JOURNAL OF CONSTRUCTIONAL STEEL RESEARCH, cilt.237, 2026 (SCI-Expanded, Scopus)
Pallet racks are characterized by boltless beam-to-column connections and the widespread use of thin-walled, cold-formed steel members. Due to the wide variety of beam-end connector types and member geometries, a reliable evaluation of their flexural behavior requires experimental testing. Manufacturers of steel rack structures aim to achieve maximum performance while minimizing modifications to the geometric features of connection components, without altering roll-forming cycles for reasons of time efficiency and cost reduction. In this context, this study investigates the influence of the weld position connecting the beam to the connector plate on the flexural performance and failure modes of the connection, proposing an easily implementable structural detail to improve connection behavior. A total of fourteen cantilever tests were conducted according to EN 15512, using seven different connection layouts and two types of uprights. The results identified an optimal beam-to-connector weld position in terms of initial elastic flexural stiffness, moment capacity, and ductility. The structural response was shown to depend on the failure mode of the connection, which changed solely by modifying the position of the beam-end weld. The findings emphasize the importance of geometric detailing in semi-rigid boltless connections and offer practical guidance for improving the design and modeling of coldformed steel storage rack systems.