Looking for a way to enhance warehouse safety, increase storage flexibility, and ensure fire code compliance all at once? The solution is wire mesh decking. It transforms the dangerous open space between your rack beams into a strong, versatile surface that prevents falling products and meets strict fire codes. This guide answers all your key questions, helping you make the perfect decision for your facility.
In This Guide:
What is Wire Mesh Deck?
At its core, wire mesh decking is a specially designed steel grid that spans across pallet rack crossbeams. It creates a strong, continuous surface that improves the rack's overall safety and functionality.
While it may look simple, it consists of three key structural parts:
Mesh Grid: The welded wire grid forms the main surface. Its open design allows light and water to pass through while providing a solid base for stored items.
Support Channels: Welded to the underside of the mesh, these heavy-gauge steel channels are the true source of the deck's strength. The number and shape of these channels determine its load capacity.
Waterfall Edge: The edges of the deck are bent, or "waterfalled," to wrap securely over the top of the rack beams. This locks the deck in place and distributes weight evenly.
The Key Benefits of Wire Mesh Deck
Upgrading your racks with wire mesh decking delivers key advantages that other solutions simply can't match.
Enhanced Safety
Prevent falling items and protect your team. Wire decking closes the dangerous gap between beams, stopping misplaced pallets or loose boxes from crashing to the floor. This immediately creates a safer environment for your personnel and protects your inventory from damage.
Increased Versatility
Store more than just standard pallets. Wire decking creates a solid shelf surface, giving you the flexibility to store smaller pallets, individual boxes, or loose cartons that can't sit on open beams.
Improved Airflow & Visibility
The open-grid design is crucial for safety. It improves visibility for forklift operators and, most importantly, helps you meet strict fire codes. The mesh allows water from overhead sprinklers to penetrate to lower levels—a critical requirement that solid wood or steel shelves fail.
Durability & Strength
Built for the demanding warehouse environment, these heavy-duty welded steel decks resist impact damage. Unlike wood, they will never warp, sag, or splinter.
Easy Installation & Low Maintenance
Installation is fast and tool-free; decks simply drop into place. With virtually no maintenance required, they save you time and labor costs for years to come.
Types of Wire Mesh Deck
Wire decks are designed to fit different types of rack beams. Choosing the right type is essential for a secure fit.
Waterfall Decking
This is the most common and widely used type. The waterfall edge hooks over the front and back of the beam, holding it firmly in place.
Standard Waterfall: Features a waterfall on both the front and back edges for maximum stability.
Inverted Waterfall: The waterfall is bent upwards, creating a flush, smooth surface on the inside of the rack bay. This is used in applications where products need to slide on or off without obstruction.
Drop-In / Flush-Fit Decking
Designed without waterfalls, these decks sit inside the step of a "step beam." They create a completely level surface with the top of the beam, which is ideal for hand-stacking applications or when a smooth edge is required.
Flared Channel Decking
This specialized type is designed for structural or box-style beams that do not have a step. The support channels are flared at the ends to rest on top of the beam, providing a stable fit where standard waterfall decks cannot be used.
How to Choose the Right Wire Mesh Deck
Follow these steps to select the perfect decking for your needs.
Step 1: Identify Your Racking System
First, look at your rack beams. Do they have an inset "step" on the top inside edge (Step Beam), or are they a simple rectangular tube (Box Beam)? This determines whether you need a Waterfall/Drop-In deck or a Flared Channel deck.
Step 2: Determine Your Load Capacity
What is the maximum weight you plan to store on a single pallet or shelf level? Decking capacity is rated per square foot or for an entire pallet level. Always choose a capacity rating that safely exceeds your heaviest planned load. This is determined by the number of support channels.
Step 3: Measure Your Racks
Accurate measurements are critical. You will need two key dimensions:
Rack Depth: Measure from the outside of the front beam to the outside of the back beam.
Beam Length: Measure the clear distance between the two upright frames.
Step 4: Consider the Finish
The finish protects the steel from its environment.
Powder Coating: The industry standard for most indoor, dry warehouse environments. It offers a durable, clean finish.
Hot-Dip Galvanization: For cold storage, freezers, humid environments, or outdoor use. The zinc coating provides superior protection against rust and corrosion.
Installation & Safety Tips
Tool-Free Installation: Wire decks are designed for simple, drop-in installation. No bolts, clips, or tools are required.
Ensure a Secure Fit: Place the deck onto the beams, making sure the waterfall edges or support channels are fully seated. The deck should not rock or shift.
Load Distribution: Always distribute weight as evenly as possible across the deck surface. Avoid point-loading with heavy, concentrated items.
Never Exceed Capacity: Always respect the manufacturer's stated load capacity to prevent failure and ensure safety.
Frequently Asked Questions
What is the difference between plywood and wire mesh decking?
Wire mesh meets fire codes by allowing sprinkler water through; plywood is a solid fire hazard that blocks it.Unlike plywood which warps and splinters, wire mesh is durable steel that provides lasting strength.
This makes wire mesh the safer, compliant, and more reliable long-term solution.
How do I know what weight capacity I need?
Calculate the weight of your heaviest pallet or the total weight of goods you plan to store on one shelf. Then, select a deck with a Uniformly Distributed Load (UDL) capacity that is higher than your calculated maximum weight to ensure a proper safety margin.
Do wire mesh decks meet fire codes?
Yes, this is one of their primary benefits. The open design allows at least 50% water pass-through, which is a standard requirement for most fire safety regulations regarding pallet racking.
What's the difference between waterfall and drop-in decks?
A waterfall deck hooks over the beam, locking it in place, while a drop-in deck sits flush inside the beam's step. Waterfall is the most common and secure, while drop-in provides a completely flat surface.
