Not every pallet rack beam is designed for standard step channel decks. When beams do not have the traditional beam step, flared wire mesh decking is often the best solution. Built as a universal fit option, this style of decking rests on top of the beam rather than inside the step, making it ideal for structural rack, box beams, and older pallet racking systems.

For warehouses upgrading existing storage, flared wire mesh decking can improve safety, product support, and day to day usability without replacing the entire rack system.

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What Is Flared Wire Mesh Decking?

Flared wire mesh decking uses welded steel support channels underneath the wire deck surface. Instead of straight channel ends that drop into a beam step, the channel ends are flared outward so they sit securely on top of the beam.

That design allows the deck to fit a wider range of beam profiles, which is why it is commonly referred to as a universal fit wire deck. It is especially useful in facilities with mixed rack styles or older systems where stepped beams are not present.

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Where It Is Used?

Flared wire mesh decking is commonly found on structural pallet rack, box beam systems, flat top beams, and older teardrop rack that does not include a step. If standard decking does not seat properly on the beam, flared decking is usually the right alternative.

Because many warehouses expand over time with different brands and generations of rack, universal fit decking can simplify replacement and future additions.

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Waterfall Front Design

Most flared wire mesh decks still use a waterfall front edge, meaning the wire mesh wraps over the front beam. This helps keep the deck aligned while giving the rack level a clean finished appearance.

The result is a deck that combines broad beam compatibility with the familiar look and performance of standard waterfall decking.

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Capacity, Safety and Strength

Most standard flared wire mesh decks use three welded support channels and are commonly rated for around 2,500 pounds under evenly distributed loads. Higher capacities are available depending on deck size, wire gauge, and support channel configuration.

Many flared decks are available with pre-punched tabs for fastening the deck to the beam. This creates a more secure installation and can help reduce movement during pallet loading and unloading.

Choosing the right deck should always be based on rack dimensions, beam spacing, and the weight of the product being stored.

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Cost and Availability

In many cases, flared wire mesh decking is priced similarly to standard channel decking. The main difference is availability. Standard decks in common sizes are often stocked, while flared decks are more commonly ordered based on rack dimensions and application needs.

That makes accurate measurements important before ordering replacement or new decks.

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Optional Features…

Galvanized finishes are also available where corrosion resistance is important, such as coolers, freezers, humid facilities, wash down areas, and food storage environments.

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Why Warehouses Choose Flared Decking?

Warehouses often choose flared wire mesh decking because it works across multiple beam styles, supports cartons and split pallets more effectively, improves sprinkler penetration, and increases visibility through rack levels. It also helps reduce dust buildup compared to solid shelving and can often be added to older rack systems without major modifications.

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Need Flared Wire Mesh Decking?

If your pallet racking beams do not accept standard step channel decks, flared wire mesh decking may be the right fit. Midwest Material Handling can help identify your beam style, confirm deck sizing, and supply the right wire decking for your storage application.

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FAQ’s

What is a flared channel wire deck?

A flared channel wire deck is a wire mesh pallet rack deck with support channels that flare outward at the ends and rest on top of the beam instead of inside a stepped beam. It is commonly used on structural, box beam, and older rack systems.

Is flared wire mesh decking considered universal fit decking?

Yes. Because it fits many beam styles without requiring a beam step, flared wire mesh decking is commonly considered a universal fit wire deck.

Does flared wire mesh decking cost more than standard decking?

In many cases, pricing is similar to standard channel decking. The biggest difference is that flared decks are often ordered in rather than stocked in common sizes.

Can flared wire decking be used on structural pallet rack?

Yes. It is one of the most common wire decking options used on structural pallet rack systems.

Can flared wire mesh decks be galvanized?

Yes. Galvanized options are available for cooler, freezer, wash down, humid, and corrosion-prone environments.

How do I know what size wire deck I need?

Measure the beam length, rack depth, and beam style. Capacity requirements should also be confirmed before ordering.

