Wire selection and straightening
Production starts with wire stock selected for the diameter and tensile strength the shelf design calls for. Before anything is welded, the wire is straightened and cut to length on automated equipment — a step that sounds trivial but directly determines whether the finished shelf sits flat or has a subtle bow that shows up only once it's loaded.
Forming the grid
Longitudinal and cross wires are arranged into the shelf's grid pattern using jigs that hold spacing consistent across the full run. Consistent spacing matters for two reasons: it keeps the load-bearing capacity uniform across the shelf surface, and it keeps every unit in a batch dimensionally identical, which matters when shelves need to be interchangeable across racking systems.
Welding and frame assembly
Grid intersections are joined by resistance welding, and the perimeter frame — typically a heavier-gauge wire or rod — is welded on to give the shelf its structural edge and mounting points. Weld consistency is checked here, since a weak intersection weld is one of the more common points of failure under sustained load.
Finishing
Depending on the end application, finished shelves are cleaned and then chrome-plated, zinc-plated, or powder-coated for corrosion resistance and appearance. The finishing step is also where any sharp edges from cutting and welding are addressed, since these shelves are frequently handled directly by end users in retail, food service and storage settings.