Don’t Use Pallet Rack Decking in These 6 Situations
Pallet rack decking is a popular storage solution in modern warehouses. It helps support pallet loads, enhances safety, and improves inventory visibility. However, despite its usefulness, pallet rack decking isn’t always the right choice for every storage scenario. Using it incorrectly can lead to safety issues, damage, or reduced efficiency.
In this blog post, we’ll explore six situations where you should avoid using pallet rack decking and suggest better alternatives to maintain safety and performance in your storage environment.
1. When Handling Liquid or Semi-Liquid Products
Pallet rack decking is typically made of wire mesh, which is not suitable for storing containers that may leak. Liquid spills can seep through the mesh and damage lower-level inventory or create hazardous work conditions. This is especially true in food processing, chemical, or paint storage areas.
In such cases, using solid steel decking or drip-proof trays is more appropriate. These solutions help contain leaks and prevent contamination, keeping your workspace clean and safe.
2. For Very Small or Loose Items
If you’re storing small tools, nuts, bolts, or loose inventory directly on racks, wire decking for pallet racks may not be ideal. The mesh structure usually has gaps that can let smaller items fall through. This results in product loss and safety risks for workers below.
Instead, opt for shelving systems with solid surfaces or bins that can hold small items securely. These setups reduce the risk of dropping goods and help in better organization.
3. When You Need a Fire-Rated Storage System with Solid Decking
Fire codes often influence storage design. While pallet wire decking is popular because its open mesh allows water from sprinkler systems to pass through, solid decking options do not offer this benefit. If you’re tempted to cover wire decking with cardboard, plywood, or sheet metal to create a flat surface—think again.
Doing so can compromise fire safety compliance. In such cases, use fire-rated solid decking tested and approved for use with sprinkler systems. This ensures you meet safety standards without sacrificing utility.
4. For Very Heavy or Point-Loaded Items
While pallet rack decking is built to hold substantial weight, it has limitations. If you’re placing loads that apply pressure to a small area—known as point loading—you might end up bending or damaging the mesh decking. Heavy machinery parts, steel rolls, or narrow containers can easily over-stress certain sections of the deck.
Instead, use steel or wood supports designed to handle point loads. Custom decking options made for concentrated weight distribution are also better suited for such applications.
5. When Cleanliness and Hygiene Are Critical
Industries like pharmaceuticals, food processing, or electronics manufacturing require high hygiene standards. Pallet wire decking, while functional, can collect dust and debris in its mesh openings, making cleaning difficult. In such settings, hygiene isn’t just about cleanliness—it’s about compliance with health regulations.
Use smooth, non-porous shelving surfaces that are easy to sanitize. Stainless steel racks or plastic-coated solid decks are commonly used in environments with strict cleanliness requirements.
6. Outdoor Storage or Humid Conditions
If your racking system is placed outdoors or in a high-humidity environment, traditional wire decking for pallet racks may not last long. Moisture can lead to rust and corrosion, reducing the decking’s load-bearing capacity and lifespan. Even galvanized or powder-coated options may degrade over time if not maintained properly.
In such cases, look for fully galvanized or stainless-steel decking designed specifically for outdoor or moist environments. This ensures longer life and reduces safety risks due to corrosion.
Optimize Your Warehouse Operations
Pallet rack decking is a valuable tool for efficient warehouse storage, but it’s not suitable for every scenario. Knowing when not to use it is just as important as knowing how to use it. Whether you’re storing liquids, heavy machinery, or sensitive items, there are better alternatives for certain conditions. Avoiding these six common mistakes can prevent accidents, preserve your inventory, and improve overall warehouse performance.
Always assess your storage needs carefully and consult with a racking expert if you’re unsure. By making informed choices, you can optimize your warehouse operations without compromising on safety or functionality.