                   

Not every pallet racking project happens in a warehouse. Some of the most interesting storage projects take place behind the scenes in buildings built for performance, education, and creativity. We were contacted by a large interior construction contractor in western Pennsylvania that was helping complete storage areas for Penn State University’s new recital hall project. They needed dependable pallet racking systems for stage equipment and instrument storage, tucked away from public view but essential to the day to day operation of the facility.

Penn State’s recital hall was developed as a modern performance venue created to support students, faculty, and visiting performers. While the audience experiences the architecture, acoustics, and stage design, a great deal happens behind the scenes. Organized storage plays an important role in keeping instruments, cases, stage materials, and support equipment protected, organized, and ready when needed.

Storage Built for a Specialized Space

The photo above is a physical mock-up the architect created of the proposed space. The storage area that used this pallet rack is located behind the seating area and is not shown. For the first phase of the project, we supplied pallet racking that included:

• 12 foot high x 42 inch deep uprights (green)
• 8 foot long beams (orange)
• Wire decking for multiple shelf levels

It was a surprisingly significant amount of pallet rack for what looked like a relatively small storage area. That is often the case when a facility needs to maximize every square foot. By using vertical storage space, the customer created organized capacity without increasing the footprint of the room.

The pallet racking system was designed to support storage for stage items, instrument cases, audio equipment, risers, maintenance materials, and other assets that needed to stay secure while remaining easy to access.

Wire decking added another important benefit by creating stable shelf surfaces for items that would not normally sit directly on pallet rack beams. This made the system more practical for storing cases, boxed materials, and irregularly sized equipment often found in performance environments.

Follow Up Order with Custom Gray Finish

After the initial phase, the contractor returned with an additional order for another storage area. This time, the project required a different configuration and a custom color finish. We supplied:

• 8 foot high uprights
• 8 foot long beams
• Custom gray finish to meet project requirements

This follow up order highlights an important point. Pallet racking is not limited to standard warehouse colors or industrial settings. In universities, commercial interiors, and specialty facilities, appearance can matter just as much as function depending on the location.

More Than Just Warehouse Storage

Projects like this show how versatile pallet racking systems can be. While pallet racking is commonly used in distribution centers and warehouses, it also solves storage challenges in theaters, schools, maintenance departments, archives, and performance venues.

When designed correctly, pallet rack creates durable, organized storage in spaces most people would never expect.

We Ship Pallet Racking Nationwide!

Although many of our projects are throughout Ohio, we also supply pallet rack, wire decking, and storage systems for customers across the United States. Contractors, universities, manufacturers, and commercial facilities often need dependable pallet racking delivered directly to jobsite’s outside our home market, and we are equipped to help with those projects.

Whether the need is standard pallet rack, custom configurations, or accessories like wire decks, we provide practical storage solutions for facilities nationwide.

Need Storage Rack for a Unique Project?

We regularly supply contractors, businesses, schools, and institutions with practical storage systems for projects outside the typical warehouse environment. If you have a unique application or need help planning a storage area, we would be glad to help.

Warehouse pallet racking systems can fail for real-world reasons, and this is a perfect example. This actually happened and this is a real photo… we took it after the damage occurred and we got the call. The pallet rack uprights shown were hit hard enough to twist and fail. In this case, there were likely two factors in play: a rack system that was not ideal for the application and the absence of post protectors at a vulnerable impact point.

Many warehouse accidents are blamed only on forklift operators, but that misses the bigger picture. Busy aisles, tight turns, limited visibility, congestion, and production pressure all increase the chance of contact. The best prevention strategy combines trained operators, properly specified pallet racking, protective guards, and routine inspections.

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Why Pallet Rack Upright Quality Matters

Pallet rack uprights carry vertical loads and help stabilize the entire storage system. When upright columns are built lighter than needed or are not the best fit for the application, they may be more vulnerable to damage in demanding environments.

The racking shown in this photo was manufactured overseas and assembled in the United States after arrival. As you can see, the vertical and horizontal cross braces are not attached directly to the upright columns. Instead, they are bolted to welded tabs located on the inside of each column.

Even damage that appears minor can create larger issues over time, including unsafe storage, lost productivity, and expensive repairs or replacement.

