Welded steel structures are frequently used in logistics and production, for example in transport boxes or storage racks. Whilst these solutions are often inexpensive to purchase and reliably fulfil their intended purpose, they quickly reach their limits when faced with dynamic requirements. The alternative here is a pipe racking system. PEK3 explains the differences between these solutions and how you can find the right system for your business.
What are welded steel structures?
Welded steel structures are the traditional solutions in logistics. As the name suggests, these are steel structures in which the individual metal parts are firmly welded together at their points of contact, thereby ensuring their stability. The components cannot be easily separated from one another; however, with shelving and transport containers, it is often still possible to use adjustable shelves flexibly, allowing you to adapt the levels according to the required height.
Welded steel beams are used in material trolleys, heavy-duty shelving, transport trolleys and boxes, and in many other products.
What are the advantages of welded steel structures?
The greatest advantage of welded steel structures is their straightforward procurement: as many products are available ‘off the shelf’, you can expect low purchase prices. In addition, welded solutions are usually available for quick delivery. Another important point is their load-bearing capacity: well-welded solutions can withstand enormous loads, and breakage at the welds is not possible under normal use. The tubes themselves are also resistant to weathering and damage. As a result, their service life is practically infinite, provided there is no damage.
What are the disadvantages of welded steel structures?
The biggest disadvantage of welded solutions in logistics and production is the lack of flexibility: with prefabricated products, subsequent modification is either severely restricted, complicated or simply not possible. This means you cannot react dynamically to changes in warehouse management and production. If major adjustments are required, the parts must be separated from one another at great expense, re-welded and repainted, which can result in immense costs. Solutions tailored to your business are possible, but they are costly and usually involve long lead times.
Another disadvantage is the weight: whilst steel is durable and highly resilient, it is also a heavy material. For products with a fixed location, this is usually less of an issue, but it makes transport boxes and mobile workstations in particular more difficult to move.
What are pipe racking systems?
In short, pipe racking systems are modular solutions that are slotted together and held in place with joints and screws. This means the systems can be taken apart and reassembled time and time again. Assembly and maintenance are carried out using standard tools and can be completed within minutes without requiring in-depth experience. There is no compromise on load-bearing capacity.
What are the advantages of pipe racking systems?
Pipe racking systems can be easily reconfigured and are modular. This offers immense advantages for logistics and production: with pipe racking systems, you can easily comply with the principles of lean manufacturing, as you can adapt the system to current requirements without difficulty. At the same time, the pipe racking system offers immense ergonomic benefits, as the respective solutions can be quickly adapted to suit different workers.
Pipe racking systems are also a sound financial investment: whilst the initial costs are sometimes higher than for welded solutions, pipe racking systems can be adapted much more easily to a company’s individual requirements and remain more cost-effective than comparable welded solutions. Furthermore, you can expand and adapt the pipe racking systems at a later date: for example, if a workstation system needs to be made mobile, all you need to do is attach wheels.
What are the disadvantages of bolted pipe racking systems?
Pipe racking systems do not have any real disadvantages, at least not for standard applications. In the event of high levels of vibration, it may be necessary to tighten the fasteners regularly; however, this can be done in no time at all. The initial costs can be high, but this is always the case with bespoke designs anyway.
Which is better: a tube-joint system or a welded steel structure?
If you compare the advantages and disadvantages of the two solutions, it quickly becomes clear that pipe racking systems are usually the better choice. On average, the only argument in favour of steel structures is their lower purchase price. However, there is one scenario in which steel structures should always be used: in the case of extreme loads, for example in property construction or as frames for industrial machinery, welded steel structures are the only option, as pipe racking systems cannot withstand these loads. Apart from these cases, however, pipe racking systems usually offer better solutions for production and warehouse logistics.
An interview with Bernd Schnappinger from PEK3 on the topic of ‘Pipe coupling systems vs. welded solutions’
Bernd Schnappinger has been a sales representative for PEK3 for 10 years and advises companies on finding the perfect solution for their logistics and workplaces.
