Pallet Supports vs. Wire Decking: Which One is Right for You?

For warehouse storage optimization, having a stable and secure pallet racking system is crucial. Pallet racks can solely support the weight of the pallet, but not all pallets are sized to do so, or sometimes not in ideal condition. If the pallets in your warehouse are too small to balance on the beams or are damaged and unstable, you might need to provide additional support to prevent product damage or workplace injuries. 

Two solutions for this are pallet supports and wire decking. Both solutions are employed for weight distribution and to improve safety in the standard pallet racks. Additionally, they can expand your storage options by allowing for more carton storage. However, each is designed to serve different purposes and offer distinct benefits. So, how to choose the right one between pallet supports and wire decking? 

This blog compares these two solutions and highlights the differences between pallet supports and wire decking to help zero in on the best option. 

Understanding Pallet Supports

Pallet supports are metal bars that run front-to-back between pallet rack beams. These help stabilize the load and provide additional support for stored pallets so the pallets do not fall because of the gaps between beams. They are available in different designs and are typically bolted or clipped onto the rack beams.

Variety in Pallet Supports

Pallet supports come in different designs to suit diverse warehouse storage needs. 

• Channel Supports: These U-shaped or C-shaped metal bars provide heavy-duty reinforcement. They hold and distribute load effectively without stressing the racking structure with weight.
• Flanged Supports: These have a small flange attached at the ends that rests on top of the beams. This design provides additional stability, improves load-bearing capacity, and prevents unnecessary pallet movement.
• Box Supports: These rectangular-shaped enclosures offer high strength and durability, which makes them suitable for high-capacity storage.
• Structural Supports: Made from thick steel to support heavy industrial loads. These are usually bolted to structural storage racks. These are utilized commonly in industrial applications and heavy-duty storage. 

Advantages of Pallet Supports

• They are cost-effective and even cheaper than wire decking. This makes them a preferred choice of many warehouses. 
• Their high load capacity allows them to handle heavy loads (industrial storage) without bending.
• They work well with standard pallet racking applications.
• Quick and simple to install without requiring extensive modifications.

Limitations of Pallet Supports

• These supports cover only the width of the beams and do not provide a complete deck surface. This makes them unsuitable for smaller or irregularly shaped loads.
• Smaller items or irregular loads might fall between the supports. So, these are not practical for warehouses that store a mix of goods.

What Is Wire Decking?

Wire decking has metal mesh panels that sit on top of rack beams. Thus, it offers a stable surface for storage. This decking system improves load distribution and prevents pallets or products from falling through gaps. Wire decking is found in warehouses where palletized and loose items are stored. 

Types of Wire Decking

• Standard Waterfall Decking: It is the most commonly used wire decking type to achieve stability. It features a front and back waterfall edge hooked over the beams. This design makes the pallet stable and increases safety.
• Flared Channel Wire Decking: Flared ends allow it to fit onto structural or step beams. This wire decking type is versatile as it pairs well with different racking systems.
• Inside Waterfall Decking: Unlike standard waterfall decking, this type sits flush inside the beams rather than wrapping over them. As a result, it has a cleaner and more streamlined appearance.
• Flat Wire Decking: This design does not have a waterfall edge but a smooth and continuous surface, which makes it ideal for applications that require uniform support across the entire rack.

Advantages of Wire Decking

• A wire mesh deck provides an entire shelf surface. This removes the probability of items falling through open gaps and causing accidents. 
• Unlike pallet supports, wire decking can accommodate palletized and non-palletized goods, which makes it a more flexible storage solution.
• Its open mesh design allows water from fire suppression systems to penetrate through the decking, thus reducing the risk of pallets catching fire.
• Its open-grid structure offers complete visibility of stored products. It helps streamline inventory checks and reduces the chances of items being misplaced.
• Wire decking for shelves is made with high-strength steel and can withstand heavy loads while preventing dust buildup and maintaining airflow around stored items.

