Pelican Expands Rack Mount Capability with Heavy Duty Square Hole Frames

Pelican’s latest enhancement to the Classic Double Entry and SuperMac rack case lines introduces a Square Hole Rack Frame option that expands payload capacity, improves hardware compatibility, and delivers validated MIL drop performance.

For aerospace, defense, communications, and industrial integrators, this is a structural upgrade designed to support higher density systems while maintaining the rugged durability expected from Pelican’s rotationally molded rack cases.

At Custom Case Pros, we see this as a meaningful advancement for teams building mission critical rack systems that require both integration precision and transport resilience.

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Expanded Payload Performance

Pelican now offers square hole frame configurations designed to support a broader range of system weights.

The standard square hole frame supports payloads up to 160 lbs and is ideal for lighter rack-mounted electronics and control systems.

For higher density builds, the new Heavy Duty Square Hole Frame supports payload ranges from 160 lbs up to 340 lbs in a fixed rack frame configuration. This increased capacity allows integrators to confidently house power distribution units, avionics, communications systems, and high-density electronic assemblies.

For applications exceeding 340 lbs, Pelican offers reinforced frame configurations that may include horizontal or vertical stiffeners. These structural reinforcements increase rigidity and improve load distribution across the rack structure, providing additional support for extreme weight requirements.

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Verified MIL-STD Drop Performance

Performance validation is critical when transporting high value electronics.

A Classic 9U case with a 33” deep rack frame equipped with the Heavy Duty Square Hole Frame was tested at a gross weight of 444.5 lbs, including a 340 lb payload. The empty case weight was 104.5 lbs.

Testing was conducted in accordance with MIL-STD-3010C, Test Method 5005, Cornerwise Drop (Rotational) from 24 inches. Multiple corner positions were evaluated.

The results were clear:

• No damage to the rack frame or rotationally molded case
• Cage nut attachment points remained secure
• Highest recorded impact measured 13 Gs

This level of performance reinforces the structural integrity of the heavy duty frame design and confirms its ability to withstand demanding transport conditions common in defense and aerospace environments.

As reflected in our capability statement, Custom Case Pros routinely supports programs aligned with MIL specifications and DFARS requirements. Validated drop performance matters when compliance and operational readiness are on the line.

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Included Hardware for Immediate Integration

Each square hole rack frame ships with a kit of 24 cage nuts, available in both standard and metric sizes. This simplifies installation and ensures compatibility with a wide range of rack mounted equipment.

Including both measurement standards eliminates the need for additional sourcing and allows integrators to move directly from configuration to assembly without delay.

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Available Sizes and Configurations

The square hole rack frame option is available in the following case depths and rack heights:

• Classic 33”, 25”, and 20” depths up to 14U
• SuperMac 24” and 30” depths up to 14U

Importantly, the Square Hole Frame option is available with no upcharge, making it a practical upgrade for teams standardizing on cage nut mounting systems.

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Why This Upgrade Matters

High density rack builds require more than shock isolation. They demand structural integrity under load, reliable hardware engagement, and validated transport performance.

The addition of heavy duty square hole frames expands Pelican’s rack mount capability into higher payload categories while maintaining the environmental protection and durability these cases are known for.

As outlined in our brand overview  , our focus remains on delivering engineered protection solutions that elevate operational reliability and professional presentation.

If you are configuring a rack mounted system and need guidance on payload capacity, frame reinforcement, or compliance alignment, our team is ready to assist.

Custom Case Pros: Securing Your Success, Case by Case.

info@customcasepros.com | (405) 566-9290