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Pallet Rack Roll Forming Machine

pallet rack roll forming machine

Pallet Rack Roll Forming Machine

The rack beams used to support a warehouse pallet racking system are usually made on a pallet rack roll forming machine. These heavy-duty steel rails connect to teardrop uprights to form a secure level of storage.

Formtek designs and builds metal forming solutions for OEM producers and job shop type manufacturers that produce rack P step beams, uprights, wire decks, and braces. Our brands B&K, Dahlstrom, Hill Engineering, Lockformer Custom Machinery, Tishken, Winpro, and Yoder deliver the flexible, scalable systems you need.

Upright Racks

Upright racks are the foundation of a warehouse pallet rack system. They are the structural component of the system and must be able to support the load the system will hold and interlock securely with other storage components.

Uprights can be manufactured from different materials, and they come in a wide range of sizes to suit specific needs. Roll form uprights are lighter and less expensive than other types of rack, which makes them a good choice for smaller storage capacities.

Structural style uprights are fabricated from high-strength, hot-rolled steel channels. They are strong enough to withstand the wear and tear of warehouse operations, especially those in harsh environments.

They are also often the best option for warehouses that are located in seismic zones because they provide additional safety. They also provide the highest maximum load capacity of all the upright styles.

For this reason, it’s important to understand how these uprights work and which ones are best for your racking system. Knowing these facts will help you make the right decisions for your racking needs and ensure that you get the highest quality racking solution possible.

The most common type of upright is the teardrop style, which uses a round hole in the front of the rack to connect beams and other attachments. It’s designed to provide secure connections and quick install times.

Another type of upright is the slotted style, which is designed to accept beams and other accessories. It’s also easy to install and disassemble.

Finally, there are t-bolt and Uncarco T-bolt styles, which use rectangular holes in the front of the upright to attach the beams. These systems are simple to set up and remove, and they offer a great deal of strength for heavy loads.

These racks can be used for a variety of applications, including selective systems and carton flow systems. They allow for fast and easy changes to the level of inventory on display, making them ideal for warehouses with fast-changing product requirements.

Uprights can be paired with any of the other components in a pallet racking system, but they are the most critical element and should be selected carefully. Having the proper knowledge will help you choose the most reliable and affordable solutions for your warehouse.

Step Beams

Step beams are used with a variety of pallet racking systems. They can be found on teardrop racks, structural racking and selective systems that utilize U-channel decking or wire mesh deck.

They come in two types: roll-formed and box. Rolled-formed beams are formed from coiled steel and shaped and welded to create a pallet rack roll forming machine strong, durable beam. These are often preferred for warehouses that have heavy or bulky products because they can take more abuse and offer higher capacities than a box-shaped beam.

These beams are available in standard and custom sizes, so they can be adjusted to fit any warehouse racking system. The roll forming process gives them a smooth and attractive finish that can be easily cleaned to avoid scratches and dents.

The roll forming machine can also be customized to suit your specific needs, and the end result is a custom-made beam that looks great in your warehouse. The machine has a series of tools for cutting, punching and forming the coiled steel.

Step beams typically have an inset step that enables wire decking, pallet supports and other items to be placed in the step and then rest flush with the top of the beam. The step usually measures 1 5/8″ deep and is located at the top inside edge of the beam.

They attach to compatible uprights using connector clips on each end of the beams. These clips connect the beams to the uprights with a variety of pins or hooks that connect them securely together.

There are many different kinds of load beams for pallet racking, including step beams, box beams and welded load beams. They all have their advantages and disadvantages, so it’s important to shop around for the right type of beam for your warehouse.

Aside from being more convenient to install and replace, box beams are generally more widely available than step beams. However, this does not mean that step beams are harder to find if you need them in a hurry.

On the other hand, welded load beams can be more difficult to install and may require additional work. They are also a more expensive option and are usually only available on custom orders.

Wire Decks

Adding wire decks to your pallet racks is a cost-effective way to improve safety and support the loads of the products stored in the system. It also makes it easier for forklift operators to load and unload the racking system.

Wire decks come in several different styles and are used for a variety of applications, including food storage and other hygiene-dependent storage. They help to keep products safe by catching any spills or other items that fall off of the pallets.

They are also used to improve fire safety by allowing water from sprinkler systems to flow through the racks, preventing losses due to fire. Additionally, they are sturdier and more reliable than wood decking or 2 x 4 planks and can help you comply with fire codes.

The main determinants of wire deck stability are pallet rack roll forming machine the size and density of the wire mesh, as well as the number of support channels per deck. Stock decks typically start at 2,500 pounds of load capacity, although they can be custom sized to meet specific needs.

Step channel wire decks are designed to rest on the stepped portion of a roll formed beam and are stronger than flare channel decks, which provide a flattened piece of steel that rests on top of the rolled beam. They are a great option for teardrop style pallet rack beams, but are not as robust for box or c channel structural beams.

Flared channel wire decks are a little more versatile and are designed to fit a wide range of beam types, but they are not as durable. These decks can be used to support the beams of a roll formed rack, but they may not be as resistant to shifting as a waterfall style deck or inside waterfall deck.

They come in several different types, and are usually installed using tek screws to securely fasten them to the beams. They are available with waterfall front and back edges that hug the beams, or in a reversed design with one upturned edge that provides stability while reducing shifting. They are also available with smaller waterfalls that hang below the beam surface, like a step channel deck.


Braces are used to give pallet rack uprights torsional rigidity to prevent them from twisting and compromising the integrity of the racking system. Without them, the assembly would collapse and be highly prone to failure.

They are available in a variety of types and can be applied to either a structural or roll-formed rack or box beam. Structural supports are more expensive than roll-formed, but they increase the capacity of a beam by preventing it from twisting or bending while it’s loaded on top of a rack.

Pallet racking is a popular storage solution in warehouses and distribution centers. It consists of metal racks or frames that hold loads, such as boxes or pallets. These racks are then accessed using some type of mechanized lifting and retrieval device, such as a forklift truck.

In addition to bracing, pallet racking systems require base plates and guard rails for extra protection from the elements. These components distribute weights between the rack, floor anchor, and other system components. They also transfer the load to the floor for further support and stability.

The main function of a pallet rack is to store large, bulky materials, such as lumber and piping. These racks are typically found in lumber yards or plumbing supply warehouses and feature vertical columns bolted to a base, as well as cantilever arms that extend from the columns.

X-bracing is often installed between the uprights to set their width and add additional stability. These x-braces are usually twelve foot long and may also include horizontal bracing for added strength.

Another important component of a pallet rack is the base plate, which is welded to the foot of each upright to distribute its weight and allow it to be anchored to the floor. The base plate is made from a steel material, such as hot or cold rolled steel, to help protect the rack’s foundation and reduce potential damage in high vibration areas.

These types of racking systems are used throughout industry for storage of boxes, containers, or pallets. They are typically accessed by forklift trucks or computer controlled cranes and shuttles.