For a manufacturer, purchasing only by nominal thickness or describing a material as “mild steel coil” is not sufficient to establish its suitability.
The steel grade, mechanical properties, punched-hole geometry, roll-forming process, surface treatment and material traceability all affect the finished component.
Cold-rolled steel sheet, hot-rolled structural steel coil, hot-dip galvanized sheet and steel plate may enter different stages of pallet rack manufacturing. Their product standards and acceptance requirements are not automatically interchangeable.
This guide explains how those steel products are used to manufacture adjustable pallet-racking components, how to avoid common material purchasing errors and what international OEM buyers should include in their quotation requests.
1. How Carbon Steel Enters the Pallet Rack Manufacturing Supply Chain
Industrial pallet racks are engineered storage structures used in warehouses, distribution centers and manufacturing facilities.
Adjustable beam pallet racks generally use vertical frames and horizontal load beams to support stored unit loads. The finished system must satisfy the applicable design and installation requirements.
Manufacturing commonly involves several supply-chain stages:
- Approval of the rack system and component designs.
- Selection of the required steel grades and product standards.
- Procurement of flat steel, coated steel and structural plate.
- Slitting coils to production widths where required.
- Blanking and punching holes according to approved tooling drawings.
- Roll-forming upright and beam profiles.
- Producing braces, connectors and base-plate components.
- Completing approved welding and assembly operations.
- Applying or finishing the specified corrosion-protection system.
- Inspecting the components and releasing them for system assembly.
Actual production sequences vary. Some manufacturers purchase structural coil and perform all forming internally; others purchase pre-slit coils, formed profiles or additional fabricated components.
The material supplier’s quotation should identify the exact stage of manufacture being supplied.
2. Which Pallet Rack Components Require Carbon Steel?
Steel pallet racks contain components with different load paths, geometry and manufacturing requirements.
The following component map represents common adjustable pallet-rack construction and does not establish the design of a particular manufacturer’s product.
| Component | Possible Steel Product | Main Purchasing Concern |
|---|---|---|
| Vertical upright | Approved cold-rolled or hot-rolled structural steel sheet or coil | Specified strength, thickness, punched openings and forming response |
| Horizontal load beam | Approved structural sheet or coil | Profile geometry, steel strength, beam connection and deflection |
| Diagonal frame brace | Specified strip, formed section or structural tube | Cross-section, connection details and applied forces |
| Beam-end connector | Approved structural sheet or plate blank | Connection geometry, material properties and fabrication |
| Upright base plate | Design-approved structural steel plate | Thickness, dimensions, welds and anchor-hole configuration |
| Foot reinforcement | Specified plate or formed steel blank | Local loading, geometry and joining |
| Row spacer or connector | Approved plate, strip or section | Part geometry and structural connection requirements |
| Protective accessory | Specified steel sheet, plate or other material | Impact exposure, installation method and finish |
Wire decking, specialized accessories and certain connectors may have their own design and product standards.
Not every rack type uses every listed component, and different systems may require substantially different structural arrangements.
3. Cold-Rolled Steel for Rack Uprights and Roll-Formed Beams
Cold-rolled carbon steel sheet can be used as a starting material for selected roll-formed storage rack components.
The suitability of a particular cold-rolled product depends on the approved design, minimum required mechanical properties, forming process and dimensional specifications.
Why Rack Uprights Need More Than a Sheet-Thickness Specification
Uprights contain formed sections and repeated openings for beam connections or other assembly functions.
Their structural behavior depends on the complete profile, steel properties, holes, local slenderness, bracing and connection arrangements.
It is not sufficient to purchase a generic commercial-quality cold-rolled steel sheet and assume that its strength and forming performance match the structural design.
For a load-bearing rack upright, the approved steel grade and its specified mechanical properties must be stated in the purchasing documents.
ASTM A1008/A1008M and Steel Grade Selection
ASTM A1008/A1008M covers several categories of cold-rolled carbon and structural steel sheet, including commercial steel, structural steel and specified high-strength low-alloy products.
The complete material designation is important because different categories have different property requirements.
