New Pallets
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Built to Your Exact Standards
While we champion used pallets for their environmental benefits, we understand that some applications require brand-new construction. Our new pallets are built with precision and care, using quality lumber sourced from responsible suppliers.
Whether you need standard GMA pallets, custom dimensions for specialized products, or ISPM-15 compliant pallets for international shipping, we can manufacture to your specifications.
Every new pallet we build starts with carefully selected lumber that meets our quality standards for grain structure, moisture content, and dimensional accuracy. Our production process combines modern efficiency with old-fashioned craftsmanship to deliver pallets that perform reliably from the first use to the last.
Pallet Construction Types
Stringer Pallets
Most common type. Uses 2x4 or 3x4 stringers between the deck boards. Available in two-way or partial four-way entry. Economical to produce and widely accepted across all industries.
Block Pallets
Uses blocks of wood between the decks. True four-way entry for maximum forklift accessibility. Stronger under racking loads and preferred for automated warehouse systems.
Double-Face Pallets
Deck boards on both top and bottom. Extra protection and stability for heavy or fragile loads. Can be reversible (both sides load-bearing) or non-reversible.
Wing Pallets
Deck boards extend beyond the stringers on one or both sides. Provides extra surface area for oversized loads without increasing stringer length. Common in the beverage industry.
Flush Pallets
Deck boards are flush with the stringers on all sides. Clean edges make them ideal for racking systems and automated conveyor operations where consistent dimensions matter.
Consider Used First
For most applications, our Grade A used pallets perform identically to new ones at 60-70% of the cost. We always recommend exploring used options first as a more sustainable choice.
Browse used palletsLumber Types and Their Properties
The wood species used in your pallet directly impacts strength, weight, durability, cost, and performance. We source lumber from regional mills and select the right species for each application. Here is a detailed look at the most common options.
Oak (Red & White)
Hardwood- Density: 44-47 lbs per cubic foot -- one of the heaviest pallet woods
- Janka hardness: 1,220-1,360 lbf -- excellent resistance to denting
- Bending strength: 14,300 psi -- superior load-bearing performance
- Nail retention: Excellent -- nails hold firmly in dense grain structure
- Durability: 15-20+ reuse cycles under normal warehouse conditions
- Moisture resistance: Moderate -- White Oak is naturally more resistant than Red Oak
- Availability: Widely available across the Midwest and Southeast US
- Cost: Premium pricing -- typically 30-40% more than softwood options
- Best for: Heavy-duty pallets, racking loads, export, long-lifecycle applications
Southern Yellow Pine
Softwood- Density: 34-36 lbs per cubic foot -- lighter than hardwood options
- Janka hardness: 690-870 lbf -- one of the hardest softwoods available
- Bending strength: 12,800 psi -- strong for a softwood species
- Nail retention: Good -- resinous wood grips nails well
- Durability: 10-15 reuse cycles under normal conditions
- Moisture resistance: Low -- requires treatment for outdoor or wet environments
- Availability: Abundant across the Southern US, most-produced lumber species
- Cost: Moderate pricing -- excellent value for performance ratio
- Best for: General-purpose pallets, shipping, standard warehouse applications
Poplar (Tulipwood)
Hardwood- Density: 29-31 lbs per cubic foot -- lightest hardwood commonly used for pallets
- Janka hardness: 540 lbf -- softer than oak, but classified as hardwood
- Bending strength: 10,100 psi -- adequate for light to moderate loads
- Nail retention: Moderate -- softer grain requires careful fastener placement
- Durability: 8-12 reuse cycles under normal conditions
- Moisture resistance: Low -- susceptible to decay without treatment
- Availability: Common in Eastern US hardwood forests
- Cost: Lower than oak -- most affordable hardwood option for pallets
- Best for: Lightweight pallets, food-safe applications (low resin), display pallets
Spruce / Fir (SPF)
Softwood- Density: 25-28 lbs per cubic foot -- among the lightest pallet lumber options
- Janka hardness: 490-560 lbf -- moderate hardness for a softwood
- Bending strength: 9,800-10,600 psi -- suitable for standard loads
- Nail retention: Fair -- lighter density means more careful fastening needed
- Durability: 8-10 reuse cycles under normal conditions
- Moisture resistance: Low -- not recommended for outdoor or wet use without treatment
- Availability: Abundant from Canadian and Northern US forests
- Cost: Lowest cost lumber option -- maximizes savings on large orders
- Best for: One-way shipping, lightweight loads, cost-sensitive applications, export pallets
Construction Methods Deep Dive
Building a pallet that performs reliably under real-world conditions is more complex than it appears. Every design decision affects strength, weight, cost, and lifespan. Here is a detailed look at how our new pallets are constructed.
Lumber Selection and Preparation
Every board is inspected for defects including knots, wane, splits, and bark inclusions. Lumber is sorted by grade, moisture tested (target: under 19%), and cut to precise dimensions on calibrated equipment. Boards with excessive defects are rejected and redirected to repair stock.
