Popular Pallet Rack Accessory Examined – Wire Decking

Wire decking is a common pallet racking accessory. It is made from a metal mesh designed to fit securely between the front and rear rack beams. It forms a foundation for placing inventory, most often non-palletized products, cases, and cartons, preventing items from falling through the rack. The mesh design is unique because it allows water and light to pass through vs. solid surface products.

Advantages:

1. Versatile storage option

2. Improved employee safety

3. Helps support broken or bad pallets

4. Ideal for hand-stacked applications (non-palletized)

5. Supports odd-sized pallets

6. Meets fire safety requirements

• Mesh material allows fire to be detected quickly

• Improves sprinkler effectiveness

• Can reduce insurance premiums

There are a variety of wire gauge options available depending on your inventory needs. Gauge options range from 2, 4, 5 and 6. You can also choose from several finishes including powder coat, oven-baked enamel, hot-dipped galvanized, pre-galvanized, or electro-zinc plated. Choosing your finish will depend on the environmental conditions within the warehouse.

Types of Wire Decking

Wire deck design is divided into two general types – Flared Channel Deck and Step Deck. Flared channel deck is used for structural or box beams and occasionally for step beams. Step decks uniquely fit step beams, as the name suggests. Within those two categories are specific channel designs that serve as the supports for the deck. The channel options vary with the types of pallet rack beams on which they are installed, such as, step, ledge, box or structural.

Your rack type and application will determine which style of wire deck you need. Here are some ideas to help you choose the right configuration for your application:

Flared Channel Deck:

Flared channel deck is a waterfall design where the wire wraps around the outside of the beam, but the underneath support is flared out and rests upon the top of the beam.

Step Deck Options:

• Outside waterfall deck is a standard design where the wire wraps around the outside of the beam but the underneath support rests on the step inside the beam.

• Inverted channel deck also has the wire wrap around the outside of the beam, but the underneath support is flipped over (as opposed to standard deck) so that the support is not open to the top. This style is often used for food storage and other clean applications.

• Inside waterfall deck allows for the beam face to be unobstructed and the wire deck and channel are rested upon the inside step of the beam. Tek screws are used to adhere the deck in both the front and back positions to prevent the deck from falling through.

• Flush (or drop-in) deck is similar to the inside waterfall deck but without the bent edge.

• Upturned deck is designed with the waterfall facing up upon the rear beam to serve as a backstop for the pallets or cartons.

Tips for Loading

The main determinants of wire decking stability are the load dimensions, shape, and size/density. Stock decks are designed and rated for a “uniformly distributed load” (UDL), however, custom decks should be used in cases where load specifications are outside of the UDL (see point loading, below). The UDL is established when the load is set over all the support channels and the majority of the deck surface and comes within 2” of the front and rear load beams.

Point loading (or line loading) is defined as any load that has its weight concentrated on individual points versus uniformly distributed as described above. Think, for example, of footed pallets or containers as opposed to standard GMA pallets with horizontal boards. If all points are not resting evenly over the wire deck it could cause deflection and potential failure.

Wire Decking Accessories

There are several options to help provide unique storage and picking areas on the wire decking shelf. Organized SKUs provide more efficient and accurate put-away and picking.

• Hanging dividers – hook to the deck above

• Freestanding dividers – clip to the deck and protrude up

• Carton stop – provides a divide between cartons