structural Pallet Rack Columns

  • Open C-Channel
  • Closed Boxed Column
  • Reinforced Column

Open C-Channel – Structural columns are often referred to as C-channels because their profile resembles the letter “C.” These solid, hot-rolled steel columns are punched with round holes along the face to connect beams securely.

Closed Box Column – When two C-channels are welded back to back, they form a boxed column. This configuration enhances both strength and impact resistance, especially against forklift strikes. In most cases, the boxed reinforcement runs up to 60 inches along the front column to support high-impact zones.

Reinforced Column – Another way to boost strength is by stacking two C-channel columns front to back. This added reinforcement increases load capacity and structural resilience—ideal for demanding applications in busy Carolinas warehouses.

Pallet Rack Columns - Structural - Apex Cos.

Structural C-Channel

Boxed Structural Column

Reinforced Structural Rack

Looking For Help With Your Pallet Rack Specifications?

Designing a pallet rack system comes with a lot of moving parts—and our experts are here to make the process easier. Apex Companies is your trusted partner for full-service material handling and warehouse storage solutions in the Carolinas. Our experienced team collaborates across specialties to deliver personalized, reliable support every step of the way.

Reach out today to discuss your warehouse layout, distribution challenges, or storage goals. We’re here to help you build smarter.