Pallet Rack Beams

PALLET RACK BEAMS connect between uprights and support palletized loads within a rack system. Beam capacity is always rated per pair, not individually, and is determined by a combination of beam length, profile height, and design. Selecting the correct beam size is critical for maintaining safe load limits, proper pallet support, and long-term system performance.

Pallet rack beams are available in a wide range of lengths and load capacities to accommodate standard and custom pallet sizes. The most common beam size used in warehouses is 96 inches, which allows two standard pallets (48” x 40”) to be stored side by side. Beam style and compatibility depend on the rack system in use, with Teardrop and Keystone remaining the most common configurations found in warehouses today.

In-Stock Pallet Rack Beam Sizes

We stock a wide selection of pallet rack beams to support most warehouse applications.

Standard In-Stock Beam Lengths

48″, 60″, 72″, 96″, 108″, 120″, 144″, and 168″

Standard In-Stock Beam Heights

2.75″, 3.66″, 4″, 4.5″, 5″, 6″, and 6.5″

Typical Beam Capacities

Beam capacities range from approximately 2,100 lbs. up to 9,100 lbs. per pair, depending on beam length and profile height.

Pallet Rack Beam Capacities

Beam capacity is calculated by combining the overall length of the beam with its profile height (top to bottom). Each beam size carries a different load rating, and capacity can vary slightly by manufacturer due to differences in testing methods.

For example:

• A 96″ L x 4.0″ H beam typically has a rated capacity of 5,100–5,300 lbs. per pair

• Increasing the height to 96″ L x 4.5″ H increases capacity to approximately 6,100–6,300 lbs. per pair

• Shorter beams with taller profiles can support significantly higher loads

Beam capacities are always rated per pair, meaning the combined capacity of the two beams supporting a pallet level.

Beam Connectors and Capacity Indicators

The number of connection points (often referred to as “fingers”) on the beam end connector plates is related to beam capacity.

• Beams under approximately 5,000 lbs. capacity commonly have three connectors

• Higher-capacity beams typically feature four or more connectors

While connector count can provide a general indication of capacity, actual load ratings should always be confirmed.

Safety Clips (Beam Locks)

All new pallet rack beams are supplied with safety clips, which vary in design by manufacturer. Common styles include spring-loaded clips, sliding pins, and locking clips.

Safety clips prevent beams from becoming dislodged from uprights if a pallet or forklift raises the underside of the beam. Safety clips should always be used in every pallet rack installation.

In applications where original safety clips are missing, a properly secured nut and bolt can be used as an alternative. When installed correctly, a nut-and-bolt connection is one of the most secure beam retention methods available.

Keystone (Republic) Style Pallet Rack Beams

Keystone Pallet Rack Beams were once a very common racking style and were widely produced by many manufacturers. The system is often referred to as Republic style, named after Republic Industries, an early contributor to its design.

Although Keystone racking has largely been replaced by Teardrop systems, a substantial amount remains in use today, primarily in existing warehouses and on the used equipment market. While Keystone racking is no longer commonly stocked as a quick-ship item, it can still be manufactured new for specific applications.

A unique design element of Keystone racking is that both beams share a single notch punched into the upright column, shaped like a keystone. Like Teardrop systems, Keystone uprights typically feature hole spacing on 2-inch vertical centers.

Keystone beams are commonly identified by their yellow color, with uprights often finished in gray, though color alone is not a definitive identifier.

“Infinite Adjust” Pallet Rack Beams

Infinite Adjust beams are a less common pallet rack beam style designed without traditional hook-style connectors. Instead, these beams are bolted directly to upright columns using nuts and bolts.

The connection plates on Infinite Adjust beams are slotted, allowing vertical adjustment during installation. These beams are typically used in pitched or sloped applications, such as pallet flow or carton flow systems, where gravity-assisted movement is required.

Due to their specialized design, Infinite Adjust beams are not commonly sold new for standard pallet rack applications and are most often found on the used equipment market.

Interlake “Old Style” vs. “New Style” Teardrop Beams

Interlake introduced a proprietary beam-to-upright connection design in the late 1990s, commonly referred to as “New Style Interlake.” This design differs from the traditional Teardrop system that had been widely used for decades.

Old Style Teardrop

The original Teardrop design used rounded connector pins that locked into the inverted teardrop-shaped holes on the upright. This design was simple, strong, and widely compatible across manufacturers.

New Style Interlake

Interlake’s New Style design replaced rounded pins with hook-shaped connectors. While equally strong, this proprietary design was not compatible with older Teardrop components.

Compatibility rules:

• New Style beams WILL fit Old Style uprights

• Old Style beams WILL NOT fit New Style uprights

This compatibility difference has historically caused confusion when expanding or replacing existing rack systems.

Shaved Pin Teardrop Beams

To address compatibility issues between Old and New Style Interlake systems, manufacturers introduced what is known as a Shaved Pin Beam.

By slightly modifying the traditional rounded connector pin, these beams can be installed on both Old Style and New Style uprights, eliminating compatibility concerns. While New Style Interlake components are no longer manufactured, a significant amount remains in circulation on the used market, making Shaved Pin beams a practical solution.

Need Help Identifying Your Pallet Rack Beams?

If you are unsure which pallet rack beam style or system you have, we offer a Pallet Rack Identification Guide designed to help identify rack brands and configurations. Most historical pallet rack styles are included.

Our team is also available to assist with beam selection, capacity verification, system expansion, and replacement recommendations.

Pallet rack beams are one of three primary components used in pallet rack systems, working together with uprights and wire deck panels to support palletized loads.

New & Used Pallet Rack Beams in Ohio

Midwest Material Handling supplies new and used pallet rack beams for warehouses throughout Ohio and nationwide. All used beams are inspected and graded to ensure structural integrity and safe reuse.

We stock a large inventory at our Plain City, Central Ohio warehouse, allowing for same-day pickup on many items and reduced freight costs. LTL, flatbed, and full truckload shipping options are also available.