For example, identifying a sheet only as ASTM A1008 does not specify whether the order is for commercial-quality or a particular structural-grade product.
A rack component requiring a defined minimum yield strength must be supplied with an approved grade and documented requirements that meet the engineering specification.
Official standard: ASTM A1008/A1008M-26 — Cold-Rolled Carbon and Structural Steel Sheet.
Cold-Rolled Coil Purchasing Requirements
- Approved steel standard and complete grade.
- Specified mechanical properties and test direction where applicable.
- Nominal thickness and permitted deviations.
- Coil or slit-coil width and tolerance.
- Coil inside diameter and maximum coil weight.
- Surface condition, flatness and edge quality.
- Forming and punching requirements.
- Required identification and inspection records.
- Order quantity and delivery destination.
JUDE publishes Carbon and Alloy Steel Coil products, including cold-rolled coil categories.
Availability of a particular ASTM structural grade, thickness, test condition and coil width must be confirmed separately.
4. Hot-Rolled Steel Coil for Structural Rack Components
Hot-rolled steel coil may also be used for selected load-bearing roll-formed components where the approved design and manufacturing process permit it.
Its suitability must be assessed against the required properties and production process rather than assumed from the words “hot rolled.”
ASTM A1011/A1011M
ASTM A1011/A1011M covers applicable hot-rolled carbon, structural, high-strength low-alloy and other specified steel sheet and strip products.
The correct grade designation is essential for applications where minimum strength and formability are controlled.
A commercial steel designation should not be substituted for a higher-strength structural grade without engineering approval.
Official standard: ASTM A1011/A1011M-25 — Hot-Rolled Carbon and Structural Steel Sheet and Strip.
Roll-Forming Considerations
Hot-rolled and cold-rolled sheet may respond differently during slitting, punching and profile forming.
Manufacturers should validate the selected material against the approved tooling and profile requirements.
Relevant considerations include:
- Material strength and available elongation.
- Required bend radii.
- Springback and profile dimensions.
- Thickness consistency across the strip.
- Flatness and residual stresses.
- Edge condition after slitting.
- Wear on punching and forming tools.
- Final section straightness and twist.
Changing the grade or supply condition may require production trials even when nominal thickness remains unchanged.
5. Galvanized Steel for Pallet Rack Components
Some storage rack manufacturers use galvanized steel for selected components or supply coated products for specific environments.
The applicable corrosion-protection system depends on the rack design, installation environment and manufacturing route.
Pre-galvanized steel sheet, painted carbon steel and fabricated components that receive post-fabrication galvanizing are different purchasing options.
ASTM A653/A653M
ASTM A653/A653M covers applicable steel sheet products that are hot-dip zinc-coated or zinc-iron alloy-coated.
The product can be supplied in different substrate categories, including commercial, forming and structural steel grades.
A coating designation alone does not specify all mechanical properties of the base steel.
For a load-bearing rack member, the approved substrate grade must be verified separately from the selected coating designation.
Official standard: ASTM A653/A653M-25a — Hot-Dip Zinc-Coated Steel Sheet.
Why Substrate Strength and Coating Designation Are Separate
A galvanized coil order should state both the required steel substrate designation and the applicable zinc or zinc-alloy coating designation.
Choosing a material solely because it has a familiar coating reference does not establish its load-bearing suitability for a rack upright.
Likewise, a structural-grade sheet without suitable corrosion protection may not satisfy the intended operating environment.
Buyers should verify both requirements independently.
Pre-Galvanized vs Post-Fabrication Coating
Pre-galvanized sheet receives its metallic coating before the manufacturer punches, cuts, forms or assembles the component.
These subsequent operations can expose cut edges or damage the coating in localized areas.
Coating repair, edge protection and inspection should follow the applicable product and fabrication requirements.
Post-fabrication galvanizing involves a different manufacturing sequence. The final coating process must account for the fabricated assembly’s geometry, material compatibility and any required dimensional controls.
Pre-galvanized coil and post-fabrication hot-dip galvanizing are not automatically equivalent alternatives.
