Pallet Rack Wire Decking

Pallet Rack Wire Decking is a welded steel mesh panel installed between pallet rack beams to form a storage surface. It supports pallets, cartons, bins and other stored materials while maintaining an open rack structure.

The main selection factors are panel width and depth, rack beam profile, mesh opening, wire diameter, support-channel arrangement, load rating and surface finish. These dimensions should be matched to the rack layout and intended loading condition.

Welded Wire Mesh
Steel wires are resistance welded at each intersection to form the deck surface. A 2.5" × 4" opening with approximately 5.0 mm wire is a common configuration. Other wire sizes and mesh openings can be produced for different structural requirements.
Support Channels
Formed steel channels are positioned beneath the mesh and welded to the panel. They transfer the applied load toward the rack beams. Channel quantity and spacing depend on panel dimensions and required capacity.
Edge Profile
Waterfall or flared edges provide the bearing interface with the rack beams. Edge dimensions are matched to the beam geometry so the panel sits correctly across the front and rear supports.

Rated Load
Capacity should be stated for a defined panel configuration and loading condition. Panel width, depth, wire diameter and support-channel layout all affect the rated value.
Load Distribution
Uniformly distributed loads and concentrated loads create different loading conditions. Pallet contact points, stored material placement and deck support positions should be considered when establishing the required capacity.

Panel Width
Panel width is selected according to the rack beam arrangement and the number of panels covering each bay. Common reference widths include 46", 52" and 58".
Panel Depth
Deck depth follows the front-to-back rack dimension. Common sizes range from 24" to 48", including 36", 42" and 48" configurations.
Beam Profile
The beam height, bearing surface and lip geometry determine the required edge configuration. Existing rack dimensions should be confirmed before replacement decking is ordered.

Powder Coated
Powder coating provides a consistent finished surface for general indoor warehouse use. Color and coating requirements can be defined in the project specification.
Galvanized
Galvanized steel provides a zinc-coated surface for applications where moisture exposure requires additional corrosion protection. The coating specification should correspond to the operating environment.

Pallet Storage
The deck provides an open storage surface across pallet rack beams for palletized materials and mixed storage loads.
Carton Storage
Cartons, bins and packaged materials can be placed directly on the mesh where the rack configuration requires continuous intermediate support.
Industrial Storage
Typical installations include distribution facilities, manufacturing storage areas, logistics warehouses, inventory rooms and general industrial rack systems.

Wire Welding
Wire intersections are resistance welded under controlled production conditions. Mesh opening and panel geometry are checked against the specified dimensions.
Channel Forming
Support channels are formed to the required section and positioned beneath the mesh according to the panel design. Channel location affects load transfer and panel stiffness.
Dimensional Inspection
Finished panels are checked for width, depth, mesh opening, wire diameter, channel position and edge dimensions. Inspection records can be maintained against the production specification.

Panel Dimensions
Width and depth can follow rack drawings, existing panel measurements or specified bay dimensions. Non-standard sizes can be produced for replacement and project applications.
Structural Configuration
Wire diameter, mesh opening and support-channel quantity can be selected according to panel span and required load rating.
Edge Configuration
Waterfall and flared edge profiles can be matched to the rack beam geometry. The bearing dimensions should be confirmed from the actual rack construction.
 

Panel Stacking
Finished panels are stacked and secured to maintain alignment during handling and transportation. Packing configuration is based on panel dimensions and shipment requirements.
Identification
Dimensions, quantities and project references can be included on packing documentation. This helps identify different deck configurations during receiving and installation.

Provide the rack beam length, rack depth, beam profile, panel width and depth, required load per deck, mesh opening, wire diameter, support-channel quantity and surface finish.
For replacement applications, an existing deck measurement, rack drawing or beam cross-section can help confirm the required dimensions before production.