Custom Wire Decking

You would be surprised how often we’re asked for Wire Decking with Special 1″ x 4″ Mesh Top Panel. Standard wire decking works well for many palletized loads, but smaller boxes, cartons, and parts can present a problem when they aren’t large enough to sit securely on conventional mesh. The tighter 1″ x 4″ mesh creates a more supportive storage surface while retaining the open-wire advantages of traditional decking.

This custom deck is durable, flexible, and especially useful for hand-stacked inventory and smaller products. The supporting channels underneath the mesh provide the deck’s load-carrying strength, and the original configuration described here is rated for up to 2,500 lbs. when properly supported and uniformly loaded. When an application requires greater capacity, additional supports can be incorporated into the custom design. For some applications, our ProDeck50 punched steel pallet rack decking may also be worth considering as an alternative.

Hot Dipped Galvanized Wire Decking for Outdoor Pallet Rack Resists Rust

Standard painted pallet rack and wire decking are primarily intended for indoor environments. Put ordinary painted steel outside in repeated rain, snow, humidity, and changing weather conditions, and corrosion eventually becomes a concern. That’s where Hot Dipped Galvanized Wire Decking for Outdoor Pallet Rack comes in. The galvanized coating provides substantially greater corrosion resistance than a standard painted finish, making it a better choice for outdoor and other moisture-prone applications.

This type of decking is especially popular with home centers, building material suppliers, garden centers, and other businesses operating outdoor storage areas. Hot-dip galvanizing can be specified for both the pallet rack and wire decking when the complete system needs enhanced corrosion protection. It is also worth considering in facilities where rust contamination is a particular operational concern. Galvanizing greatly improves corrosion resistance, although no finish should be considered completely maintenance-free or universally “rust-proof” under every environmental condition.

Custom Heavy Duty Wire Decking with 6-8 Channel Supports 4,000 LBS CAP.

Sometimes standard wire decking simply isn’t enough. Our Custom Heavy Duty Wire Decking with 6–8 Channel Supports is designed for applications where strength and durability take priority over finding the lowest-priced deck. The described configuration combines 6–8 heavy 14-gauge steel channel supports with tight 2″ x 4″ mesh manufactured from heavy wire to create an extra-heavy-duty pallet rack deck.

The 4,000-lb. rating is based on a UDL, or Uniformly Distributed Load, meaning the rated weight must be spread appropriately across the deck rather than concentrated at a few small points. That’s an important distinction. A 4,000-lb. UDL rating does not mean the deck can safely handle a 4,000-lb. concentrated or point load. The wire deck, rack beams, uprights, connections, and overall rack system must all be suitable for the intended load. For demanding warehouse applications where standard decking is frequently damaged or replaced, heavy-duty custom decking can provide a longer-lasting alternative and may also be more economical than bar grating for certain applications.

Heavy Duty Wire Decking with Steel Top Plates Support Wire Baskets

Here’s a storage problem we’ve encountered many times: a customer places a heavy wire basket or steel container on ordinary wire decking, and the small feet on the bottom of the container concentrate the load into a few spots. Those feet can bend or crush the mesh because standard wire decking is generally intended for distributed loads rather than concentrated point loads. Heavy Duty Wire Decking with Steel Top Plates Support Wire Baskets was developed to address that problem.

These custom decks can incorporate heavy steel top plates, tighter and heavier mesh, and additional channel supports positioned beneath the container feet. One configuration uses 6–8 14-gauge steel channel supports, heavy 2″ x 4″ wire mesh, and steel top plates positioned toward the front and rear of the deck. Wider plates can provide some side-to-side flexibility when positioning standard wire containers. The critical design detail is that the container feet need to bear over the steel plates and the structural channel supports beneath them so the concentrated loads are transferred properly.

This design can give warehouses the flexibility to store both pallets and compatible wire baskets on the same rack system without relying on the mesh alone to carry concentrated container-foot loads. Because container dimensions, foot locations, weights, and rack dimensions vary, this is an application where custom engineering really matters. We can configure the deck dimensions, steel plate locations, and support channels around the container being stored rather than forcing the container onto a standard deck that wasn’t designed for it.

Reverse Waterfall Wire Decking takes a completely different approach to customization. Instead of the wire mesh waterfall wrapping downward over the rack beam, the rear portion turns upward to create an integrated backstop. This provides a simple way to help keep hand-stacked boxes and cartons from accidentally falling off the back of a rack shelf.

Reverse waterfall decking can eliminate the need for a separate carton stop in certain hand-load applications while helping keep products contained and organized. It is important, however, to understand what it is—and what it isn’t. Reverse waterfall wire decking is intended as a backstop for hand-stacked cartons, not as a pallet safety stop. A forklift pushing a pallet against the raised wire can bend or damage it. Applications requiring pallet push-through protection should use a properly designed Single or Double Pallet Load Stop rather than relying on the reverse waterfall.

Why Go Custom?

The biggest advantage of custom wire decking is that we can start with the application instead of starting with an off-the-shelf deck. Tell us what you’re storing, how much it weighs, how the load contacts the deck, what rack you’re using, and where the system will be installed. From there, we can help determine whether the application calls for tighter mesh, additional channels, heavier wire, steel top plates, galvanized construction, custom colors, a reverse waterfall, or another configuration.

That’s especially important when you’re dealing with unusual loads. A pallet creates a very different loading condition than four small feet on a wire basket, and outdoor storage creates different requirements than an indoor warehouse. Matching the decking to the actual application helps improve durability, organization, and safety while reducing the chance of buying a deck that isn’t suited to the job.

Frequently Asked Questions About Custom Wire Decking

How do I know what custom wire deck design I need?

Start with the pallet rack dimensions and the products that will actually sit on the decking. We typically want to know the deck width and depth, beam type, load weight, load dimensions, whether the load is uniformly distributed or concentrated, and whether you’re storing pallets, cartons, totes, wire baskets, or steel containers. Container feet and other point loads deserve particular attention because they may require steel plates and strategically positioned channel supports rather than simply increasing the deck’s overall UDL capacity.

Can custom wire decking be installed on my existing pallet racks?

In many cases, yes. Custom wire decking can be manufactured around an existing rack configuration, but the rack dimensions and beam style need to be confirmed before ordering. The decking must properly engage and be supported by the rack beams. A higher-capacity wire deck also does not increase the capacity of the pallet rack itself; beams, uprights, connections, anchorage, and decking all need to be appropriate for the intended loads.

What maintenance does custom wire decking require?

Wire decking is relatively low maintenance, but it should still be inspected regularly. Look for bent mesh, damaged welds, distorted support channels, corrosion, improperly seated decks, and damage caused by forklifts or overloaded products. Heavy baskets and containers should also be checked to make sure their feet remain positioned over the supports intended to carry them. Galvanized decking used outdoors should still be inspected periodically, particularly where the coating has been damaged or the decking is exposed to aggressive environments.

Are there special requirements for designing custom wire decking?

Requirements depend on the rack system, load, facility, and application. Load capacity should be based on the actual loading condition rather than weight alone, especially when point loads are involved. Fire protection requirements can also depend on the storage arrangement, commodities, sprinkler design, and locally adopted codes. Before installing a custom configuration, verify the decking and rack capacities and, where applicable, review the system with the manufacturer, rack professional, fire protection professional, insurer, or local authority having jurisdiction.