Pallet Rack Frame Bracing: To Weld or To Bolt… That is the Question

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Pallet Rack Design - Apex Companies

What is the Difference Between Welded and Bolted Pallet Rack Frames?

At Apex we design and integrate both bolted and welded pallet rack frames in our storage rack systems. Sometimes we are asked if we prefer one design type over the other and the answer is (as is common in warehousing system design)… “Well, that depends.”  And most often, the answer comes down to customer preference.

Welded Frames – When we say “welded” pallet rack frames, we are talking about the method whereby the cross-bracing or struts are welded to the frame columns.  The struts are usually attached directly to the lips of the C-channel as in the photo to the left below.

Bolted Frames – Strutting can also be bolted to the frame.  As you can see from the photo to the right, the bolted frame struts or brace panels are also attached to the sides of the C-channel on the column but via prepared holes along the sides to accommodate the support hardware.

Welded Bracing Pallet Rack

Welded Bracing

Bolted Bracing Pallet Rack

Bolted Bracing

At one time, welded pallet racking was considered the “gold standard” here in North America while the popularity of bolted systems was widespread in Europe.  Today, we are starting to see greater acceptance of both designs in the US as customers come to recognize that there’s essentially very little difference. There are, however, several variables to consider prior to choosing which frame design is the best fit for your storage needs.  Take a look…

Pallet Rack Design – Frame Considerations

  • Structural Integrity – “Survey says”… or rather, what we’ve heard and read from the industry experts is that there’s little to no difference in terms of structural integrity and performance between welded and bolted systems. Given that the design, engineering, and installation of the frames are of sound quality, both should perform equally as well.

 

  • Quality Assurance – There are mixed opinions on this one and it really depends on the manufacturer’s quality assurance program. All frame types require the components to be fabricated via strict quality requirements and undergo inspection and testing.  For welded frames, manufacturers typically validate their welding process, and operators are trained and AWS Certified.   Otherwise, weld quality variation can put carrying capacity at risk.  Even with these rigorous controls, poor quality welded joints can occur as the issues cannot be easily seen.

 

  • Manufacturing – Welded and bolted frames are more similar in finished cost than most might realize. The main differentials in cost are that a welded system includes higher labor costs for the skilled labor of the welder whereas a bolted system requires a significant amount of additional hardware to assemble the system. The costs can essentially offset one another making the playing field more level between the two systems.

 

  • Repairs – Both types of systems can be damaged… it’s the nature of the beast! For welded systems, the repair is more difficult as the damaged component must be cut out and then a repair kit would be bolted into place.  For bolted systems, the columns or struts are also replaced but bolted components can usually be replaced with minimal time and effort by simply unbolting the damaged item and replacing it.  Take a moment to check out our Rack Repair web page to see how easy it is to repair a pallet rack frame on-site with minimal downtime and disruption.

 

  • Cost – As noted above, the manufacturing cost of the welded system is often higher because of the skilled labor required to furnish the welds. The bolted system may be less expensive to manufacture, but it does require a significant amount of hardware (bolts, nuts, washers).  So, essentially, you are either paying for skilled labor or components depending on which system you choose.  In terms of repair costs, the bolted system has an advantage over the welded system when replacing damaged struts, however, the repair process and cost are similar in terms of damaged columns.

So, do we favor one design type over the other? The answer is “No… we recommend both”.  We stock both welded and bolted frames and it really comes down to customer preference.  The Apex team will help you understand ALL of the variables and elements of the project in order to design and specify the best racking solution for your needs… including your bottom line.

Call or contact us to discuss your next project or storage challenge.