Galvanised pallet racking is a form of steel storage racking that has been coated with zinc to protect it from corrosion. The galvanising process creates a durable, sacrificial layer that shields the underlying steel from moisture, chemicals and general environmental conditions that would otherwise cause rust.
In this article, we explain what galvanised pallet racking is, how it differs from painted pallet racking alternatives and where it is most effectively used, helping you understand when a galvanised finish offers genuine practical and operational advantages.
How galvanised pallet racking is made
The defining feature of galvanised pallet racking is the zinc coating applied to the steel components. This is most commonly achieved through hot-dip galvanising, where fabricated steel is immersed in molten zinc.
During this process:
- Zinc bonds metallurgically to the steel surface
- A uniform protective layer forms across all exposed faces
- The coating continues to protect even if the surface is scratched
Unlike paint, which acts as a barrier only, galvanised provides cathodic protection. This means the zinc corrodes preferentially, protecting the steel beneath it.
The result is a racking system that remains structurally sound even in environments where standard finishes would degrade rapidly.
Why galvanised pallet racking is use
Galvanised pallet racking is typically specified where the operating environment places sustained stress on standard painted finishes. In these conditions, corrosion resistance becomes a functional requirement rather than a preference, shaping the choice of racking system from the outset. Typical applications include:
- Cold stores and chilled warehouses
- External or semi-exposed storage areas
- Food processing and wash-down environments
- Agricultural and chemical storage facilities
In these settings, moisture, condensation and cleaning chemicals can quickly damage painted racking. Galvanised finishes resist this deterioration, which reduces maintenance requirements and the risk of premature replacement.
The choice is often driven by lifecycle cost rather than initial outlay.
Load capacities of galvanised racking
From a structural perspective, galvanised pallet racking performs in the same way as non-galvanised systems when designed to the same specification. Load capacities are determined by factors such as section size, steel grade and configuration, rather than by the surface finish.
Racking designed and manufactured in line with BS EN 15512 and BS EN 15620 will carry identical loads whether galvanised or powder coated, provided the galvanising process has been properly controlled.
Where galvanising is applied after fabrication, allowances are made for coating thickness so that fit-up and tolerances remain within acceptable limits.
Galvanised vs Painted pallet racking
Choosing between galvanised pallet racking and painted alternatives depends largely on environment and expected service conditions.
| Feature | Galvanised pallet racking | Painted pallet racking |
|---|---|---|
| Corrosion resistance | High resistance to corrosion and moisture | More vulnerable to chips and corrosion |
| Typical environment | Suitable for harsh or hygienic environments | Best suited to dry, indoor warehouses |
| Maintenance requirements | Minimal ongoing maintenance | May require repair or repainting over time |
| Finish options | Functional zinc finish | Wide range of colours and finishes |
| Initial cost | Higher initial cost | Lower upfront cost |
In dry, controlled environments, painted racking remains a cost-effective and reliable option. In contrast, galvanised pallet racking is often specified where repainting, repairs or replacement would be disruptive or impractical.
Is galvanised pallet racking suitable for food environments?
Galvanised pallet racking is widely used in food and drink facilities, particularly where frequent wash-downs are required. The zinc coating resists corrosion and is easier to keep clean than damaged paintwork.
That said, design details still matter. Smooth finishes, appropriate beam profiles and correct installation all contribute to hygiene and cleanability. Galvanising alone does not replace the need for proper system design and maintenance.
For these reasons, galvanised racking is often paired with disciplined inspection and cleaning regimes rather than relied on as a single solution.
Does galvanised pallet racking still need inspections?
Yes, while galvanised pallet racking is more resistant to the environmental damage, it is still subject to overloading and wear.
Under BS EN 15635, all pallet racking systems require regular visual checks and periodic expert inspections, regardless of finish. Galvanising reduces corrosion risk but does not prevent mechanical damage.
In practice, the improved durability often means few corrosion-related defects are flagged during inspections.
Conclusion
When deciding whether galvanised pallet racking is appropriate, consider:
- Exposure to moisture, condensation or chemicals
- Cleaning methods and frequency
- Expected service life of the installation
- Cost and disruption associated with future replacement
Answering what is galvanised pallet racking is ultimately about understanding where its added durability delivers real operational value.
If you’re looking for expert advice on what sort of pallet racking might suit your set-up, speak to a member of our team to discuss your environment, load requirements and long-term operational needs.