Explore JUDE Galvanized Steel Coil and Galvanized Steel Sheet for available material categories.
6. Steel Upright Manufacturing: Punching Before Roll Forming
Many pallet rack uprights use repeated perforations that allow beams or other components to engage at defined positions.
The holes and slots are part of the engineered structural and connection system, not merely decorative openings.
The punching and forming sequence must be consistent with the approved manufacturing process.
Hole Geometry and Pitch
The production drawing should define opening geometry, dimensions, tolerances and their position relative to appropriate reference features.
Important purchasing and manufacturing data can include:
- Approved blank or slit-strip width.
- Nominal sheet thickness and tolerance.
- Specified hole or slot geometry.
- Vertical and transverse hole pitch.
- Minimum edge distances where required.
- Hole-position tolerances.
- Material rolling and forming direction where relevant.
- Permissible burrs and edge condition.
- Final profile dimensions and straightness.
Perforations reduce or change the effective section properties and can influence local buckling, connection resistance and other structural behavior.
These effects must be addressed by the rack designer and applicable design procedures.
Forming and Springback
When a punched strip is roll-formed, the finished profile depends on material properties, tooling, geometry and process settings.
Higher nominal material strength alone does not guarantee that the same tooling will produce an identical finished section.
Changes in yield behavior and springback can affect dimensions or assembly fit.
For recurring OEM production, the manufacturer should approve the actual material grade and supply condition before changing steel sources.
7. Horizontal Rack Beams: Material Grade and Connection Design
Horizontal pallet-rack beams carry stored-unit loads between upright frames.
Depending on the design, beams may use formed sheet sections, built-up profiles or other approved structural members.
The final beam performance depends on geometry, steel properties, connection design, loading and system configuration.
Beam Material Selection
The approved raw material must provide the properties needed for the chosen section and manufacturing procedure.
Relevant purchasing information includes:
- Complete steel grade and product standard.
- Required mechanical-property acceptance criteria.
- Nominal thickness and tolerance.
- Coil width or blank size.
- Delivery and surface condition.
- Required forming and joining operations.
- Material identification and test documentation.
A steel mill certificate establishes the applicable raw-material conformity; it does not independently establish the beam’s permitted uniformly distributed load or point-load capacity.
Beam-End Connectors
Beam-end connectors transfer loads between beams and uprights.
Their geometry and engagement with the upright openings influence the behavior of the rack connection.
Connector blanks may require separate steel grades, thicknesses and fabrication procedures.
Changing a connector’s material or geometry without design approval can change the connection behavior even if the beam section itself remains unchanged.
8. Base Plates, Bracing and Mounting Components
Rack base plates and bracing members perform different functions from the main formed uprights and beams.
As a result, they may require separately specified steel products.
Base Plates
Base plates provide part of the connection between rack uprights and the supporting floor or foundation.
The required material is determined by the engineered rack and anchorage design.
Depending on the design, a specified structural carbon steel plate may be used for the base-plate blank.
ASTM A36/A36M is a carbon structural steel product specification that may be relevant to certain approved structural plate applications.
However, ASTM A36 should not be assigned automatically to every rack base plate.
The purchase schedule may need to specify:
- Approved material grade and product standard.
- Plate thickness and dimensions.
- Flatness and applicable tolerances.
- Anchor-hole sizes and locations.
- Required edge preparation and weld details.
- Material certificates and traceability.
Explore JUDE Carbon and Alloy Steel Plate for relevant raw-material categories.
Bracing and Other Profiles
Frame bracing can be manufactured from specified formed sections or other suitable steel products.
The chosen material must meet the loads, connection geometry and manufacturing requirements of the approved design.
Where prefabricated structural profiles or tubing are used, those products may require standards different from those applicable to flat steel coil.
JUDE also publishes Carbon Steel Structural Profiles and Carbon and Alloy Steel Pipe and Tube.
Actual available cross-sections, grades, wall thicknesses and fabrication services must be confirmed before order acceptance.
9. ANSI MH16.1 and EN 15512: Raw Steel Is Not Rack Certification
Industrial storage racks are structural systems. Their load capacity cannot be derived from the raw steel grade alone.
