Pallet Rack Crossbars
Pallet supports are heavy-duty steel channels or bars that sit horizontally between the front and rear load beams of a pallet rack system. These components are positioned beneath the palletized inventory and act as secondary structural members to bridge the gap between the primary rack beams. They are available in various styles, such as flange, hat-channel, and drop-in designs in order to match different beam profiles and operational preferences. They provide a stable foundation that works with traditional racking setups.
One big advantage of pallet supports is the safety net they provide against undersized or damaged pallets. In standard racking, a forklift operator must place a pallet precisely across the front and rear beams. If a wooden pallet is split, warped, or too short, it risks falling through the open space. Pallet supports sit beneath the load to eliminate this risk and prevent “drop-through” accidents. They also give forklift drivers a greater margin of error during high-level loading.
Installing pallet supports increases the structural integrity and flexibility of your existing rack system. By distributing concentrated point loads more evenly across the main step beams, these supports reduce beam twisting and deflection under heavy weight. This structural reinforcement allows facilities to safely store non-standard load configuration such as skids and smaller or irregular bins and pallets.
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48″ Mecalux Double Flanged Pallet Support Cross Bar. 1,122 lbs/cap. PN. U0072731
42″ Mecalux Double Flanged Pallet Support Cross Bar. 1,300 lbs/cap. PN. U0072729
48″ L. x 2″ W. x 16 GA. Double Flanged Pallet Support Crossbars PN. NDCBF482140H
42″ L. x 2″ W. x 16 Ga. Double Flanged Pallet Support Crossbars PN. NDCBF422140H
Pallet Support Crossbars for Structural Pallet Racking
Increase Wire Decking Capacity by Adding Top Hat Crossbar Supports Under Existing Wire Decking
Hat Style Pallet Rack Crossbar Supports
Pallet Rack Cross Bars | Double Flanged Pallet Supports
Pallet Supports
Top Hat Style Pallet Supports
Interlake Roll-In Pallet Supports
Double Flanged Pallet Supports
Structural Pallet Supports
48″ Mecalux Double Flanged Pallet Support Cross Bar. 1,122 lbs/cap.
The 48″ Mecalux Double Flanged Pallet Support Cross Bar (Part Number: U0072731) provides reliable, budget-friendly structural support for 48-inch-deep selective pallet rack bays. Rated for an evenly distributed load capacity of 1,122 lbs. per bar, this 6-lb. flanged support drops directly into standard 1-5/8″ beam steps, with outer tabs wrapping neatly over the front and rear beam faces to resist spread and movement. While Tek screws are not included, securing the bar through its pre-punched flange holes is strongly recommended by rack engineers and safety auditors to prevent pallet collapse, product drops, and expensive frame damage during aggressive forklift loading.
42″ Mecalux Double Flanged Pallet Support Cross Bar. 1,300 lbs/cap.
Engineered for standard 42-inch-deep rack frames, the 42″ Mecalux Double Flanged Pallet Support Cross Bar (Part Number: U0072729) delivers a robust 1,300-lb. load capacity based on an evenly distributed weight. Weighing just 5 lbs., this new flanged bar sets securely into standard step beams, giving forklift drivers immediate visual placement targets and adding vital reinforcement against uneven or heavy wooden pallet loads. In stock for immediate dispatch, these supports ship quickly within 4 to 5 days from strategic distribution centers in Chicago, IL, Sumter, SC, Dallas, TX, and San San Diego, CA.
48″ L. x 2″ W. x 16 GA. Double Flanged Pallet Support Crossbars
Combining lightweight strength with superior corrosion resistance, the 48″ L. x 2″ W. x 16 GA. Double Flanged Pallet Support Crossbar (Part Number: NDCBF482140H) features a durable pre-galvanized steel finish. Designed specifically for 1-5/8″ step beams, this 4.6-lb. support carries a rated load capacity of 1,250 lbs. per bar (evenly distributed). Its double-flanged ends hook over the front and rear beam faces to lock horizontal beams together, making it an ideal choice for facilities needing high-volume pallet stability across deep 48-inch rack bays.
42″ L. x 2″ W. x 16 Ga. Double Flanged Pallet Support Crossbars
Built for high-density storage setups, the 42″ L. x 2″ W. x 16 Ga. Double Flanged Pallet Support Crossbar (Part Number: NDCBF422140H) offers an impressive 1,450-lb. evenly distributed load rating. Manufactured from pre-galvanized 16-gauge steel, this 4.5-lb. crossbar drops directly into standard 1-5/8″ beam steps to support heavy wooden pallets and irregular containers. By securing the flanged ends to the load beams with Tek screws (sold separately), operators eliminate the risk of support dislodgement while protecting personnel in busy picking aisles below.
Pallet Support Crossbars for Structural Pallet Racking
When your warehouse relies on heavy-duty structural steel pallet racks built with C-channel beams, standard step-style crossbars simply will not fit. Structural Pallet Supports solve this challenge with extra-heavy, hand-welded steel cuffs (or collars) welded to each end that rest securely over the flat top crown of structural C-channel beams. Weighing a massive 6 lbs. per bar, these heavy-duty crossbars get all their load-bearing capacity directly from top-of-beam placement, making them the ultimate solution for extreme industrial loads. Stocked in standard 42-inch depths (with custom 36-inch and 48-inch depths available to order), these supports are undeniably rugged, hand-crafted, and built to match the extreme capacity of structural steel racks.
