IS WIRE DECKING THE PERFECT ACCESSORY FOR YOUR PALLET RACK?

read more

Wire Decking - Pallet Racking Apex Companies

Wire Decking Designs & Features for Your Pallet Rack Application

Adapting your Colorado warehouse space to accommodate a range of inventory doesn’t always require a big solution… sometimes a rack accessory can do the trick.  Wire decking is a popular pallet rack accessory that turns your pallet-only storage system into a multi-functional space.  Constructed with a durable metal mesh, wire decks install quickly and fit snugly between the front and rear rack beams. This specialized decking provides a reliable foundation for storing non-palletized inventory and can also serve as a protective shelf underneath palletized inventory. . The mesh design allows water and light to travel through it, making it perfect for fire safety, food service and other clean operations. 

HIGHLIGHTS:

  1. Transforms pallet-only storage into a versatile storage solution
  2. Enhances warehouse safety
  3. Capable of supporting compromised pallets
  4. Converts pallet bays for hand-stacked applications
  5. Accommodates odd-sized pallets
  6. Complies with essential fire safety regulations
    • Mesh material facilitates quick fire detection
    • Boosts the efficiency of sprinkler systems
    • Potential for reduced insurance premiums

We offer a range of wire gauge options to cater to your unique inventory requirements: from 2 to 4, 5, and even 6 gauge. Additionally, you can select from various finishes such as powder coat, oven-baked enamel, hot-dipped galvanized, pre-galvanized, or electro-zinc plated. You should choose your finish based on the environmental conditions within your warehouse – but if you’re not sure what to pick, your Apex Colorado representative is happy to help. 

SO MANY WIRE DECK OPTIONS:

Wire deck design can be divided into two main types: Flared Channel Deck and Step Deck. The Flared Channel Deck is primarily utilized with structural/ box beams and occasionally with step beams. On the other hand, Step Decks are specifically designed to seamlessly fit step beams. Within these two categories, there are specific channel designs that act as supports for the wire deck. The available channel options differ based on the particular types of pallet rack beams they are installed on, including step beams, ledge beams, box beams, or structural beams. This diverse range of channel designs ensures optimal compatibility and functionality with differing pallet rack configurations.

For example, a popular wire deck product is 42″ deep x 46″ wide and fitted for a step beam. This deck includes three support channels and a stated weight capacity of 2,500 pounds. Generally, wire decks have three support channels, but wider decks may require four. 

You’ll choose your style of wire deck based on your rack & beam design, but the general design styles are as follows.

Flared Channel Deck

Flared Channel:

The flared channel deck features a waterfall design, where the deck wraps around the outside of the beam. However, the underneath support is flared outwards and securely rests on top of the beam, providing stable and reliable support.

Step Deck Options:

  • Outside waterfall deck: This standard design features the wire wrapping around the outside of the beam, while the underneath support rests on the beam’s step.Inverted channel deck: In this style, the wire also wraps around the outside of the beam, but the supports underneath are flipped so that it is closed on top.This design is often employed in clean environments like food storage.
  • Inside waterfall deck With this configuration, the beam face remains unobstructed, and the wire deck and channel rest on the inner step of the beam. Firmly affixed with Tek screws, it eliminates the risk of deck displacement.
  • Flush (or drop-in) deck: Offering a sleek and seamless surface, this variation sits on the inner step of the beam without a bent edge, ensuring a level and unobstructed platform.
  • Upturned deck Using the waterfall as a backstop, it faces upwards on the rear beam, providing enhanced stability and preventing pallets or cartons from shifting backward of the shelf.

Flue Decking:

Wire decking is a valuable solution when used between back-to-back rack configurations, effectively preventing products from falling through the flue space at the rear of the racks. This setup ensures enhanced safety and stability for your stored items.

Wire Decking for Flue Space - Apex Companies

The channels running beneath the wire decking play a crucial role in its application. They serve as a key factor in determining the rated capacity of the deck and provide essential support for odd-sized pallets and point loads. These channels contribute to the overall strength and stability of the wire decking system.

Choose from two different channel designs: V-Shaped or U-Shaped.

WIRE DECK Mesh Pattern Options

We’ve talked about design styles – but let’s talk wire deck mesh patterns. Each has advantages based on your inventory needs, but the most common are as follows:

1” x 2”
1” x 4”
2” x 2”
2” x 3”
2” x 4”
4” x 4”
2 ½” x 4”

Measuring for Your Wire Decking

To accurately install your wire deck and ensure a secure fit between the front and rear beams, follow these steps:

    1. Measure the length of your pallet rack beam to determine the appropriate size for your wire deck.
    2. Determine the front-to-back distance of your uprights by measuring from one outer end to the other outer end of the same upright.
    3. Measure the width of the top surface of your beam to ensure the wire deck matches the dimensions precisely.
    4. For box or structural beams, there is no need to measure the depth of the beam step.
    5. Consider any potential point loading on the wire deck. Keep in mind that wire decking is typically rated for Uniform Distributed Load (UDL). If your application involves point loads or if the pallet will rest directly on the wire deck instead of the beams (i.e. for small pallets), you must ensure the wire deck can support these loads. If necessary, seek guidance from the wire deck manufacturer or a rack design engineer with expertise in point- or line-load applications.
    6. Use Tek screws to securely fasten the wire deck to the rack, ensuring the front and rear positions are properly secured.

LOAD IT UP:

The stability of wire decking depends on key factors such as load dimensions, shape, and size/density. Stock decks have been specifically designed and rated for a “uniformly distributed load” (UDL). In situations where load specifications fall outside of the UDL, custom decks should be employed. It is also important to consider point loading, described below, as custom decks may be necessary. The UDL is achieved when the load is evenly distributed across all support channels, covering most of the deck surface and coming within 2″ of the front and rear load beams. 

Point loading, also known as line loading, refers to a load distribution where the weight is concentrated on specific points rather than uniformly distributed. A prime example is footed pallets or containers, which differ from standard GMA pallets with horizontal boards. It’s crucial to ensure that all points of the load are resting evenly on the wire deck to prevent deflection and potential failure of the deck. Uneven weight distribution can compromise the stability and integrity of the wire deck.

BUT WAIT, THERE’S MORE!

Various accessory options are available to enhance storage and picking capabilities on wire decking shelves. These solutions create distinct storage and picking areas, promoting efficiency and accuracy in put-away and retrieval processes.

  • Hanging dividers – These dividers hook to the deck above, providing a practical way to organize SKUs and segregate different items.
  • Freestanding dividers – Clip-on dividers securely attach to the wire deck and extend upward to create partitions and boundaries for improved organization.
  • Carton stop –This feature serves as a barrier between cartons, helping to maintain separation and prevent items from mixing or falling off the wire decking.

The Apex Colorado team has the know-how and inventory to support your operation, no matter your needs. Give us a call, or browse our large inventory of new and used pallet racking and accessories in our online store. Need help with installation? Your local Apex team has you covered –call today to schedule your next project.