Wire Decking Options to Boost Pallet Rack Flexibility & Warehouse Safety

How Flexible is Your Pallet Rack? Maybe Wire Decking Can Help!

Wire decking may be unassuming at first glance, but it is a critical pallet rack accessory that can boost warehouse safety and create more flexibility in your pallet rack use. Wire decking is a metal mesh product that creates a shelf between the front and rear pallet rack beams. The mesh surface provides a foundation for inventory of various sizes, including cases, cartons, and non-palletized items. It can also act as a failsafe against pallets in poor condition to prevent falling objects or debris. The mesh wire design enables light and water to move through, making it a favored choice for overall warehouse safety. 

Why is Wire Decking a Good Idea?

1. Expands pallet rack useability
2. Increases employee safety
3. Secures non-palletized inventory
4. Holds/fits odd-sized pallets
5. Supports poor/broken pallets
6. Meets fire safety requirements
   • See-through design enables fire detection
   • Increases sprinkler effectiveness
   • May reduce insurance premiums

The proper wire gauge option depends on your inventory needs –choose from 2, 4, 5 & 6 ga thicknesses. You can also customize your finish, such as hot-dipped galvanized, pre-galvanized, electro-zinc plated, oven-baked enamel, or powder coat. Selecting the correct finish for your warehouse depends on your environmental conditions. If you have questions about which wire deck product is right for your facility, just ask your Apex Carolinas representative. No one understands the Southeast humidity like your local team –a cold glass of tea, anyone? Also, be sure to ask about our current new and used wire decking inventory to speed up delivery and save a few dollars in the process.

Wire Decking Styles

There are two main styles of wire decking: flared channel deck and step deck. The differences emanate from the way that the deck secures to the cross beams, and the design of the channel supports underneath the wire surface.

The channels underneath the wire deck are a vital design component. They provide the primary determinant of the rated capacity of a given wire deck and support for odd-sized pallets and point loads. There are two designs for channels: standard U-shape or inverted U-shape.

When choosing your wire deck surface, there are several design options. Be sure to match your rack type, application, and load capacity to the appropriate wire deck product. 

For example, a standard wire step deck is 42” deep x 46” wide and mounts to a step beam. With three channel supports, the deck has a load capacity of 2,500 pounds. Three supports are typically sufficient for a standard deck, but four or more may be required for wider decks. 

Flared Channel Wire Deck

Flared channel deck has a signature waterfall design where the wire wraps around the outside of the beam. The support channel on the underside flares out at the edge to rest flat on top of the beam. You can choose U-shape or an inverted U-shape channel in a flared style. This channel is most often used for box or structural beams and occasionally step beams. 

Step Deck Design Options

• Outside waterfall deck – standard option where the wire wraps around the outside of the beam. The channel support sits on the inside step of the beam and is positioned in a “u” shape or open-faced to the deck above.
• Inverted channel deck – wire wraps around the outside of the beam, but the channel support is reversed (as opposed to standard deck) so that the support is not open to the top. This style accommodates washdown and cleaning requirements for food storage facilities and other applications with similar restrictions.
• Inside waterfall deck – the wire deck tucks behind the beam leaving the beam face unobstructed. The channel secures to the inside step of the front and rear beams with Tek screws.
• Flush (or drop-in) deck – similar to the inside waterfall wire deck, but it doesn’t have a bent edge and instead lays flat against the step of the beams.
• Upturned deck – configured with waterfall facing up on the back beam to serve as a backstop. Most often used to prevent cartons and pallets from encroaching on the rear flue space or falling from the back of the pallet rack system.

Flue Wire Decking

Wire decking can be placed between back-to-back rack rows to stop products from falling and encroaching on the flue space. See photo below.

Wire Decking Design, Installation & Use

There are numerous wire decking design styles and common patterns to meet your inventory needs. These are the most common:

1” x 2”

1” x 4”

2” x 2”

2” x 3”

2” x 4”

4” x 4”

2 ½” x 4”

Measure Properly for a Tight Fit

Wire decking must fit tightly between the front and rear beams. Here are the steps to correctly measure your pallet racking to install your wire deck:

1. Measure the length of the pallet rack beam.
2. Measure the upright front to back from outer end to outer end.
3. Measure the width of the top beam.
4. For step beams, measure the depth of the step.
5. Determine if there is any point loading –Wire decking is rated for uniform load distribution. If you have point loads or pallets resting on the deck vs. the beams, you must configure your wire deck to support this. Contact the wire deck manufacturer or a rack design engineer to discuss a point or line-load application. See UDL below for more detail.
6. Secure the decking to rack with Tek screws in both the front and rear beam positions.

UDL & Wire Deck Safety

Wire decking stability relies on the load specs, i.e., shape, size, and density. Stock decking is rated for a uniformly distributed load (UDL). UDL is determined when a load is placed on top of support channels and most of the deck surface and falls within 2” of front and rear load beams.

When the load is not evenly distributed across the surface area of the pallet or deck, it is considered a point load, i.e., a portion of the load weight is concentrated on individual points. If all points are not equally resting over the wire decking, it could trigger deflection and possible failure. For example, footed pallets or containers with shifting content may be candidates for point loading. In this case, consider custom wire decking. 

Accessorize Your Rack with Wire Deck Components

Organized SKUs with wire deck accessories to improve put-away and picking functions. By adding a wire barrier between SKUs, you can improve worker efficiencies and increase accuracy. Handy accessories include…

• Hanging dividers – hook to the deck on the level above 
• Freestanding dividers – clip to the deck surface and extend up
• Carton stop – create a wider divide between storage spaces

Local Expert Advice on Wire Decking & Pallet Rack Accessories

We’ll gladly answer your questions about wire decking or pallet rack accessories –The Apex Carolinas team is here to help. We have a large inventory of new and pre-owned Quick Ship Rack Accessories that may be just right for your warehouse. We’re also conveniently located in Charlotte and Hickory, North Carolina, as well as Greenville, South Carolina

Apex offers full-service design and installation to streamline the process and ensure your complete project satisfaction. Contact us today to schedule an on-site visit or zoom call to get the ball rolling.