Question: For which applications are push-fit tube systems clearly better suited than welded solutions?
Schnappinger: In companies and sectors where tasks relating to the workpieces or items to be handled change very rapidly and a high degree of flexibility is required in production or logistics, adaptable systems such as our push-fit tube system are considered the significantly better choice.
Question: Where do tube-fitting systems reach their limits?
Schnappinger: Pipe-fitting systems are designed for manual loading up to a maximum of 1,000 kg – typically, we’re looking at loads of around 400 to 500 kg. Anything above that requires a significantly greater amount of material or, ultimately, uneconomical construction costs.
Question: Are there any differences in service life between tube-joint systems and welded shelving?
Schnappinger: When it comes to ‘service life’, a slight distinction needs to be made, as both metal alternatives are ‘durable’ in their own right.
However, tubular plug-in systems represent a significantly more sustainable solution, as the components can be reused time and again for new constructions and modifications. Welded systems, on the other hand, lose their ‘justification’ as soon as new requirements arise, as these then necessitate welding a new structure and, where necessary, the old rack having to be laboriously dismantled by cutting or disposed of. Welded structures are also significantly more prone to rusting, unless they are subsequently and laboriously alloyed using a special process or coated with a protective finish.
Question: How do push-fit pipe systems prevent the joints from coming loose?
Schnappinger: In push-fit pipe systems such as the one from Easytube, the stability of the joints is primarily ensured by correctly tightened screw connections. It is usually sufficient to tighten the M6 screws used to a torque of approximately 14 Nm using a 5 mm Allen key. This, combined with the structural grip of the connectors, creates a sufficiently high clamping force to prevent the connection from coming loose unintentionally.
In addition, professional installation plays an important role: in pre-assembled applications – such as those already built and delivered by PEK3 – the tensile strength of the screws should be checked again, particularly at points subject to heavy loads or where safety is critical. This follow-up check ensures that no loosening occurs, even under load or vibration.
Question: How do the prices compare? Are there any subsequent maintenance costs?
Schnappinger: As a rule, welded frames are initially ‘cheaper’ to manufacture or procure. In the medium to long term, however, this initial cost advantage is offset when new requirements or modifications to these structures arise. Tubular plug-in systems incur no maintenance costs whatsoever; their components can be stored in a space-saving manner and used as required for new designs and modifications. Welded frames do not offer this flexibility and – once they are no longer of use – must be disposed of entirely so as not to waste valuable storage space.
Question: What are some specific examples where you have replaced welding solutions with plug-in systems?
Schnappinger: Particularly in the automotive sector, but also wherever new tasks and requirements are the norm (logistics companies, haulage firms, contract manufacturers, etc.), tubular plug-in constructions offer advantages over welded frames or – in the case of bespoke roller conveyor and feeding systems – the often standard method of material supply via forklift trucks, mesh boxes or pallets.
Question: If you were to start a new project today, under what circumstances would you personally opt for plug-in systems rather than a welded solution?
Schnappinger: In more ‘static’ sectors or small and medium-sized enterprises, where work processes and requirements often remain fundamentally the same for decades (craft businesses, car repair workshops, DIY stores, etc.), welded applications or ‘off-the-shelf’ shelving will always be the most sensible and cost-effective solution.
However, wherever it is essential to respond quickly to market or order requirements, and where processes need to be redesigned and optimised at short notice, there is no getting round flexible modular systems such as our Easytube tube-connection system, which has itself been progressively improved and optimised over many decades.
In today’s highly volatile markets, with increasing demands for rapid responses and constant adaptation to new market and customer needs, we continue to see significant growth potential for these tried-and-tested, flexible and, at the same time, cost-effective modular solutions.
Bernd Schnappinger
With over 10 years’ experience in sales, Bernd Schnappinger is your expert on implementing PEK3 Easytube systems within your organisation. In the course of his work, he has already helped numerous customers to successfully introduce the Easytube system.
