Retrofit Industrial Bar Grating & Mezzanine Plank Flooring

Replace or Cover Steel Bar Grating with ResinDek^® Panels

Why Industrial Facilities Are Replacing Steel Bar Grating

While steel bar grating and metal plank decks expand mezzanine floor space, their perforated grid surfaces create severe operational bottlenecks, safety risks, and employee fatigue.

Heavy Wheel Strain & Noise: Rolling dollies, carts, and pallet jacks across perforated grates causes intense vibration, requiring workers to exert significantly more pushing force while generating disruptive ambient noise.
Biomechanical Fatigue & Injury: Steel grating is rigid and unforgiving. Biomechanical testing shows that walking on bar grating increases tibial shock force by over 10%—the physical equivalent of adding 18 pounds of body mass with every step.
Blockade to Warehouse Automation: Open gaps and textured grid surfaces prohibit the deployment of Autonomous Mobile Robots (AMRs), AGVs, and motorized transport fleets.
Safety & Inventory Hazards: Bar grate openings create constant trip hazards, prohibit workstation setup, and allow tools or inventory items to drop through to lower work levels.

Retrofit Directly Over Steel Bar Grating (Overlay Solution)

For maximum operational continuity, ResinDek® heavy-duty engineered panels are fastened directly onto existing metal grating.

No Demolition Needed: Avoid expensive structural tear-outs and landfill fees.
Zero Line Shutdowns: Fast installation allows retrofitting in active zones, aisle by aisle.
Instant Upgrade: Turns unstable steel grates into a smooth, solid floor overnight.

Why Choose ResinDek^® Over Steel Bar & Plank Grating?

Application Parameter	Specification & Compatibility
Structural Compatibility	Roll-formed beams & structural steel under 3/16″ thick
Minimum Deck Valley Clearance	2.5″ minimum width (required for screw gun clearance)
Panel Compatibility	Approved for ResinDek® LD, MD, and HD panels
Custom Fastening Systems	Custom solutions available upon request; contact Cornerstone for details

How to Install ResinDek® Flooring Over Bar Grating

Discover the straightforward process of installing ResinDek flooring panels directly over existing bar grating flooring systems. This innovative installation method allows you to transform your industrial workspace without the need to remove your current grating infrastructure. Learn the proper techniques, required tools, and best practices for securing ResinDek panels to create a smooth, durable walking surface that maintains the structural integrity of your bar grating below.

ResinDek Industrial Bar Grating FAQs

Can you install solid flooring directly over existing steel bar grating?

Yes. ResinDek® composite flooring panels can be installed directly over existing steel bar grating or metal plank decks using specialized engineered fasteners. This overlay method eliminates the need to tear out old grating, saving significant time, labor, and material disposal costs.

Is it better to cover or replace mezzanine bar grating?

Covering bar grating with a ResinDek overlay is ideal if you want a fast, cost-effective retrofit with minimal facility downtime. Full replacement (removing grates and installing ResinDek over corrugated B-Deck) is recommended if strict structural weight limits or vertical overhead clearance requires removing the weight of the steel grate.

How does retrofitting bar grating improve warehouse ergonomics?

Steel bar grating increases walking shock force on employees by over 10%. Retrofitting with solid ResinDek panels creates an ergonomic, shock-absorbing surface that significantly reduces worker fatigue, joint strain, tibial shock force, and slip-and-fall hazards.

Can AGVs and AMRs operate on steel plank grating?

No. Autonomous Mobile Robots (AMRs) and Automated Guided Vehicles (AGVs) require a smooth, continuous surface to maintain traction, sensor accuracy, and wheel balance. Installing ResinDek panels over steel grating provides the exact surface levelness, durability, and ESD-rated finish needed for warehouse automation.