Selective Rack Load Table [TCVN Standard + Actual Drawings]

1. Why is the load capacity of Selective racks so important?

In industrial warehouses, Selective racks are the most commonly used type. However, because they are “familiar,” many warehouse owners overlook the most important part: safe working load.

• If the selected beam is thinner than the required load → sagging, cracking, breaking of the beam.
• If the column is under-calculated → when a forklift brushes or collides, the column may bend, tear, or even collapse the entire rack row.
• If dynamic loads (forklifts, vibrations, sudden braking…) are not considered → the load table is only good on paper, not usable in practice.

A properly standardized Selective rack load table must:

1. Be based on calculated loads with a safety factor considered.
2. Comply with general requirements of steel structure standards and warehouse safety (TCVN/Eurocode/AS…).
3. Be attached directly on the rack for operators to easily recognize and avoid overloading.

A strong rack is not the one using the most steel, but the one calculated correctly for actual loads and warehouse operating habits.

2. Basic load concepts in Selective racks

Before delving into the load table, some concepts need to be agreed upon:

2.1. Pallet Load (Unit Load)

This is the total weight of both the pallet and the goods on it, usually calculated in kg or tons.

Example:

• Wooden pallet 25kg + goods 775kg → pallet load = 800kg.
• Plastic pallet 20kg + goods 980kg → pallet load ≈ 1,000kg.

2.2. Load per rack level (Beam Level Load)

Each Selective rack level usually has 2 parallel beams. Depending on the design, 1 rack level can hold 2, 3, or 4 pallets.

Example:

• 2 pallets × 800kg = 1,600kg/level.
• 3 pallets × 1,000kg = 3,000kg/level.

2.3. Load per bay (Bay Load)

A rack bay is the space between two upright columns.

Bay load = (load per level) × (number of levels holding goods).

Example:

• 1 level 1,600kg, 4 levels holding goods → 6,400kg/bay.

2.4. Total frame load (Frame Load)

The upright frame must bear the total load of all beams on that frame, plus loads from collisions, misalignments, eccentricities, etc.

This is why just looking at the load of each beam is not enough – the column can still be “overloaded.”

3. General principles: TCVN & actual Selective rack design

In Vietnam, Selective racks are usually calculated based on:

• Steel structure standards (regarding materials, yield limits, strength, safety factors…).
• Warehouse safety standards, fire prevention, and lifting equipment inspection.
• Technical recommendations from European/Australian standards (EN/Eurocode, FEM, AS…).

In principle, the load table must reflect the safe load, multiplied by a factor:

• Safety factor according to steel material.
• Factor considering manufacturing errors, assembly errors.
• Factor considering dynamic loads (forklifts, collisions).

In practice, design units prioritize using a total safety factor of 1.2 – 1.5 times the usage load.

In other words:

If you want to store 1,000kg/pallet, engineers will design beams to withstand at least about 1,200–1,500kg/pallet in calculations.

4. Reference Selective rack load table (calculated for 1,000kg pallet)

Note: This is a reference table for guidance purposes. Actual load depends on: steel grade, hole punching method, beam type, rack height, connection to the floor, warehouse conditions…

4.1. General assumptions

• Pallet: 1,000kg/pallet (including both pallet and goods).
• Each level holds: 2 pallets (common standard).
• Beam width: 2.7m (suitable for 2 pallets of 1.2m).
• Forklift: common counterbalance type.
• Rack height: 5m, 4 levels holding goods.

4.2. Load table by column – beam configuration

How to read the table:

• If your warehouse uses 1,000kg pallets, 4 levels, 2 pallets per level → choose a configuration of minimum column 70×90×2.0mm, beam 50×100×1.8mm or higher.
• If there is a trend to increase load in the future (raising to 1,200–1,500kg/pallet), choose a configuration of 80×100×2.3mm or higher from the start.

5. Selective rack load table by rack height and beam spacing

Besides steel dimensions, rack height and beam spacing also affect allowable load.

5.1. Influencing parameters

• The higher the rack → the easier the column loses stability, reducing allowable load.
• The larger the beam spacing → the easier the beam sags.
• The more levels → the greater the load concentrated on the column base.

5.2. Reference table with 1,000kg pallet – 2 pallets/level

Cold storage, warehouses with frequent forklift traffic, high collisions → should choose a configuration one level higher than suggested.

