In the world of warehouse storage solutions, the debate often comes down to cantilever racks vs. pallet racks. Both systems are widely used across warehouses, distribution centers, lumberyards, and manufacturing plants. However, each has its own advantages depending on what materials you store, how much floor space you have, and the level of accessibility you need.
If you’ve ever wondered, “When should I choose cantilever racks over pallet racks?” this guide will break down the differences, advantages, and best applications for each system. By the end, you’ll know which racking solution makes the most sense for your business.
What Are Cantilever Racks?
Cantilever racking systems are designed with arms extending from a central column, allowing long or irregularly shaped materials to be stored without vertical obstructions. Instead of being limited by horizontal beams like pallet racks, cantilever racks provide open storage access.
These racks are ideal for:
- Lumber storage (timber, plywood, MDF sheets)
- Pipe and tubing storage (steel pipes, PVC, conduit)
- Furniture storage (sofas, mattresses, long tables)
- Sheet materials (drywall, metal sheets, plastic boards)
Because there are no front columns, forklifts and workers can easily load and unload items of varying lengths.
What Are Pallet Racks?
Pallet racking systems are the standard warehouse storage solution in the U.S. They consist of upright frames and horizontal beams designed to store palletized goods. Pallet racks maximize vertical storage and are highly compatible with forklifts, automated systems, and bulk pallet handling.
Pallet racking is best for:
- Standard palletized goods
- Bulk storage and distribution
- Food and beverage warehouses
- Retail distribution centers
They are highly customizable, offering configurations such as selective racking, push-back racks, drive-in racks, and flow racks.
Key Differences Between Cantilever Racks and Pallet Racks
| Feature | Cantilever Racks | Pallet Racks |
|---|---|---|
| Storage Type | Long, bulky, irregular materials | Palletized and uniform goods |
| Accessibility | Open front for easy loading | Beam-supported, requires pallets |
| Load Support | Arms extend outward | Beams connect uprights |
| Ideal Use Cases | Lumber, pipes, furniture, sheet goods | Food, retail products, bulk storage |
| Flexibility | Highly adjustable arm lengths | Multiple racking configurations |
When to Choose Cantilever Racks Over Pallet Racks
1. When Storing Long or Awkward Items If your facility handles
lumber, steel bars, pipes, or sheet goods, cantilever racks are the superior option. Pallet racks are designed for standardized pallets, making them inefficient for materials that extend beyond pallet dimensions.
2. When You Need Quick and Easy Access
Cantilever racks provide unobstructed access, meaning forklifts and workers don’t have to maneuver around vertical columns. This reduces handling time and improves overall warehouse efficiency.
3. When Flexibility is a Priority
Cantilever systems allow you to adjust arm lengths and spacing depending on the size of the product. This flexibility makes them perfect for businesses storing a mix of different long and heavy-duty materials.
4. When Maximizing Horizontal Space
Unlike pallet racks, which focus on vertical storage, cantilever racks excel in maximizing horizontal floor space. If your warehouse has limited ceiling height but ample floor area, cantilever racks are a better choice.
5. When Safety Is a Concern
Storing long or irregular materials on pallet racks can be unsafe, as items may overhang or become unstable. Cantilever racks are specifically engineered to handle these types of loads safely.
Benefits of Cantilever Racks Over Pallet Racks
- Improved accessibility for non-palletized items
- Safer storage for oversized and heavy-duty loads
- Customizable design for different material types
- Efficient handling with forklifts or side-loaders
- Durability and strength, often made from heavy-duty steel
When to Choose Pallet Racks Instead
While cantilever racks are excellent for irregular loads, pallet racks still dominate when:
- You store standardized palletized goods
- You need high-density vertical storage
- You operate in industries like food distribution or retail
- You want to integrate with automated warehouse systems
Industry Applications of Cantilever Racks
- Construction and Lumber Yards – Ideal for timber, drywall, plywood, and steel beams.
- Manufacturing Plants – Great for pipes, raw materials, and sheet goods.
- Furniture Warehouses – Perfect for storing sofas, mattresses, and bulky furniture.
- Metal Fabrication Shops – Used for steel plates, bars, and tubing.
Cost Considerations
When comparing cantilever rack costs vs. pallet rack costs, cantilever systems can be slightly more expensive due to their specialized design and heavy-duty construction. However, the cost difference is justified when you consider:
- Reduced material damage
- Faster loading/unloading times
- Increased worker safety
- Long-term durability
FAQs About Cantilever Racks vs Pallet Racks
1. What is the main advantage of cantilever racks?
The biggest advantage is their ability to store long, bulky, and irregular materials without obstruction. They make it easy to load and unload products safely.
2. Can pallet racks be used for lumber storage?
Technically yes, but it’s not recommended. Lumber and pipes often overhang pallets, creating safety risks. Cantilever racks are specifically designed for these materials.
3. Are cantilever racks more expensive than pallet racks?
In most cases, yes. However, the long-term return on investment is better when you handle oversized materials because of reduced damage and improved efficiency.
4. Do cantilever racks save space?
They save horizontal floor space and allow for efficient organization of long products. Pallet racks, on the other hand, are better for maximizing vertical warehouse space.
5. Can cantilever racks hold heavy loads?
Yes, heavy-duty cantilever racks can store thousands of pounds per arm level, making them suitable for steel, pipes, and other dense materials.
6. Which industries benefit most from cantilever racks?
Lumberyards, metal fabrication shops, furniture distributors, and construction supply companies typically see the most benefit.
7. Do I need special forklifts for cantilever racks?
Not always. Standard forklifts can be used, but side-loader forklifts improve efficiency in narrow aisles.
8. Are cantilever racks customizable?
Yes. Cantilever systems can be configured with single-sided or double-sided arms, adjustable lengths, and varying weight capacities.
Final Thoughts
Choosing between cantilever racks and pallet racks ultimately comes down to what type of materials your warehouse handles. If you primarily store long, irregular, or heavy-duty products, cantilever racks are the best choice. They provide safer handling, better accessibility, and customizable storage for oversized items.
On the other hand, if your business revolves around palletized goods and vertical storage efficiency, pallet racks remain the go-to option.
By understanding your storage needs, floor space, and material types, you can make the right decision and improve both safety and efficiency in your warehouse.