In the pallet rack industry, there are several rack styles and types, each with its own advantages. One of the most common systems used in North American warehouses is teardrop pallet racking.
Depending on the purpose or intended loading of the racking system, you may want to select one style of racking over another. Also, understanding that pallet racks are a long-term investment is crucial when selecting them. This article will explore the most common racking style: teardrop pallet racks. This rack style gets its name from the teardrop-shaped holes located on the front face of the column, as shown below.
Generally, teardrop pallet racks are made using roll-formed steel. Roll forming involves continuously bending a long strip of metal by passing it through a series of rolls, each of which makes a small, incremental bend. This process gradually shapes the metal into the desired cross-section. Form rolling also increases the yield and tensile strength of the steel while keeping the components lightweight, allowing teardrop pallet racks to reach great heights without compromising carrying capacity.
Teardrop pallet racks feature a bolt-less design. The beams slide into the upright via the teardrop-shaped holes and lock into place. The larger part of the teardrop hole guides the beam connector into place, while the smaller part provides a tight, secure fit. See below for a close-up of an upright-to-beam connection via the teardrop holes:
Teardrop pallet racking also features a locking device that secures the beam into the upright, preventing accidental dislodgement. Furthermore, the ease of assembly can minimize downtime, reduce manufacturing and labor costs, and ultimately, eliminate the need for bolts or specialized tools.
Thanks to their design, teardrop pallet racks are easily adjustable to accommodate varying pallet sizes and load capacities. Thus, they are especially useful for warehouses with frequently changing inventory. Generally, the distance between the centers of each teardrop hole is 2 inches, allowing ample flexibility in adjusting teardrop shelving.
The modular design of teardrop pallet racks allows for easy reconfiguration, expansion, and reduction of racking systems. Also, by maximizing vertical space, warehouses can make the most of their footprint with teardrop racking systems.
Although form rolling offers several benefits, it uses thinner steel, which is more susceptible to damage from forklifts and other warehouse equipment. As such, warehouses may choose to protect their teardrop racking systems further.
For more information on protecting columns, visit our blog post Storage Rack Guards: Your First Line of Defense Against Damage.
The thinner steel used in form rolling also reduces the load capacity of teardrop racks. This can limit the use of roll-formed teardrop racks in heavy industry.
For more information on the codes and regulations governing load capacity requirements, please refer to our blog post, Load Capacity Calculation Requirements for Racks.
Although teardrop racks have standardized components that offer enhanced flexibility, they are generally less customizable than structural racks. This other type of racking can be engineered to precise specifications.
The versatility of teardrop pallet racks increases with the variety of accessories that may be used to enhance their functionality and safety. Common accessories include, but are not limited to:
For more information on safety pins and their usefulness, please consult the blog post Pallet Rack Safety Pins: Extra Security in a Tiny Package.
Due to their versatility and efficiency, teardrop pallet racks are used in various industries. A common example is warehouses with high goods turnover, such as e-commerce fulfillment centers or retail warehouses. These types of racks are also common in warehouses with a wide variety of goods, as they can be modified to accommodate varying load sizes.
However, like all pallet rack systems, teardrop racks can be vulnerable to forklift impacts and other operational damage over time. When rack damage occurs, it is important to evaluate the structural integrity of the system and determine the most appropriate repair solution.
Damotech’s engineered rack repair kits are custom-manufactured to repair any pallet racking system, including standard teardrop designs as well as less common, obsolete, or discontinued rack profiles. Find out more.