Limitations of Wire Decking

• Wire decking is more expensive than pallet supports. It requires a high upfront investment.
• Wire decking is strong but may not support extreme loads as effectively as dedicated pallet supports.

Pallet Rack Supports vs Wire Decking: A Detailed Comparison on Various Parameters

1) Load Distribution

• Pallet Supports: Offers support at only specific pallet points. Thus, they are ideal for heavier loads that rest securely on beams and are not moving.
• Wire Decking: Distributes weight evenly across the rack. This makes it a better choice for mixed inventory and loose goods.

2) Storage

• Pallet Supports: It is best for warehouses that store standard-sized pallets and do not require additional support beyond the rack beams.
• Wire Decking: Works well for both palletized and non-palletized goods. Its versatility and adaptability make it a preferred option for warehouses with varied storage needs.

3) Fire Safety and Compliance

• Pallet Supports: Allows enough space for fire sprinklers to pass. However, due to less surface area, fire containment can be difficult.
• Wire Decking: It has a palletized wire mesh, which makes it fire-code compliant. It allows proper water penetration in case of a fire and thus reduces the risk of fire spreading within the racking system.

4) Installation and Maintenance

• Pallet Supports: Screws or clips make their installation simple. Also, apart from sporadic inspections, they require very little maintenance.
• Wire Decking: Its installation process is often complex. However, it offers stability and long-term ease of use with little or no maintenance.

5) Cost

• Pallet Supports: Generally, they are less costly. However, they may require additional support to carry heavier loads.
• Wire Decking: Its upfront cost is high. However, it offers better long-term value due to increased storage efficiency and safety.

Make the Right Choice Between Pallet Supports and Wire Decking

In warehouse storage systems, both wire decking and pallet supports play crucial roles. However, when it comes to deciding between these, the choice will depend on your budget, safety regulations, and circumstances. Pallet supports reinforce heavy loads, whereas wire decking offers flexibility, safety, and fire code compliance. Make sure you clearly understand the differences between these options before deciding. This will help you optimize your warehouse storage efficiently and safely.

At SRSI, we specialize in industrial storage rack and shelving solutions. We serve a variety of industries and help businesses find the best storage solutions for their unique needs. If you are still confused about these two options, connect with our team of experts to zero in on the right choice.

Frequently Asked Questions 

1) Which option improves warehouse safety more?

Wire decking provides a stable surface that prevents smaller items from falling through, improves load distribution, and reduces the risk of accidents. Pallet supports also ensure proper pallet placement and minimize the chances of pallets tipping or falling. However, wire decking offers better protection in warehouses where forklifts frequently load and unload pallets.

2) Can wire decking or pallet supports prevent pallet deflection?

Yes, both options minimize pallet deflection by offering additional support. Pallet supports cater to specific points under the pallet and reduces sagging where beams do not fully support the load. Wire decking provides even weight distribution across the entire pallet. Therefore, it efficiently prevents long-term pallet warping or collapse.

3) Do I have to modify my pallet racking system to use wire decking or pallet supports?

Most standard pallet racking systems can accommodate wire decking and pallet supports without modification. However, check their compatibility with your rack type, beam dimensions, and weight capacity.

4) Are pallet supports a good choice for automated storage systems?

Yes. Pallet supports are used in automated storage and retrieval systems (AS/RS). They provide extra stability for pallets placed by automation. However, wire decking is preferred in non-standard pallet sizes or mixed inventory.

5) Which option works best for cold storage or food-grade warehouses?

Wire decking is often the better choice for cold storage and food-grade environments because its open mesh design allows better airflow, prevents moisture buildup, and maintains consistent temperatures. 

6) Is wire decking better for hand-stacked inventory?

Yes. Wire decking is ideal for hand-stacked inventory since it creates a stable and solid surface for placing smaller items, like cartons, bins, or irregularly shaped goods.