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Lowest Price Is Not Always Lowest Cost

Warehouse racking is a structural system, not just shelving. Differences in steel thickness, column design, bracing, connections, and tested capacity can affect long-term durability.

A lower upfront price can become more expensive later if the system is damaged easily, difficult to expand, or costly to replace after an incident. Before buying pallet racking, it is worth reviewing capacity requirements, forklift traffic, future expansion plans, replacement part availability, and overall layout efficiency.

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Why Post Protectors Matter

Even high-quality pallet rack systems benefit from impact protection. Accidents can happen in any active warehouse, which is why front columns and aisle ends should be protected wherever possible.

Post and Column Protectors

Post protectors mount around the base of pallet rack uprights to absorb incidental contact and reduce direct damage to the column. They are one of the most effective and affordable ways to protect vulnerable rack legs.

End of Aisle Guards

End of aisle guards create a barrier in front of exposed rack frames where turning forklifts and pallet jacks commonly make contact.

Guard Rails and Guide Rails

Steel rails help separate travel lanes from storage rows and reduce the chance of direct rack impact in high traffic areas.

Bollards and Safety Barriers

Fixed bollards and barriers are ideal near doors, dock areas, and building columns where vehicle movement is constant.

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Where Protection Matters Most

The highest risk areas are usually front columns at floor level, aisle ends, tight turning zones, forklift intersections, and traffic lanes near shipping doors or dock openings.

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Protection Costs Less Than Emergency Replacement

Many facilities wait until damage happens before adding guards or upgrading their racking. In most cases, prevention costs far less than replacing uprights, unloading inventory, blocking aisles, and dealing with lost productivity.

The better investment is choosing the right rack system from the start and protecting it properly.

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What to Do If a Rack Upright Is Hit

If pallet racking has been damaged, remove loads if necessary, secure the area, inspect nearby components, and replace damaged parts promptly. Once repairs are complete, adding post protectors or guards can help prevent repeat incidents.

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Protect Your Warehouse Racking Before Damage Happens

Midwest Material Handling helps facilities choose the right pallet racking for their application and supplies rack protection products including post protectors, column guards, end of aisle guards, and other warehouse safety solutions.

If you need help evaluating existing racking or improving protection in high traffic areas, our team can help.

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Frequently Asked Questions

Are small dents in pallet rack uprights a problem?

Yes. Even minor dents or bends should be evaluated because they can affect capacity and worsen over time.

Do quality pallet rack uprights really make a difference?

Yes. Properly specified uprights can provide better durability, capacity, and long-term performance for the application.

Where should post protectors be installed first?

Start with front columns, aisle ends, and any area with frequent forklift traffic.

Can damaged uprights be repaired?

They can but it depends on the severity and rack type. In many cases, replacement is the safest and least expensive option.

In warehouses across Ohio, pallet rack damage usually doesn’t come from one big incident, it comes from small, repeated impacts that weren’t properly addressed. We spend a lot of time in customer facilities for inspections, quotes, and layout work, and we see things like this all the time. Not because people don’t care, but because quick fixes get put in place and never revisited.

This one, though, was well… creative, to say the least!

Someone had clearly decided the rack upright needed protection. That part is right. But instead of installing a proper pallet rack post protector, they strapped a yellow pipe to the column with zip ties and called it good. From a distance, it almost looks like pallet rack protection. Up close, it’s not anchored, not secure, and not actually protecting the part of the upright that takes the impact. It’s a common situation in working warehouses, good intention, wrong solution.

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Why Pallet Rack Post Protection Matters

Pallet rack systems are designed to handle vertical load, not repeated impact from forklifts and pallet jacks. That’s why pallet rack post protectors and column protectors are such an important part of warehouse racking safety. Most damage happens low, right at the base of the upright. That’s the area that takes the hit in tight aisles and high-traffic zones. Once that section is compromised, it can affect the strength of the entire rack bay. Without proper pallet rack protection in place, even small impacts can lead to bigger issues over time, bent uprights, reduced load capacity, and eventually repair or replacement.

