Pallet rack wire decking is one of the simplest parts of a rack to order, as long as you take three measurements first: frame depth, beam length and the shape of the beam. This guide walks through each one, explains what the capacity ratings mean, compares wire decking with punched steel decking, cross bars and wood, and answers the questions buyers ask us most.
What wire decking is and why racks use it
Wire decking (also called wire mesh decking, wire decks or steel wire decking) is a welded steel wire grid supported by steel channels that run front to back. Each deck drops onto a pair of beams and turns an open beam level into a shelf.
Racks use it for three reasons:
- Nothing falls through. Broken pallet boards, cartons, bins and loose items stay on the level instead of dropping between the beams.
- Water and light get through. The open mesh lets water from overhead sprinklers pass to the levels below. It also improves airflow and visibility, lets light filter down and reduces dust buildup.
- It installs in seconds. Our decks have 1.5 in waterfall edges (1 in on the 2,000 lb 42 x 46 in deck) at the front and rear that wrap over the beam flange, so each deck drops into place and stays seated with no tools, clips or hardware.
Our stock decks are welded steel wire in a 2.5 x 4 in grid, typically 6-gauge wire, on cold-formed steel channels, with a powder-coat finish. They are manufactured in accordance with ANSI MH26.2, the standard for welded wire rack decking. Galvanized decking is available on request.
How to measure for wire decking
You need three things from your rack. None of them require you to measure between the beams.
1. Frame depth sets the deck depth
Measure the upright frame from the front column to the back column. The deck depth matches the frame depth: a 42 in deep frame takes a 42 in deep deck. The most common depths are 36, 42, 44 and 48 in, and we stock decks from 24 to 60 in deep.
2. Beam length sets the deck width and the number of decks
Measure the beam from left to right. Most levels use two decks; very long beams use three. This is how we cover the common beam lengths with the widths we stock:
| Beam length | Decks per level |
|---|---|
| 92 in (7 ft 8 in) | Two 46 in decks |
| 96 in (8 ft) | Two 46 in decks |
| 102 in (8 ft 6 in) | One 46 in and one 52 in deck |
| 108 in (9 ft) | Two 52 in decks |
| 120 in (10 ft) | Two 58 in decks |
| 144 in (12 ft) | Three 46 in decks |
So a search for "42x46 wire decking" or "pallet rack wire decking 46 wide 42 deep" is a deck for a 42 in deep frame on a 92 or 96 in beam. To count decks for a whole run, multiply decks per level by levels by bays.
3. Beam shape sets the channel style
Look at the inside top edge of the beam. A roll-formed step beam has a ledge of 1.5 to 1.625 in. A structural channel beam or box beam has no ledge. That decides step channel or flared, covered next.
Step channel vs flared (universal) wire decking
| Step channel | Flared (universal) | |
|---|---|---|
| How it sits | Channels drop into the beam step for a flush, integrated fit | Flared channel ends rest on top of the beam |
| Beams it fits | Roll-formed step beams | Structural channel and box beams with no step; also standard step beams |
| Depths we stock | 36 to 60 in | 24 to 48 in |
| Widths we stock | 46, 52 and 58 in | 46 and 52 in |
If your building has a mix of step beams and box beams, flared decks let you run one style throughout.
Wire deck capacity ratings and what they mean
Our decks are rated from 2,000 to 3,500 lb. Three points matter when you read those numbers.
- The rating is per deck, not per level. A level with two decks has two ratings, one for each deck.
- The rating assumes a uniformly distributed load. Weight spread across the deck is what the number describes. For heavy point loads, use additional supports.
- Decking does not raise the rack's capacity. The beams and upright frames set what the rack can hold. Stay under both the deck rating and the beam rating.
Standard decks have 3 support channels. Larger or higher-capacity decks use 4 channels, and that is what to choose for extra-long spans or heavier loads. For example, in a 42 x 46 in step channel deck we stock 3-channel decks at 2,000 and 2,500 lb and 4-channel decks at 2,500 and 3,500 lb. The wire decking product page lists the rating for every size, and our pallet rack wire decking collection has the full size table.
