Pallet Rack Wire Decking-Mesh Decks & Panels, Waterfall, Rivet Shelving, New-Used. Columbus, Ohio

Wire Mesh Deck Panels

One of the three basic components of a Pallet Rack system (Beams, Uprights and Wire Decks). Wire Decks have had a bit of an evolution… 30 years ago, we exclusively used wood (2” x 6” or 2” x 8”) to support the skids on the Pallet Rack shelves.

We often tell customers when they ask about using wood to create a shelf (generally 2″ x 6″ or 2″ x 8″) that what you are essentially doing is “de-rating” the capacity of the Beams to the unknown load ratings of the wood (which we estimate at roughly 900 lbs. per shelf on a 96″W x 42″D shelf).

Wood decking evolved into steel “Flanged Cross Bars” which were basically 2” x 4”’s but constructed of steel and featured the ability to Tek screw in the front and back to keep them from moving and secure. These Flanged cross Bars created exponentially greater capacity than wood.

At that time, Wire Deck Panels were being hand welded and were extremely expensive to manufacture as they were built by primarily by hand. As robotic welding technology was introduced and became more common, the cost to manufacture and distribute these Decks came down considerably. Wire Deck Panels have become a better functioning, safer and more economical method to support product on Pallet Rack shelves.

MOST COMMON IN-STOCK WIRE DECK SIZES

• Standard in-stock 24″D Wire Decks: 24”D x 46”W, 24”D x 58”W
• Standard in-stock 36″D Wire Decks: 36”D x 46”W, 36”D x 52”W, 36”D x 58”W
• Standard in-stock 42″D Wire Decks: 42”D x 46”W, 42”D x 52”W, 42”D x 58”W
• Standard in-stock 48″D Wire Decks: 48”D x 46”W, 48”D x 52”W, 48”D x 58”W
• Standard in-stock 60″D Wire Decks: 60”D x 46”W
• Standard in-stock Wire Deck capacities: 2,100 lbs., 2,500 lbs. and 3,100 lbs.

Welded steel wire decks generally feature 2-1/2″x 4″ wire openings with a powder coated or gray baked enamel finish and heavy gauge steel channel supports. Unlike wood or metal decking, wire decks permit light, air and sprinkler penetration. They are self-cleaning and maintenance free. Wire decks also allow a clear view of upper tiers, minimize dust or debris accumulation and protect employees and products. Most importantly, Wire Decks maintain the capacity integrity of the pallet rack system. Wire decks are easy to install, they just drop into place (no tools required).

We are often asked if skids could potentially “snag” or get caught on the wire as they are slid across the wire to the rear of the wire deck. The simple answer is no… the wire deck is built with the top layer of wire in a  “front-to-back” configuration (the bottom layer runs side-to-side and is welded to the support channels), so product can slide across the wire decks smoothly and with ease.

There are several different styles of Wire Deck to accommodate virtually every application…

Standard U-Channel (and Inverted U-Channel) Waterfall Wire Decks

Often referred to as Waterfall Wire Decks or Decking, these Decks are the most common we sell and are generally designed for standard 1 5/8” step Pallet Rack Beams. They have a “waterfall” design (1.5” outside waterfall) as they lap over the front and back of the Beam. This feature keeps the Deck from sliding or moving during loading. Wire Deck Panels have support channels welded to the bottom of the wire which supply the load bearing capacity. Most decks include three support channels to get the standard 2,500 lbs. capacity.

Higher capacity decks or decks wider than 52” include four channels per deck. Step channels provide greater strength and higher standard capacities than flared channels.

NOTE: In some applications, primarily the food industry, an Inverted Channel Deck is used to prevent product from catching in the body of the U-channel.

Flared Channel Waterfall Wire Decking

These decks are used on beams (many older beams did not include an inside step) where no inside step exists or beams with different size steps. The channel of the deck is “flared” and simply rests on top of the beam.

Structural/Flared Wire Deck

Similar in design to U-Channel Decks, these are designed for use on Structural Pallet Rack Beams (C-Channel Beams) and come in both a standard channel and a flared channel.

Solid Steel-Perforated Rack Decking

These solid steel Rack Decks are a unique combination of a Wire Mesh Deck Panel and a more costly Corrugated Steel Deck. What makes these Steel Decks attractive is their standard 3,000 lbs. capacity. They are available in a wide range of sizes to fit any upright depth and beam length.

They are all-welded and  constructed of 14 gauge steel with 12 gauge reinforcing channels to fit 1-5/8” step beams, have a powder coated finish and feature 1-1/2” waterfall on front and back edges.

Corrugated Steel Decking

Corrugated Steel Rack Deck sits flush with the top surface of the pallet rack beam, creating a semi flat surface (the corrugated ridges sit below the deck surface) for product to easily slide on and off. Sizes are available to fit any standard rack. It can also be used fastened to the floor for elevated bottom level storage, keeping product from sitting directly on the floor surface.

Corrugated steel decking is considerably stronger than wood and wire. It provides a seamless, solid support from the front all the way to the back of the rack bay for even the longest stored items.

*Corrugated Decking is the preferred method for extreme heavy capacity applications as it has the highest rated capacities available for standard Pallet or Cantilever Racking.

Corrugated Decking is perfect for use in cantilever racking as well. It is often used to provide a stacking surface between the cantilever arms for storage of everything from lumber to furniture to fabric. Solid Rack Decking is available in a plain, stainless, galvanized or a painted finish. It can also be provided with perforations to allow for water penetration in the lower part of the channel and allows for light exposure (limited) below the deck.

One downside to Corrugated Decking is it should be properly cut to length at the factory, it is very difficult to trim, cut and modify on-site.

Flat or Flush Wire Deck

These unique Wire Decks do not have the waterfall feature; the deck ends at the inside edge of the beam. Flush decks can be made with an inside waterfall or flat flush edge where the end wire comes to the inside edge of the beam.

The Decks are commonly used on lower levels and for hand stacking and order picking applications. One advantage of the Flush Deck is they allow for a clear and unobstructed view of labels attached to the beam face.

Light Duty Wire Decks (for Wide Span or Rivet/Boltless Shelving)

A flat type of wire decking, light duty decking is a superior replacement for particle board and can be used in a wide range of applications. It is constructed of 5-gauge wire and a 2” x 4” grid pattern.

Call for information on a wide range of Wire Mesh Deck Panels for virtually any application. We sell Wire Mesh Deck Panels for use on Pallet Rack, Bulk Rack, Steel Shelving, Widespan Shelving and Rivet Shelving. These decks come in a wide range of styles, sizes and capacities. Choose from our wide variety of stock & quick ship sizes and capacities. Or, let us design and build a custom deck to your specifications!

We stock and sell Wire Decking from leading Manufacturers including: Nashville Wire Products, ITC Manufacturing, Nelson Wire and Steel, Husky Rack and Wire and Cogan Wire Products.