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The Part Most Warehouses Overlook

What stands out in situations like this is how avoidable it is. Pallet rack post protectors are one of the least expensive safety upgrades you can make in a warehouse. Most steel post protectors cost $50 or less, install quickly, and are designed specifically for this exact problem. Instead, we often see makeshift solutions, pipes, wood blocks, or guards that aren’t anchored, giving the appearance of protection without actually doing the job. That’s where problems start.

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What Proper Post Protectors Actually Do

A real pallet rack post protector is built to take impact and protect the upright behind it. It anchors directly to the floor, sits tight to the column, and absorbs or deflects contact before it reaches the rack itself. That’s the key difference, without anchoring, there’s nothing stopping the force from transferring into the upright.

Most facilities use either a 12-inch or 18-inch post protector depending on the application. The 18-inch height is the most common because it lines up with typical forklift impact zones. For operations with mixed rack systems or multiple upright sizes, universal post protectors are a practical option. They fit a range of columns and only require two anchor bolts, which makes installation fast and consistent across the facility.

In seismic areas, properly anchored pallet rack protection becomes even more important. At that point, you’re not just preventing day-to-day damage, you’re supporting the overall stability of the rack system.

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Warehouse Racking Safety Starts at Ground Level

It’s easy to focus on beams, decking, and load capacity when thinking about pallet racking. But most real-world damage starts at the floor. That’s why pallet rack column protection plays such a critical role in warehouse safety. It protects the most vulnerable part of the system and helps prevent small impacts from turning into structural problems.

In busy Ohio warehouses, where forklift traffic is constant, this is one of the simplest ways to extend the life of your racking and avoid unnecessary repairs.

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Final Thought…

We see a lot of creativity out in the field, and there’s nothing wrong with trying to solve problems with what you have. But pallet rack protection isn’t an area where improvising pays off. When a proven solution exists and costs less than $50, it makes more sense to install something that’s actually designed to do the job.

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Get the Right Pallet Rack Protection in Place

Midwest Material Handling supplies pallet rack post protectors and column protectors throughout Ohio, including standard 12-inch and 18-inch options, universal post protectors with simple two-bolt installation, and solutions designed for seismic environments.

If you’re looking to improve pallet rack safety or prevent damage in your facility, we can help you choose the right protection without overcomplicating it.

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Frequently Asked Questions About Pallet Rack Post Protectors

What is a pallet rack post protector?

A pallet rack post protector is a steel guard that anchors to the floor and protects the base of a rack upright from forklift impact. It helps prevent damage to the most vulnerable part of the pallet racking system.

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How much do pallet rack post protectors cost?

Many pallet rack post protectors cost $50 or less, making them one of the most affordable and effective warehouse safety upgrades available.

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What size post protector do I need?

The most common sizes are 12-inch, 18-inch and 24-inch heights. An 18-inch post protector is the post common and is typically used in active forklift areas because it covers the main impact zone, while 12-inch options work in lighter-duty or tighter spaces.

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Are universal post protectors worth it?

Yes. Universal post protectors are a practical option for facilities with different rack types. They fit a range of upright sizes and only require two anchor bolts, making them quick and easy to install. The are designed with Interlake-Mecalux Bolted Uprights in mind.

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Do I need post protectors in a low-traffic warehouse?

Even in lower-traffic environments, pallet rack protection is important. Most rack damage comes from small, repeated impacts over time, not major collisions.

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Are post protectors required in seismic areas?

While requirements vary, properly anchored pallet rack protection is especially important in seismic zones. It helps improve the stability of the rack system and adds an extra layer of safety.

     

If you’ve spent any time around lumber storage or long material racks, you’ve probably seen the same thing play out. Everything looks fine at first, but over time material starts creeping toward the end of the arm.

It doesn’t take much. A slightly off-center load, a little settling, or just repeated handling can shift things more than you expect. Before long, you’ve got boards or bundles sitting right at the edge.

That’s exactly why pipe stops for cantilever racking are used so often. They’re simple, relatively inexpensive, and they solve a problem that shows up in just about every real-world setup.

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What Are Pipe Stops for Cantilever Racking?

