Professional welded storage racks for industrial warehouses, automotive parts, and commercial storage. Lightweight aluminum. Corrosion resistant. Custom sizes available.

Why Aluminum for Storage Racks?

Steel has been the traditional choice for welded storage racks. It is strong and relatively inexpensive. However, steel welded storage racks have significant disadvantages in many environments.

Weight – A steel welded storage rack weighs three times as much as an equivalent aluminum welded storage rack. This makes installation difficult and limits floor load capacity. Aluminum welded storage racks can be moved by two people rather than a forklift.

Corrosion – Steel welded storage racks rust in humid environments, cold storage, and outdoor applications. Rust weakens the structure and stains stored products. Aluminum welded storage racks do not rust. Aluminum forms a protective oxide layer that stops further corrosion, making aluminum welded storage racks ideal for harsh conditions.

Maintenance – Steel welded storage racks require painting or galvanizing to prevent rust. Scratches on steel welded storage racks expose bare metal to corrosion. Aluminum welded storage racks require no painting. Scratches on aluminum welded storage racks do not cause rust.

Appearance – Aluminum welded storage racks have a clean, professional look that stays attractive for years. Unlike steel welded storage racks, aluminum welded storage racks do not develop the orange-brown staining common with aging steel welded storage racks.

For applications in food processing, cold storage, marine environments, or clean manufacturing, our aluminum welded storage racks are the superior choice.

Rack Types We Fabricate:

We build several types of storage racks.

Selective Pallet Racks – Standard industrial racks with vertical uprights and horizontal beams. Pallets sit on beams. Forklifts access from aisles. Adjustable beam heights available.

Drive In Racks – High density storage where forklifts drive into the rack structure. Multiple pallets deep per lane. Used for bulk storage of identical products.

Cantilever Racks – Arms extend from a vertical column. Used for long items like pipe, lumber, and bar stock. Arms can be straight or inclined.

Mobile Racks – Racks mounted on carriages that move on rails. Eliminates fixed aisles. Increases storage density significantly.

Shelving Racks – Multi-level racks with solid or wire mesh shelves. Used for smaller items, bins, and boxes.

Custom Racks – Any configuration you need. Irregular shapes, non-standard sizes, or special attachments.

For each type, our welded storage racks are designed to meet or exceed RMI (Rack Manufacturers Institute) standards.

Aluminum Alloys for Racks:

Different rack components use different alloys.

6061-T6 – The primary structural alloy for rack uprights and beams. Excellent strength, good weldability. Used for heavy duty applications up to 5000 lbs per shelf.

6063-T5 – Extruded alloy with better surface finish. Used for shelving racks and cosmetic applications. Slightly lower strength than 6061.

5052 – Good corrosion resistance. Used for racks in cold storage, food processing, and marine environments.

5083 – High strength marine alloy. Used for welded storage racks on ships, docks, and coastal facilities.

3003 – General purpose alloy. Used for light duty shelving and non-structural components.

Our team selects alloy based on load requirements, environment, and budget. For most industrial applications, 6061 provides the best balance of strength and cost.

Extrusion Profiles for Racks:

We work with standard and custom extrusion profiles.

Square Tube – 2 inch, 3 inch, and 4 inch sizes. Wall thickness from 0.125 to 0.375 inches. Used for uprights and main beams.

Rectangular Tube – 2×3 inch, 2×4 inch, and 3×4 inch sizes. Used for horizontal beams where depth is needed for strength.

Channel – C shaped profiles for shelf supports and cross braces.

Angle – 1.5 x 1.5 inch to 3 x 3 inch. Used for bracing and light duty components.

I Beam – For very heavy loads. Less common in aluminum racks due to extrusion limitations.

Flat Bar – For gussets, base plates, and connection points.

For large production runs, we can work with custom extrusions designed specifically for your welded storage racks.

Joint Configurations:

Proper joint design ensures rack strength.

Upright to Base Plate – The vertical column is welded to a base plate that bolts to the floor. Full penetration weld required.

Beam to Upright – Horizontal beams attach to vertical uprights. For welded racks, we use a direct fillet weld or a welded connector tab.

Beam to Beam – For long spans, multiple beams may be spliced. We use a sleeve joint with plug welds.

Cross Bracing – Diagonal braces between uprights prevent rack sway. We weld brace ends to gusset plates or directly to uprights.

Shelf Support – Angle or channel welded between beams to support shelving.

End Frame – The complete welded assembly of uprights, base plates, and cross braces.

For every welded storage racks project, we design joints for full strength without excessive weld size.

Load Ratings and Testing:

Rack safety depends on accurate load ratings.

Upright Capacity – Depends on extrusion size, wall thickness, and height. Typical 3×3 inch 6061 tube with 0.250 wall can support 8000 lbs per upright.

Beam Capacity – Depends on span length and profile. A 4 inch deep beam spanning 8 feet supports approximately 3000 lbs uniformly distributed.

Shelf Capacity – Depends on beam spacing and shelf material. Wire mesh decks support less than solid decks.

Total Rack Capacity – Sum of all shelf capacities, limited by upright capacity.

Our welded storage racks undergo proof load testing before shipping. We apply 125 percent of rated capacity and measure deflection. Permanent deformation is not permitted.

For customers who need certified ratings, we provide engineering calculations and test reports.

Distortion Control:

Large racks have many welds. Each weld adds heat and stress. Without control, racks can twist or bow.

Our methods include the following.

Weld Sequence – We weld in a pattern that balances thermal contraction. For an end frame, we weld the four corners first, then cross braces, then attachments.

Symmetrical Welding – We weld opposite sides of the rack simultaneously when possible. Two welders working together balance heat input.

Fixture Welding – Rack components are clamped in position during welding. Fixtures maintain alignment until the rack cools.

Tack Welding – All joints are tacked and checked for square before final welding.

Interpass Cooling – Between weld passes, we cool the rack with compressed air.

Post-Weld Straightening – For racks with minor distortion, we use hydraulic presses and straightening fixtures.

Using these techniques, we hold rack squareness to within 1/8 inch over 10 feet for most welded storage racks.

Surface Preparation and Finishing:

Aluminum racks can be used as-welded or finished.

As-Welded (Mill Finish) – The rack is cleaned after welding but not treated. Suitable for indoor use in dry environments. Oxide layer provides natural protection.

Clear Anodized – An electrochemical process that hardens the surface. Resists fingerprints and minor abrasion. Good for clean rooms and retail environments.

Powder Coated – Available in any RAL color. Provides a durable, attractive finish. Best for outdoor or high visibility applications.

Chemical Brightening – Creates a reflective, polished appearance. Used for architectural and display racks.

Our welded storage racks are thoroughly cleaned before any finish is applied. We remove all weld spatter, grind sharp edges, and degrease the entire assembly.

Common Applications:

Our service supports many storage needs.

Warehouse Storage – Pallet racks for distribution centers and logistics facilities. High density configurations available.

Automotive Parts – Racks for engine blocks, transmissions, tires, and body panels. Heavy duty construction required.

Cold Storage – Freezer and cooler racks. Aluminum performs well at low temperatures and resists moisture.

Food Processing – Racks for ingredient storage and finished goods. Easy to clean and corrosion resistant.

Manufacturing – Work-in-process racks, raw material storage, and finished goods staging.

Retail Backrooms – Shelving racks for merchandise. Attractive appearance and no rust stains.

Marine and Coastal – Racks for boatyards, docks, and coastal warehouses. Saltwater resistant.

For each application, we adjust alloy selection, finish, and load ratings to match your specific needs.