Rack design may require analysis, testing and evaluation of the upright profile, beam section, perforations, connections, bracing, anchorage and complete system configuration.
ANSI MH16.1-2023
ANSI MH16.1-2023 addresses the design, testing and utilization of industrial steel storage racks within its stated scope.
It includes relevant cold-formed and hot-rolled steel rack systems but does not cover every possible storage-rack configuration.
The approved system must be evaluated under the standards and jurisdictional requirements applicable to the project.
Standard reference: ANSI MH16.1-2023 — Industrial Steel Storage Racks.
BS EN 15512:2020+A1:2022
BS EN 15512:2020+A1:2022 addresses structural design principles for adjustable pallet racking systems within its scope.
The requirements differ from those governing raw steel coil or sheet materials.
Design requirements for other rack configurations, seismic conditions or special installations may involve additional standards.
Standard reference: BSI — BS EN 15512 Adjustable Pallet Racking.
10. Inspection and Traceability Before Roll-Forming Production
A pallet-rack manufacturing line may consume several coils of material during repeated production runs.
The receiving inspection procedure should ensure that the delivered material matches the approved specifications before it is released to punching and roll-forming.
Incoming Coil Checks
- Correct material standard and steel grade.
- Mill test certificate and coil identification.
- Specified chemical and mechanical properties.
- Sheet thickness and dimensional tolerances.
- Coil width and required slitting dimensions.
- Coil inside diameter and coil weight requirements.
- Surface quality, flatness and edge condition.
- Coating designation and inspection where applicable.
- Packaging and transport damage.
Maintaining Traceability After Slitting
Slitting a parent coil into narrower coils can separate the material from its original identification.
Where traceability is required, the manufacturer should use an approved identification-transfer process that links every slit coil and production batch to the applicable parent material record.
The same principle applies when plate is cut into connectors or base-plate blanks.
The required records should follow the customer’s quality plan and purchase agreement.
For supplier quality information, see JUDE Steel Quality Control and Material Inspection.
11. Common Steel Purchasing Mistakes in Pallet Rack Manufacturing
Mistake 1: Ordering Only by Thickness and Price
Two sheets of the same nominal thickness may have different mechanical properties and delivery conditions.
For load-bearing rack components, the grade and applicable mechanical requirements must be part of the approved purchase specification.
Mistake 2: Treating Commercial Steel as Structural Steel
Commercial-grade sheet and structural-grade sheet are not automatically equivalent.
The buyer must confirm the correct product category and complete grade under the applicable ASTM or EN standard.
Mistake 3: Specifying Galvanizing Without a Substrate Grade
The coating designation addresses corrosion-protection characteristics but does not independently identify the structural strength of the steel.
Both coating and substrate requirements need to be defined.
Mistake 4: Ignoring Coil Width and Hole Geometry
A coil may satisfy its steel grade but still be unsuitable for the intended rack tooling because its width, thickness tolerance or forming characteristics are incorrect.
The approved manufacturing plan should link the material order to the punching and roll-forming requirements.
Mistake 5: Assuming Coating Remains Unchanged After Fabrication
Cutting, punching, forming, welding and assembly can affect coatings and exposed edges.
Any required repairs or protective treatment must be defined by the finished-product manufacturing specification.
Mistake 6: Using a Mill Certificate as a Load-Rating Certificate
The material certificate supports verification of the raw steel product.
Finished rack capacity and system compliance require separate engineering evaluation and any applicable testing.