Pipe stops are vertical steel posts that mount at the end of a cantilever rack arm. In most cases, they attach using a field-installable, bolt-on flange, which means you can add them to an existing system without modifying the rack itself.

Once they’re in place, they do one job. They stop material from moving past the end of the arm.

Some people call them pipe stops, others call them arm stops or safety stops. Either way, the goal is the same—keep the product where it’s supposed to be.

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Why Material Movement Becomes a Problem

Cantilever racks are built for long materials, but a lot of what gets stored on them isn’t perfectly stable.

Lumber shifts. Pipe rolls. Bundles settle. Even when everything is loaded correctly, materials don’t just sit there forever. Forklift placement is not always perfect, and over time small movements add up. That’s when you start to see product hanging over the edge of the arm, or worse, ending up on the ground.

Pipe stops are a simple way to get ahead of that instead of reacting to it.

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Why You See Them Everywhere in Lumber Storage

Lumber isn’t always uniform. Lengths vary, stacks aren’t perfect, and things settle over time. Without something stopping it, material naturally works its way outward.

Adding a pipe stop gives you a defined end point. It keeps stacks from creeping, makes loads easier to manage, and reduces the chances of material falling off the rack. It also just makes the whole system feel more controlled. And just as important, it’s not an expensive upgrade. That’s a big reason why so many operations use them.

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Field Installable Makes This an Easy Upgrade

This is where pipe stops really stand out. Because they use a field-installable flange, you’re not locked into making this decision upfront when the rack is first installed. You can add them later, exactly where you need them. In many cases, if you know the original manufacturer of your cantilever rack, pipe stops can be added after the fact and matched to your existing system without any issue.

Installation is straightforward. The flange bolts onto the end of the arm and the pipe stop drops into place. There’s no cutting, no welding, and no major disruption to your operation. That flexibility is what makes this such a practical upgrade. You can start with a basic setup and add stops later as your needs change or as you start to see how your material behaves over time.

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When Pipe Stops Make Sense

Not every setup needs them, but there are some clear situations where they’re worth adding. If you’re storing round materials like pipe or conduit, loose lumber that isn’t banded tightly, or anything with mixed lengths, you’re already dealing with movement. The same goes for operations where material gets handled frequently throughout the day.

In those cases, pipe stops are less of a nice-to-have and more of a practical improvement.

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Keeping It Simple vs. Overthinking It

There are other ways to control material on cantilever racks, but most of them either add cost or require ongoing effort.

You can strap loads, but that takes time every time. You can build more containment into the system, but that can limit flexibility and increase cost. Or you can do nothing and deal with the occasional issue when it happens. Pipe stops sit in a good middle ground. They’re simple, permanent, and they don’t interfere with how the rack is used.

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How This Fits Into Your Cantilever Rack Setup

Pipe stops are technically an accessory, but they have a real impact on how your system works day to day.

When you’re looking at a cantilever setup, it’s really part of a larger warehouse racking system, and small upgrades like this can make a big difference. It’s about how the material behaves once it’s on the rack. How it sits, how it shifts, and how easy it is to handle safely. Small additions like this tend to make a bigger difference than people expect.

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Need a Second Set of Eyes?

Every operation is a little different. The type of material, how often it moves, and how it’s handled all play a role in what makes sense.

If you’re seeing material creep toward the edge of your rack arms, pipe stops are usually one of the first things to look at. They’re simple, cost-effective, and because they can be added after the fact, they don’t require a major system change.

If you want help thinking through your setup, Midwest Material Handling can walk through it with you and help you figure out what actually makes sense.

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FAQ: Pipe Stops for Cantilever Racking

Do they take up usable space?
A little, but most people find the added control is worth it.

Can they be added to existing racks?
Yes. In most cases they are designed for field installation, and if the original manufacturer is known, matching components is usually straightforward.

Do they require welding or modification?
No. Most designs use a bolt-on flange, so installation is simple.

Do you need them on every level?
It depends on what you’re storing. Usually just where material is more likely to move.

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Final Thought…

Not every improvement needs to be complicated or expensive.

