Do I need wire decking or pallet supports, and how do I size them correctly?
Quick Answer
Choose wire decking when you handle loose cartons, mixed SKUs, or need fire-code water flow and easy visual checks. Select pallet supports when every load rests on sound pallets and you only need extra bearing bars. In either case, match depth to rack frames, width to beam length, and meet the highest load rating with two supports per pallet.
Detailed Answer
Warehouse optimization starts with choosing the right shelf surface for your pallet racking systems. Wire mesh decking and welded-steel pallet supports both reinforce selective racks, yet they solve different problems. Wire decking creates a full shelf that catches broken pallets, allows sprinkler water flow, boosts airflow and visibility, and lets you store cartons or loose SKUs. Pallet supports are two or more bars that bridge the beams; they cost less and keep forklift access clear but only work when every load sits on a consistent, good-quality pallet.
Sizing steps:
1. Depth: match the rack frame depth—most U.S. racks are 36″, 42″ or 48″. A 42″ frame gets a 42″ deep wire deck or 42″ pallet support.
2. Width: wire decks are sold to fit clear beam length (e.g., two 46″ decks for a 96″ beam or three 46″ decks for a 144″ beam). Pallet supports should overhang the step or box beam about 1″ per side and be tek-screwed or clipped in place.
3. Capacity: choose a deck or support rating that meets or exceeds the heaviest uniformly distributed pallet load, typically 5,000–6,000 lb per pair of beams with pallet weights of 2,000 – 2,500 lbs; increase gauge or channel count for point loads.
4. Quantity: use at least two pallet supports per pallet position—add a third for heavy, weak, or nonstandard pallets.
Warehouse Cubed’s warehouse consulting services can verify load data, conduct rack inspections, and integrate the right material handling systems, supplying wire decking, flanged or hat-style pallet supports, and other industrial storage solutions that keep your operation safe, compliant, and ready for growth.