Open area and sprinklers
Open wire mesh lets water from overhead sprinklers pass through to the levels below. That is why fire codes and insurers generally favor open decking over solid surfaces in racked storage. Requirements vary by occupancy and jurisdiction, so confirm with your fire marshal or insurer before you specify.
If you need a flat surface and an open area, punched steel decking is 50% open, so sprinkler water reaches every level. Final acceptance rests with your fire marshal or insurer.
Pallet rack decking options: wire, punched steel, cross bars or wood
| Option | Best for | Beams it fits | What to know |
|---|---|---|---|
| Wire decking | Pallets, cartons, bins and irregular loads | Step beams (step channel); structural and box beams (flared) | Open mesh; 2,000 to 3,500 lb per deck |
| Punched steel decking | Hand-stacked cartons, small parts, items that snag on mesh | 1-5/8 in step beams | Flat, 50% open, 20-gauge galvanized; rated per panel, and the rating falls as depth grows |
| Cross bars | Pallet-only levels | Step beams; structural style for box beams | Two bars per pallet position; no shelf surface |
Pallet rack wood decking such as plywood gives a solid shelf, but a solid shelf can block sprinkler coverage of the levels below. If you are weighing wood, check with your fire marshal or insurer first.
Punched steel decking drops into 1-5/8 in step beams and sits flush, which keeps the beam face clear for labels. Panels come in 24 and 30 in widths, so a level takes more of them: four 24 in panels on a 96 in beam, four 30 in panels on a 120 in beam. Choose it when people pick from the shelf.
Pallet rack cross bars are 16-gauge steel bars, 1,250 to 1,450 lb each, that drop in between the beams and tie the front and rear beams together. Use two per pallet position, spaced evenly front to back, and three for heavy loads or poor-quality pallets. A 96 in level with two pallets takes four bars; a 144 in level with three pallets takes six. Many warehouses run bars on pallet levels and decking on pick levels.
Common mistakes
- Ordering by the gap between beams. Deck depth matches the upright frame depth, measured front to back from column to column.
- Ordering step channel decks for box beams. If there is no ledge on the beam, you need flared decks.
- Reading the deck rating as the level rating. The rating is per deck, and the beams have their own limit that decking does not change.
- Putting point loads on a deck rated for spread loads. Ratings are for uniformly distributed loads. Add supports under concentrated weight.
- Forgetting what goes on the deck. Plan wire mesh dividers to split a deck into lanes and a pallet rack backstop to stop cartons going off the back.
Frequently asked questions
What size wire decking do I need?
Match the deck depth to your upright frame depth, measured front to back, and pick the width from your beam length. A 42 in deep frame with 96 in beams takes two 42 x 46 in decks per level.
How much weight can wire decking hold?
Our decks are rated 2,000 to 3,500 lb each, as a uniformly distributed load. The rating applies to each deck, not the whole level, and you must also stay under the beam rating.
Does wire decking increase pallet rack capacity?
No. Decking supports the load between the beams and stops items falling through. The rack's rated capacity comes from its beams and upright frames.
Step channel or flared wire decking: which do I need?
If your beams have a 1.5 to 1.625 in step ledge, choose step channel. If they are structural channel or box beams with no step, choose flared (universal). Flared decks also fit step beams.
How many cross bars do I need?
Two per pallet position, spaced evenly front to back, or three for heavy loads and poor-quality pallets. A 96 in beam level holding two pallets needs four.
What are pallet rack wire deck dividers?
Our wire mesh rack dividers are 12 in high mesh panels that snap into the deck wires with no tools to split a shelf into lanes. Choose the 34, 40 or 46 in divider for a 36, 42 or 48 in deep deck.
What is a pallet rack backstop?
Our backstop is a 45 x 12 in wire mesh panel that hangs from the rear wire of a 46 in wide deck on loop hooks. It stops cartons pushed during put-away from dropping into the flue or the aisle behind.
Is galvanized wire decking available?
Yes, on request. Our stock decks have a powder-coat finish that resists corrosion in normal warehouse use; galvanized decking suits wash-down, cold storage or outdoor areas.
Ready to order? Find your size in the pallet rack wire decking collection, or see pallet rack dividers for the parts that go on top.