How Much Weight Can a Pallet Rack Hold? (Expert Guide)

The pallet racking system is the esstential storage equipment of almost every modern warehouse. It is the critical equipment used to maximize storage space and streamline warehouse management. But there is one question that keeps warehouse managers up at night: "Is it safe? How much weight can this rack actually hold?"

With over 20 years of racking project experience at HEDA SHELVES, we have seen it all—from light retail storage to massive industrial distribution centers. Generally speaking, a standard industrial pallet rack system is designed with a load capacity of around 3-5 tons per layer, depending on the configuration. However, guessing is not an option when safety is on the line.

In this article, we will provide a thorough understanding of pallet racking weight capacity, offer solutions for accurate calculations, and share a real-world case study from our portfolio.

Key Takeaways

• Standard Capacity: Common heavy-duty pallet racking can hold up to 5 tons per layer with the right specifications.
• High-Density Limits: High-density systems (like Shuttle or Flow racks) often optimize for 1-3 tons per layer/position to balance automation and stress.
• Critical Factors: The strength of the beams and upright frames is the biggest factor affecting capacity.
• Safety First: Never store products beyond the beam’s maximum rated capacity.

Understanding Pallet Rack Weight Capacity

When we talk about "capacity," we are actually talking about two different ratings that work together. As experts, we encourage you to distinguish between them:

1. Beam Capacity (Per Layer): This is the maximum weight a pair of beams can hold. For example, if you have two pallets weighing 1500kg each sitting on one level, your beam capacity must be at least 3000kg.

2. Upright Frame Capacity (Total Bay): This is the total weight the vertical frames can support. This includes the weight of all the layers combined.

Expert Note: Most rack damage case failures happen not because the steel wasn't strong enough, but because the weight was unevenly distributed. Always ensure your loads are uniformly distributed (UDL).

Factors That Determine Pallet Rack Capacity

Why can one rack hold 1000kg and another hold 5000kg? It comes down to engineering.

Beam Profile and Plate Thickness

As the horizontal components directly bearing loads, common beam types include box beams and ladder beams. Beam thickness and profile cross-section determine load-bearing capacity. Deeper cross-sections and thicker, stronger beams enhance load capacity and durability.

At HEDA, we focus on two aspects:

• Profile Height: Refers to the vertical height of the beam face (e.g., 100mm, 120mm, or 160mm). Higher beam profile height strengthens the bridge structure's bending resistance and reduces deformation under pressure.
• Thickness (Specification): Manufactured from high-strength steel, standard thickness ranges from 1.5mm to 2.0mm. Each 0.5mm increase in steel thickness significantly boosts load capacity and torsional strength.

When selecting a shelving system, prioritize beam specifications, as these parameters directly determine the load-bearing capacity of pallet rack beams.

Upright Frame Construction

The upright frames take the total vertical load of the entire bay and transfer it to the floor.

• Column Size: Common sizes like 80x60mm, 90x70mm, or 100x70mm determine how much total weight the bay can hold.
• Vertical Beam Spacing: This is a "hidden" factor. If your first beam level is 2 meters high, the upright has a long "unsupported span," which reduces its capacity. Adding a beam level actually makes the frame more stable by reducing this span.

Beam Span (Length)

With Our 20 years experience in racking system design, the beam span limited in 3m can balance the pallet postion and load capacity.  As the span (the distance between the two uprights) increases, the capacity of the beam decreases.

For example, a 120mm beam might hold 3,000kg at a 2,300mm length, but that same beam may only safely hold 2,000kg if stretched to a 3,300mm length.

Types of Pallet Racks and Their Weight Capacities

Different types of pallet racks are engineered for specific weight capacities and operational purposes. Selecting the correct system based on your load requirements is critical for maintaining structural safety and maximizing warehouse efficiency.

Selective Pallet Racking

Selective pallet racks are the most widely used systems and are designed to handle medium to heavy-duty industrial loads. At HEDA SHELVES, we engineer these to support between 1,000kg to 5,000kg per level, making them highly versatile for most industries.

• Best For: Warehouses requiring 100% accessibility to every pallet and frequent stock rotation (FIFO).
  
• Capacity Insight: The capacity is easily adjusted by selecting different beam profiles (from 100mm up to 160mm).

Double Deep Racking

Double deep racking is a high-density variation of selective racking that stores pallets two-deep. Because it holds two pallets per lane per level, the beam strength is paramount.

• Capacity: Typically supports up to 5,000kg per layer.
• Best For: Businesses looking to increase storage density by 30-40% using a LIFO (Last-In, First-Out) operation.

Drive-In and Drive-Through Racks

These are high-density storage solutions where forklifts enter the racking structure itself. Instead of beams, they use rails to support the pallets.

• Capacity: These systems are built for heavy-duty bulk storage, often exceeding 1,500kg per pallet position.
  
• Best For: Large quantities of the same SKU where pallets are stacked several levels high and deep.
  

Cantilever Racks

Cantilever racks feature a specialized design with arms extending from a central column, specifically for items that don't fit on standard pallets.

• Capacity: Depending on the arm length and gauge, they can hold 1,000kg to 3,000kg per pair of arms.
  
• Best For: Long or bulky items such as timber, steel pipes, and furniture.

Radio Shuttle Racking

This semi-automatic high-density system uses a robotic shuttle to carry loads through the deep lanes of the rack.

• Capacity: Most shuttles are rated for 1,000kg to 1,500kg per pallet.
• Best For: Cold storage and FMCG (Fast-Moving Consumer Goods) where high speed and maximum space utilization are required.

Gravity Flow Racking

Also known as "Live Storage," these racks use inclined rollers to move pallets from the loading side to the picking side via gravity.

• Capacity: Generally holds 1,000kg to 3,000kg per layer.
• Best For: Perishable goods and high-volume picking environments that require strict FIFO rotation.

Common Pallet Racking Beams Maximum Load Capacity （Basic on HEDA SHELVES Standard）

Single Beam

Case Study: Heavy Duty Racking in Panama 

Client Challenge: A large logistics center in Panama needed to store heavy industrial machinery parts. They required a system that could handle extreme weight loads while remaining stable in a seismically active region.

HEDA Solution: We engineered a custom Heavy Duty Selective Racking System.

• Specs: We utilized our 160mm Integrated Beams to achieve a reliable load capacity of 3.5 tons per layer at a 2700mm beam length.

• Safety: We installed column guards and frame protectors to prevent forklift damage.

• Result: The client maximized their vertical space safely, holding heavy machinery parts that standard racks couldn't support.

Looking for Pallet Racking?

If you’re looking for pallet racking in your warehouse, HEDA SHELVES has got you covered!

From pallet racking design to on-site installation support, we offer OEM/ODM shelving and racking solutions available to suit your business needs. As shown in our data above, we engineer racks for everything from light storage to super-heavy industrial loads.

Got any questions about our products? Contact our friendly team today who will be happy to assist you with your enquiry!

FAQs

Q: How do I calculate the weight of my pallets?

A: Weigh your heaviest pallet load (product + pallet weight). Multiply this by the number of pallets per beam level. Your beam capacity must exceed this total number.

Q: What happens if I overload a rack?

A: Overloading causes beam deflection (bowing). If the beam bows more than its limit (usually 1/180th of the length), it is structurally compromised and risks collapsing.

Q: Can HEDA Shelves customize the beam length?

A: Yes. While 2300mm, 2500mm, and 2700mm are standard, we can manufacture beams to any specific length (e.g., 1000mm to 4000mm) as shown in our technical capabilities.