Increase Wire Decking Capacity by Adding Top Hat Crossbar Supports Under Existing Wire Decking
If your facility needs to increase the point-load capacity of existing wire mesh decks without replacing them entirely, adding top-hat crossbar supports beneath the wire mesh provides a brilliant, low-cost retrofit. By purchasing hat-style pallet supports and positioning them strategically under the mesh at key pallet contact points, you reinforce the wire deck from below. Because top-hat channels sit completely flush inside the 1-5/8″ beam step without wrapping over the beam face, the wire decking sets flat on top without rocking, while Tek screwing the supports into the beam step prevents beam bowing and guarantees the supports will never fall to the floor.
Hat Style Pallet Rack Crossbar Supports
Top-Hat Style Pallet Rack Crossbar Supports have exploded in popularity as our lowest-cost steel pallet support solution, commonly purchased in high-volume orders of 10,000 pieces or more. Named for its profile resemblance to Abraham Lincoln’s top hat, this crossbar features a 1.4mm (16-gauge) steel body with four-corner rolled edges for incredible strength and a clean pre-galvanized finish. Its primary operational advantage is that it sits completely flush inside the 1-5/8″ beam step without a waterfall flange, leaving the front beam face 100% unobstructed for barcode labels, SKU identification, and stock picking tags—making it a favorite for modern order-picking hubs.
Pallet Rack Cross Bars | Double Flanged Pallet Supports
Double-flanged pallet supports are rapidly replacing traditional wire mesh decks as our top-selling rack accessory because they cost approximately one-third as much as wire decks while providing identical load capacity for full, stretch-wrapped pallet loads. Unlike competitors who manufacture bulky 3-inch-wide bars, our design utilizes an engineered 2-inch-wide bar with rolled structural corners that yields equal or greater strength while reducing material costs and maximizing freight density—allowing up to 1,000 supports to ship on just two pallets. While companies picking loose, unbanded cartons still benefit from full wire decks, operations storing tightly secured pallet loads save thousands of dollars on product and freight by choosing double-flanged crossbars.
Pallet Support Bars serve as a fundamental preventative safety measure, taking severe point loads off horizontal beams and distributing inventory weight evenly across the entire rack structure. Made from high-grade steel, these crossbars drop over horizontal step beams to protect expensive rack frames from forklift impact and material fatigue, eliminating the massive downtime and financial loss caused by a rack collapse. Warehouse Rack & Shelf LLC maintains the world’s largest inventory of new and used pallet rack crossbars, stocking over 100,000 units in standard 36″, 42″, and 48″ depths across nationwide facilities in St. Louis, MO, Chicago, IL, Atlanta, GA, Dallas, TX, and Los Angeles, CA for 24- to 48-hour shipping.
Top-Hat Style Pallet Supports offer the ultimate economical support option for selective pallet racking systems where smooth, unencumbered beam faces are required. By resting down inside the standard 1-5/8″ step beam without flanging over the front, these supports keep beam faces completely flat for seamless location labeling. To guarantee total safety and prevent accidental dislodgement during loading, each top-hat brim features pre-drilled holes allowing installers to quickly secure the support into the beam step with Tek screws.
Interlake Roll-In Pallet Supports
Designed exclusively for Interlake slotted step beams, Interlake Roll-In Pallet Supports feature a specialized snap-in end bracket that locks directly into the beam step slots without requiring Tek screws. Because slotted beams feature pre-punched notches along the step, workers can position these flush-mount crossbars at various interval positions instantly. The massive reduction in installation labor and hardware time more than offsets the specialized bar cost, making roll-in supports the fastest-installing pallet support solution on the market.
Double Flanged Pallet Supports
As the most popular and time-tested style of pallet support on the market, Double Flanged Pallet Supports offer effortless drop-in installation for standard 1-5/8″ step beams. The outer end tabs flange neatly over the front and rear edges of the horizontal load beam, locking the beams together to prevent outward bowing under extreme weight. Featuring pre-punched Tek screw holes on each flange for optional mechanical fastening, double-flanged supports deliver the most economical way to secure full pallet loads in selective pallet racking systems.
Engineered specifically for structural channel beams and box beams that lack a standard 1-5/8″ step, Structural Pallet Supports feature oversized, heavy-duty end flanges that set directly over the top crown of the beam. These specialized safety bars allow operations storing extreme weight capacities to support wooden pallets safely without investing in custom wire decks. By giving forklift drivers an expanded, stable base to land heavy pallets, structural supports speed up loading cycles, prevent accidental load dislodgement, and maintain high safety standards across industrial facilities.
Frequently Asked Questions
How many pallet support crossbars should be installed under each wooden pallet?
Standard industry safety guidelines require a minimum of two (2) pallet support crossbars under every pallet position. For example, a standard 8-foot (96-inch) load beam holding two pallets should be fitted with four crossbars, while a 12-foot beam holding three pallets requires six crossbars to ensure proper load distribution across the shelf.
Why is it necessary to secure pallet supports with Tek screws if they drop securely into the beam step?
While flanged and top-hat supports drop into beam steps easily, securing them with self-drilling Tek screws prevents the horizontal beams from spreading or bowing outward under heavy loads. Tek screwing also guarantees that active forklift loading, pallet scraping, or accidental upward impacts will not dislodge the support bar or cause it to fall into the aisle below.
What is the main operational difference between Double Flanged and Top-Hat Style pallet supports?
Double-flanged supports feature outer tabs that wrap over the front and back face of the load beam, providing maximum resistance against beam spreading; however, this flange partially covers the beam face. Top-hat style supports set completely inside the beam step and sit flush with the top, leaving the front beam face 100% open for location barcodes and stock picking labels.