Pipe stops for cantilever racking are a straightforward solution to a very common problem. They’re easy to install, relatively inexpensive, and flexible enough to be added after the fact when needed.

If you’ve ever seen material slowly work its way toward the edge of an arm, you already know why they’re worth considering.

     

There comes a point in almost every storage environment where standard shelving starts to fall short, but full warehouse storage systems start to feel like more system than you actually need. That is where a wide span shelving system fits in.

It fills that middle ground. Strong enough to handle heavier inventory, but still designed for hand loading and easy access. In the right setup, it can completely change how space is used. A great example of that comes from a national pet food retailer headquartered in Northern Ohio.

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A Smarter Way to Handle Bulk Inventory on the Retail Floor

This retailer operates locations across the United States and needed a better way to manage bulk inventory inside the store itself.

Large bags of dog food move quickly, and storing them in a backroom was not always practical. At the same time, stacking product on the sales floor created clutter and made restocking more difficult. The solution was simple and very effective. Wide span shelving was installed above the existing retail shelving, creating a two level system within the same footprint. The lower level remains clean and organized for customer facing product, while the wide span above supports bulk storage.

Instead of expanding outward or relying on a separate stockroom, they made use of the vertical space already available.

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Why Wide Span Shelving Works So Well in This Application

This type of setup highlights exactly where wide span shelving performs best.

Those large dog food bags add weight quickly. Over time, lighter shelving systems tend to flex or fail under that kind of load. Wide span shelving is built to handle heavier inventory without needing pallet positions or forklifts.

It also keeps product close to where it is sold. Employees can restock directly from above, which helps keep shelves full without slowing down daily operations.

From a space standpoint, it is efficient. The system turns unused overhead space into active storage without disrupting the layout of the store.

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A Design Detail Worth Noticing

There is a detail in wide span shelving that often gets overlooked.

If you look closely at the beams and the way they connect to the uprights, they resemble pallet rack beams. That is not by accident. Wide span shelving is essentially a scaled down version of older Keystone style pallet racking. It uses a similar beam and upright connection, adapted for hand loaded applications instead of forklift access.

That design gives you strong, stable shelves with open spans and flexible adjustability, which is why it performs so well in real world environments.

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Where Else Wide Span Shelving Is Used

Once you start paying attention, wide span shelving shows up across a wide range of industries.

E-commerce and Order Fulfillment

Ideal for operations that rely on hand picking. It handles cartons, mixed inventory, and products that do not sit neatly on pallets.

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Automotive and Parts Storage

Strong enough for heavier components while still allowing easy access without equipment.

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Maintenance and Industrial Supply Areas

A practical choice for storing tools, repair parts, and operational supplies that need to stay organized and accessible.

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Archive and Bulk Box Storage

When boxes get heavier and stack higher, wide span provides a clean and reliable solution.

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When Wide Span Shelving Makes the Most Sense

Wide span shelving is a good fit when you are dealing with heavier items that are still handled by hand. It works especially well when products are bulky, inconsistent in size, or do not palletize efficiently.

It is also a strong option when you want to build storage above an existing layout, like in retail environments where floor space is limited.

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Get Help Selecting the Right Wide Span Shelving

If you are looking for a practical way to store heavier inventory without moving to full pallet racking, wide span shelving is a strong option.

We supply wide span shelving systems to customers across Ohio and the Midwest and can help you choose the right configuration based on your space, product weight, and how your operation actually runs.

For regional projects, we also offer installation services and work with local and regional installation crews to make sure everything is set up correctly.

Whether you are planning a retail setup, warehouse storage area, or in-store bulk storage like the example above, we can help you get it sized right from the start. Reach out and we will walk you through the options.

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Wide Span Shelving FAQ

What is wide span shelving used for?
Wide span shelving is used for storing heavier items that are handled by hand rather than by forklift. It is common in retail storage, warehouses, parts rooms, and bulk storage applications where standard shelving is not strong enough.