12. Illustrative Steel BOM for Pallet Rack Manufacturers
The following bill of materials is a purchasing template for rack component production. It is not a certified rack design.
| Item | Rack Component | Potential Starting Material | Required RFQ Data |
|---|---|---|---|
| 01 | Roll-formed upright | Approved structural cold-rolled or hot-rolled coil | Grade, mechanical properties, thickness, slit width, condition and quantity |
| 02 | Horizontal beam | Specified structural steel sheet or coil | Grade, width, thickness, forming and inspection requirements |
| 03 | Diagonal brace | Approved steel section, tube or flat product | Cross-section, grade, dimensions and connection requirements |
| 04 | Beam-end connector | Specified structural sheet or plate blank | Material, thickness, drawing revision and processing |
| 05 | Base plate | Design-approved structural steel plate | Grade, thickness, blank dimensions and anchor-hole geometry |
| 06 | Galvanized component | Specified metallic-coated steel sheet or coil | Substrate grade, coating designation, thickness and finish |
| 07 | Replacement structural blank | Approved steel sheet, plate or section | OEM part number, drawing, grade and quantity |
Every material must correspond to an approved rack component drawing and the applicable purchasing specification.
Steel supply should not be interpreted as confirmation of finished rack-system certification.
13. How to Prepare a Pallet Rack Steel RFQ
For international steel purchasing, a technically complete RFQ allows suppliers to compare requirements and identify possible material or processing limitations before quoting.
For Cold-Rolled or Hot-Rolled Coil
- Approved steel standard and edition.
- Complete grade and required mechanical properties.
- Nominal thickness and tolerance.
- Mother-coil or slit-coil width and tolerance.
- Coil ID, required coil weight and packaging.
- Surface and edge requirements.
- Required testing and certificates.
- Quantity and delivery schedule.
For Galvanized Coil
- Approved coated-steel standard.
- Required substrate grade and properties.
- Applicable zinc or alloy-coating designation.
- Sheet thickness and specified thickness basis.
- Width, finish and any required surface treatment.
- Coating inspection and material documentation.
- Required processing and packaging.
Commercial Information
- Purchasing company and manufacturing application.
- Required raw-material or processing scope.
- Trial order and expected recurring quantities.
- Material certificates and supplementary tests.
- Destination country or port.
- Requested Incoterms and shipment schedule.
- Applicable origin and project-specific requirements.
14. Example Pallet Rack Steel Procurement Email
Subject: RFQ – Structural Steel Coil, Galvanized Sheet and Base Plate Materials for Pallet Rack Manufacturing
Dear JUDE Sales Team,
We manufacture industrial pallet-racking components and are sourcing carbon steel raw materials for our production program.
Our material schedule includes structural steel coil for roll-formed uprights and beams, specified galvanized sheet for selected components, and structural plate for base plates and connectors.
Please review the attached approved material schedule and component drawings.
For coil items, please confirm the complete steel grade, product standard, mechanical-property requirements, available thicknesses, slit widths and delivery conditions.
For galvanized materials, please identify the substrate grade, coating designation, dimensions, surface condition and applicable inspection documentation.
For plate materials, please confirm the required grade, thickness, available sizes, cutting options and material certificates.
Please state clearly whether the quotation covers raw material, slit coil, cut blanks or any additional processing.
Any proposed change of grade, product standard, mechanical requirements, coating or dimensions must be submitted separately for engineering approval.
Please provide your commercial quotation, lead time, material availability, packing details and delivery terms.
Best regards,
OEM Purchasing Department
15. Frequently Asked Questions
1. What steel is used for pallet rack uprights?
Selected cold-rolled or hot-rolled structural steel sheet may be used for roll-formed uprights, depending on the approved rack design. The required grade, thickness and mechanical properties must be defined by the manufacturer.
2. Can ASTM A1008 commercial steel replace a structural grade?
Not automatically. ASTM A1008 includes different material categories. A structural component requiring specified mechanical properties must use an approved designation that satisfies the design and purchasing requirements.
3. Is hot-rolled steel suitable for pallet rack beams?
It may be suitable for certain designs when the approved grade and manufacturing process allow it. Final beam properties depend on the material, formed section, connections and rack design.
4. Does galvanized steel coil have a guaranteed rack load capacity?
No. A galvanized coil specification can establish applicable substrate and coating requirements. It does not independently certify the load capacity of a completed upright, beam or rack system.
5. Are DX51D and S350GD automatically interchangeable?
No. These are different European coated-steel grade designations with different intended property requirements. Substitution for a structural rack component requires engineering review of the governing material standard and the specified mechanical properties.