Stringer or Block Cutting
Stringers are cut from dimensional lumber (typically 2x4 or 3x4 stock) to exact lengths. Notches for four-way forklift entry are cut with precision jigs that ensure consistent depth and width across every unit. Block pallets use hardwood blocks cut to 3.5x3.5x3.5" or larger.
Deck Board Layout
Top deck boards are laid out with precise spacing calculated for the intended load. Standard GMA pallets use 5-7 top deck boards with gaps between them. Full-deck designs use tightly spaced boards for maximum surface coverage. Board width and spacing are adjusted based on load requirements.
Assembly and Fastening
Deck boards are secured to stringers using pneumatic nail guns with precisely calibrated pressure settings. Each nail is driven to exact depth -- flush with the surface, neither protruding nor countersunk. Fastener patterns follow industry standards for optimal holding strength.
Bottom Deck Assembly
Bottom deck boards (typically 3 boards for stringer pallets) are attached to complete the structure. Bottom boards prevent stringer splitting during forklift operations and provide additional surface area for stacking stability.
Quality Inspection
Every completed pallet undergoes a multi-point quality check: dimensional accuracy within 1/4", all fasteners flush and secure, no splits or cracks, proper board spacing, and visual inspection for cosmetic defects. Rejected pallets are disassembled and rebuilt.
Treatment (If Required)
Pallets requiring ISPM-15 certification are loaded into our heat treatment chamber where they are brought to a core temperature of 56 degrees Celsius and held for a minimum of 30 minutes. Post-treatment, each pallet receives the IPPC certification stamp.
Fastener Types We Use
The fastener used in pallet construction is just as important as the wood itself. Different fasteners provide different holding power, cost, and performance characteristics. Here is what we use and when.
Helically Threaded (Screw-Shank) Nails
Our primary fastener. The twisted shank grips wood fibers as it is driven, providing 40-50% more holding power than smooth nails. Resists backing out under vibration and dynamic loads. Used for all structural connections.
Ring-Shank Nails
Concentric rings along the shaft create maximum withdrawal resistance. Once driven, they are extremely difficult to pull out. Used for high-stress connections and pallets destined for heavy racking applications.
Smooth-Shank Nails
Traditional nail with no surface texture. Lowest cost and fastest to drive. Suitable for light-duty pallets and applications where pallets will be disassembled for repair or recycling.
Heavy-Duty Staples
Wide-crown staples provide excellent shear strength and are faster to apply than nails. Used for bottom deck boards and light-duty connections. Not recommended for primary structural joints on heavy-load pallets.
Bolts and Lag Screws
Used for specialty and heavy-duty custom pallets where maximum connection strength is required. Common in pallets designed for machinery, oversized equipment, or extreme racking loads exceeding 3,000 lbs.
Standard Construction Specs
Design Customization Options
Our new pallets can be customized across more than 15 different parameters to match your exact requirements. From basic dimensional changes to advanced engineering modifications, here is everything you can specify.
Overall Dimensions
Any length, width, and height combination. From compact 24x24" pallets for small goods to oversized 72x120" pallets for industrial equipment. No minimum or maximum size restrictions.
Deck Board Width
Choose from 3.5", 4.5", 5.5", or 7.25" wide deck boards. Narrower boards allow better ventilation; wider boards provide more surface coverage for small or irregularly shaped items.
Deck Board Spacing
Set the gap between top deck boards from zero (full deck / no gap) to 4" or more. Tight spacing supports small items; wider spacing saves material and weight.
Deck Board Count
Specify the exact number of top and bottom deck boards. More boards mean more load distribution; fewer boards reduce weight and cost for light loads.
Stringer vs. Block Design
Choose between 2-way stringer entry, 4-way notched stringer entry, or full 4-way block construction. Block pallets offer universal access; stringers are more economical.
Entry Type
Two-way (forklift access from two sides), partial four-way (forklift from two sides, pallet jack from four), or full four-way (forklift and pallet jack from all four sides).
Wood Species
Select from oak, pine, poplar, spruce, fir, or mixed hardwood/softwood. Species affects weight, strength, cost, and appearance. We recommend the best species for your use case.
Board Thickness
Standard 5/8" or 3/4" thick boards, or up to 1" thick for extreme loads. Thicker boards increase weight capacity but also increase pallet weight and material cost.
Stringer Dimensions
Standard 2x4 stringers for most applications, heavy-duty 3x4 or 4x4 stringers for increased capacity. Custom stringer profiles available for specialty requirements.
Edge Treatment
Square-edge boards for standard use, chamfered (beveled) edges for smoother forklift entry, or radiused edges for applications where product or worker safety is a priority.
Surface Finish
Rough-sawn (standard), planed smooth on one or both sides, or sanded for display and retail applications. Smooth surfaces cost more but reduce splinter risk and improve appearance.