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How much weight can wide span shelving hold?
Weight capacity depends on the size of the unit, beam length, and decking type. Most systems are designed to handle significantly more weight than standard shelving, making them ideal for bulk boxes, parts, and heavy inventory.

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Is wide span shelving the same as pallet racking?
No, but it is similar in design. Wide span shelving uses a beam and upright system that resembles pallet racking, but it is designed for hand loading instead of forklift use.

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Can wide span shelving be used on the retail floor?
Yes. Wide span shelving can be installed above existing shelving to create bulk storage without disrupting the layout of the store. It is a practical way to use vertical space in retail environments.

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Do you supply and install wide span shelving?
We supply wide span shelving systems nationwide. Installation services are available for projects throughout Ohio and the Midwest, where we have local and regional installation crews available to complete the setup efficiently.

Pallet rack systems are commonly used for warehouse storage, but the components are far more versatile than many people realize. In addition to storing palletized inventory, pallet rack parts can also be used to build extremely durable shop furniture such as workbenches, storage tables, and tool stations.

At Midwest Material Handling we often reuse pallet rack components around our own warehouse for practical shop projects. One of the most useful pieces we built was a heavy duty mobile workbench constructed entirely from used pallet rack components.

The goal was to create a strong work surface that could handle daily shop tasks while still being easy to move around the warehouse whenever needed.

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Starting with a Used Pallet Rack Upright

The base of the workbench started with a used pallet rack upright frame that originally measured about 96 inches tall and 42 inches deep. Instead of using the full frame, we cut the upright in half to create two shorter frames that were the perfect height for a comfortable workbench.

Because pallet rack uprights are designed to support very heavy loads in warehouse environments, the finished bench provides excellent strength and stability even under demanding shop use.

Using pallet rack components also allowed us to build the structure using materials we already had available in our warehouse.

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Adding Beams and Wire Decking

After preparing the upright frames, we installed 48″ pallet rack beams to create both the upper work surface and a lower storage shelf. Because pallet rack beams are designed for warehouse storage, the workbench ended up being extremely strong. The beam set used for this project is rated for approximately 6,000 pounds per shelf, far more capacity than typical shop workbenches or retail storage shelving.

Wire decking panels were installed across the beams to support each level. The lower shelf provides convenient storage for tools, materials, and small equipment while keeping the work surface clear.

Wire decks are commonly used in pallet rack systems because they distribute weight evenly across the beams while still allowing light and air to pass through the rack.

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Creating the Work Surface

For the work surface we cut a sheet of plywood to fit over the wire decking on the top level of the rack. The plywood was secured to the decking using tek screws so it would remain firmly in place during everyday shop work.

Once installed, the plywood was coated with epoxy to improve the appearance and create a durable surface that holds up well to oils, grease, and general shop wear.

The result is a smooth, strong work surface that performs well for assembly work, small fabrication projects, and general shop tasks.

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Making the Workbench Mobile

One of the most useful features of the bench is its mobility.

To allow the workbench to move easily around the shop, we welded four heavy duty casters (2 swivel with brakes and 2 rigid) directly to the pallet rack upright footplates. Two of the casters swivel and include locking brakes while the other two are rigid.

This configuration allows the bench to roll easily when needed and remain stable when locked into position.

Being able to reposition the bench anywhere in the warehouse has made it far more useful than a traditional stationary work table.

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A Practical Use for Used Pallet Rack

This project is a good example of how pallet rack components can be repurposed for many different applications beyond warehouse storage.

Because pallet rack systems are modular and extremely strong, the components lend themselves well to custom shop projects such as workbenches, storage carts, tool tables, and garage shelving.

Another advantage of this design is flexibility. If the workbench is ever no longer needed, the entire structure can be disassembled in just a few minutes and the pallet rack parts can be reused for other storage projects.

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No Project Is Too Small

Midwest Material Handling primarily supplies pallet rack systems and warehouse storage equipment to businesses throughout Ohio and across the country. At the same time, we always enjoy helping customers with smaller projects as well.

Whether someone needs a full warehouse storage system or just a few pallet rack components for a garage workshop or shop project, we are happy to help.

As we like to say, no project is ever too small.