6. Principle drawing of Selective rack (verbal description)

A basic Selective rack drawing will show:

1. Rack elevation view
   • Shows rack height, number of levels, beam positions.
   • Dimension:
     • Total height (frame height).
     • H1, H2, H3… (spacing between levels).
   • Load notes: For example: “2,000kg/level – 4 levels holding goods.”
2. Rack plan view
   • Forklift aisle width (usually 2.7–3.5m depending on the type of forklift).
   • Rack row length, number of bays, gaps between frames.
   • Column base position relative to the floor (distance from walls, columns).
3. Beam – column detail (Connection Detail)
   • How beams connect to columns using hooks, bolts, safety locks.
   • With/without support bar, pallet stop.
4. Column base – anchor plate detail (Base Plate Detail)
   • Anchor plate dimensions.
   • Number of expansion bolts / chemical bolts.
   • Concrete floor requirements (Grade, thickness).

In Long Quyền’s catalog, each configuration comes with a principle drawing and load table. This helps warehouse engineers, investors, fire prevention units, and inspectors easily cross-reference.

7. What should be recorded on the load table hanging on the Selective rack?

According to warehouse safety practices, each Selective rack row should have a load table hanging in a visible location, with at least the following content:

1. Maximum load per pallet (kg).
2. Number of pallets allowed per level.
3. Maximum number of levels holding goods.
4. Total maximum load for 1 rack bay.
5. Warning:
   • Do not change beam height without engineer approval.
   • Do not load goods beyond the designed pallet size.
   • Do not collide forklifts with columns; if a collision occurs, report for inspection immediately.

Example content of the table:

SELECTIVE RACK – LOAD TABLE

• Max load per pallet: 1,000kg
• 2 pallets/level – 4 levels holding goods
• Max load per level: 2,000kg
• Max load per bay: 8,000kg
  Do not arbitrarily change beams, do not overload goods.

8. Common mistakes when reading (or misunderstanding) the load table

Even with a load table, many warehouses still face issues due to some misunderstandings:

8.1. Confusing “design load” with “maximum allowable load”

• Design load: the number used in calculations, usually already multiplied by a safety factor.
• Maximum allowable load: the number printed on the load table for users to comply with.

If you try to “utilize” a few extra hundred kg on the pallet thinking the structure “has surplus,” in the long run, it will:

• Cause the beam to sag beyond the allowable limit.
• Lead to permanent deformation, requiring early beam replacement.

8.2. Ignoring the dynamic load of forklifts

Forklifts running fast, sudden braking, continuous lifting – lowering, colliding with pallets and beams.
If only considering “static” as in books, the load table will be more optimistic than reality.

8.3. Changing beam spacing after handover

Many warehouses after operation want to:

• Add more levels
• Move beams up/down a bit to “fit goods”

But each time the beam height is changed, the internal force diagram and load-bearing capacity of the column change. The original load table is no longer accurate.

9. Long-term benefits of standardizing the Selective rack load table

When warehouse owners invest correctly from the start:

• Reduce labor accidents (goods falling, rack collapse).
• Reduce goods damage due to pallet sagging, slipping off the beam.
• Optimize investment plans: knowing exactly how much “load room” is left to increase goods in the future.
• Facilitate fire prevention and insurance: having complete load tables, drawings, inspection records.

From the perspective of engineering units like Gia Kệ Long Quyền, the load table is not just a decorative board, but:

“A mini technical contract” between the rack manufacturer – warehouse owner – forklift operator.

As long as everyone complies with that number, the warehouse will operate safely and durably for many years.

10. Conclusion: The Selective rack load table cannot be “estimated by eye”

Selective racks may seem simple: a few columns, a few beams, a few supports. But behind it is:

• Calculating vertical, horizontal loads, impact forces.
• Height, slenderness of columns, type of steel, hole punching method.
• Forklift driving habits, type of pallet, warehouse environment.

Therefore, the Selective rack load table [TCVN Standard + Actual Drawings] is a mandatory step if you want to:

• Expand the warehouse safely.
• Optimize storage capacity without worrying about rack collapse.
• Easily work with inspection units, fire prevention, insurance.

Related articles Long Quyền mezzanine floor racks, cheap selective pallet racks, Mobile Steel Racks, selective racks, various types of steel racks.

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