6. Does punching holes into an upright affect its structural performance?
Yes. Openings affect the geometry and may influence local buckling, effective section properties and connection behavior. The approved rack design and manufacturing tolerances must account for the holes.
7. Is thicker steel always better for pallet racks?
No. The required thickness depends on the design, material properties, profile geometry, connections and loading. Increasing thickness without engineering review is not a substitute for proper structural design.
8. Can a mill test certificate prove compliance with ANSI MH16.1?
No. A material certificate supports raw-steel conformity. ANSI MH16.1 addresses the design, testing and utilization of industrial steel storage racks within its scope.
9. Can JUDE supply steel coil and plate for pallet rack manufacturing?
JUDE publishes carbon/alloy steel coil, galvanized steel and structural plate product categories. Buyers can submit the approved material schedule for availability, grade and processing-feasibility review.
10. Does JUDE manufacture complete certified pallet racks?
JUDE’s published steel catalogue does not independently establish that it manufactures or certifies complete pallet-racking systems. Finished rack manufacture, structural design and system certification should be confirmed separately.
11. What should be specified for steel coil slitting?
The purchase order should identify the parent material, required slit width and tolerance, edge condition, coil dimensions, packaging and traceability requirements. Actual slitting capability must be confirmed with the supplier.
12. What information should an OEM include in the first quotation request?
Provide the approved grade, steel product standard, required mechanical properties, thickness, width, coating where applicable, quantities, processing requirements, inspection documents and delivery destination.
16. Request Carbon Steel Coil, Galvanized Sheet and Plate from JUDE
Steel Raw Materials for Warehouse Pallet Rack and Storage System Manufacturers
JUDE Carbon Steel publishes steel coil, galvanized sheet and structural plate product categories for industrial manufacturing and international procurement.
Manufacturers of pallet rack uprights, beams, bracing systems and metal connectors can submit approved material requirements for a quotation review.
Relevant JUDE Carbon Steel product categories:
- Carbon and Alloy Steel Coil
- Galvanized Steel Coil
- Galvanized Steel Sheet
- Carbon and Alloy Steel Plate
- Carbon Steel Structural Profiles
- Quality Control and Inspection
For a material quotation, please provide:
- Required ASTM, EN or other approved steel standard.
- Complete steel grade and specified mechanical properties.
- Coil width, thickness and quantity.
- Required zinc coating where applicable.
- Surface, flatness and edge requirements.
- Part drawings for cut plate blanks or special material processing.
- Material certificates and inspection requirements.
- Trial and recurring purchase quantities.
- Destination and requested shipment schedule.
Request a steel quotation: Contact JUDE Carbon Steel.
Email your steel BOM and requirements: carbon@jiscojude.com.
The formal quotation will confirm material availability, exact grade, dimensions, processing scope, certificates, quantities, pricing and delivery arrangements.
Raw material supply does not establish finished pallet rack structural certification or installation approval.
17. Technical Standards and References
- ASTM A1008/A1008M-26 — Cold-Rolled Carbon and Structural Steel Sheet.
- ASTM A1011/A1011M-25 — Hot-Rolled Carbon and Structural Steel Sheet and Strip.
- ASTM A653/A653M-25a — Hot-Dip Zinc-Coated Steel Sheet.
- ANSI MH16.1-2023 — Industrial Steel Storage Rack Design, Testing and Utilization.
- BSI — BS EN 15512:2020+A1:2022, Adjustable Pallet Racking Structural Design.
Technical notice: This article provides general carbon steel procurement guidance for pallet rack manufacturing. It is not a storage-rack structural calculation, load-rating certificate, installation approval, corrosion-life guarantee or finished rack certification.
Steel selection, punching, forming, connection design, anchorage, structural testing and final rack system acceptance must follow the approved engineering requirements and applicable codes.
The material and component examples are illustrative. Actual steel grades, thicknesses, coating systems, available processing and finished component requirements depend on the approved design and purchase contract.
International transactions are subject to applicable trade regulations, end-use checks, payment conditions and shipping requirements. Availability and delivery arrangements must be confirmed before commercial commitment.