Heat Treatment (ISPM-15)
Kiln heat treatment to 56 degrees Celsius core temperature for 30 minutes. Required for international shipping. Each treated pallet receives the official IPPC certification stamp.
Anti-Fungal Treatment
Borate-based or other EPA-registered anti-fungal coatings applied to prevent mold growth during storage and transit. Essential for products shipped to humid climates.
Color Coding or Paint
Pallets can be painted or color-coded for inventory management, department identification, or brand consistency. Water-based, non-toxic paints in any color.
Branding and Marking
Company logo, handling instructions, weight limits, or tracking barcodes applied via stencil, hot brand, or ink stamp. Permanent or semi-permanent marking options.
Reinforcement Plates
Metal connector plates or gussets at high-stress joints for extreme-duty applications. Significantly increases load capacity and extends pallet lifespan.
Non-Slip Surface
Textured deck boards or applied non-slip coatings to prevent cargo shifting during transport. Critical for loads that cannot be stretch-wrapped or strapped.
Load Testing Procedures
We do not just build pallets and hope they work. Our testing procedures validate that every pallet design meets its rated capacity with a built-in safety margin. Here is how we test and what the results mean for your operation.
Static Compression Test
A uniformly distributed load is applied to the pallet while it rests on a flat surface. Load is increased incrementally until the target capacity is reached. The pallet must support the load for 24 hours without deformation exceeding 1/4" at center span.
Dynamic Fork Lift Test
The pallet is loaded to rated dynamic capacity and lifted by a forklift from each entry point. Tests include lifting, transporting across a rough surface, and setting down. The pallet must maintain structural integrity with no board loosening or stringer cracking.
Racking Span Test
The pallet is placed across rack beams with only the edges supported and loaded to rated racking capacity. Center deflection is measured at 1-hour and 24-hour intervals. Maximum acceptable deflection is 1/2" at center span under full rated load.
Corner Drop Test
A loaded pallet is dropped from a height of 12-18 inches onto one corner. This simulates the most destructive real-world event a pallet faces. The pallet must survive with no more than cosmetic damage at rated dynamic load.
Fastener Withdrawal Test
Individual fasteners are tested for withdrawal resistance using a calibrated pull tester. Each nail must resist a minimum of 100 lbs of withdrawal force. Below this threshold, the fastener type or wood species is changed.
Moisture Content Verification
Pin-type moisture meters are used to verify that all lumber is below the target moisture content (19% for standard, 12% for kiln-dried). High moisture content weakens joints and promotes mold growth during storage.
When to Choose New Over Used
We always encourage customers to consider used pallets first for their environmental and cost benefits. However, there are specific scenarios where new pallets are the clearly better choice. Here are eight situations where new is the right call.
International Export Requirements
Many countries require ISPM-15 certified wood packaging for imported goods. New pallets with verified heat treatment and fresh IPPC stamps ensure your shipment clears customs without delays. While some used pallets carry valid stamps, new pallets guarantee compliance from the start.
Automated Warehouse Systems
Automated storage and retrieval systems (AS/RS), automated guided vehicles (AGVs), and conveyor systems require pallets with precise, consistent dimensions. New pallets guarantee the tight tolerances (typically within 1/4") that automated equipment needs to function reliably.
Food and Pharmaceutical Applications
Food safety regulations and pharmaceutical GMP standards often require clean, uncontaminated pallets with no history of previous use. New pallets provide a documented, verifiable chain of custody from lumber mill to your loading dock.
Retail and Point-of-Sale Display
When your pallet is part of the customer experience -- in-store displays, trade show exhibits, or showroom setups -- appearance matters. New pallets with sanded finishes and clean edges present a professional image that worn used pallets cannot match.
Heavy Loads Exceeding 3,000 lbs
Extremely heavy loads require maximum structural integrity with zero prior wear. New pallets built with heavy-duty hardwood, reinforced stringers, and tested fastener patterns provide the full rated capacity with a safety margin that used pallets may not offer.
Long-Term Storage (12+ Months)
Products that will sit on pallets for extended periods need pallets with maximum remaining lifespan. New pallets with 10-15 reuse cycles ahead of them are a better investment for long-term storage than used pallets with fewer remaining cycles.
Brand Identity and Customer Perception
When your customers see your pallets as part of your brand -- in deliveries, at job sites, or in their receiving areas -- branded new pallets with your logo and color scheme reinforce professionalism and attention to detail.
Non-Standard or Custom Sizes
If your product requires an unusual pallet size that is not commonly available in the used market, new construction is the only way to get the exact dimensions you need with guaranteed quality. Used pallets are primarily available in standard sizes only.
For Everything Else, Consider Used
If your scenario is not on this list, there is a good chance that used pallets will serve you just as well at a fraction of the cost. Our Grade A used pallets are particularly close to new-pallet performance for most standard applications. We are always happy to help you evaluate both options.
Explore used pallet options