Pallet Size Guide
Comprehensive reference for standard pallet dimensions, capacities, industry applications, and international standards
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How to Measure a Pallet Correctly
Accurate pallet measurement is essential for proper racking fit, truck loading optimization, and product stability. Follow these guidelines to measure any pallet correctly.
Measure the Length (Stringer Length)
The length of a pallet is the dimension along the stringers or the longer structural members. Place your tape measure along the stringer from one end to the other. For a standard GMA pallet, this is 48 inches. Always measure from the outside edges of the outermost boards.
Measure the Width (Across Stringers)
The width is measured perpendicular to the stringers, across the top deck boards. For a GMA pallet, this is 40 inches. The width determines how the pallet sits in racking beams and truck beds. Always measure at the widest point.
Measure the Height (Overall)
Measure from the floor to the top surface of the top deck boards. Standard stringer pallets are typically 5 to 6.5 inches tall, while block pallets may be 6 to 7 inches. Height matters for racking clearance, container stacking limits, and total shipment height calculations.
Check the Fork Entry Opening
Measure the internal opening between the top and bottom deck boards where the forklift forks enter. Standard opening is 3 to 3.5 inches. This must accommodate your forklift fork thickness. Insufficient clearance causes pallet damage and safety hazards.
Important Measurement Tips
Standard North American Pallet Sizes
The Grocery Manufacturers Association (GMA) pallet (48" x 40") is the most widely used in North America, but the industry relies on 15+ standard sizes to serve specific product types, industries, and transportation requirements. Below is a comprehensive reference of every common North American pallet size with full specifications including static, dynamic, and racking load capacities.
Understanding Pallet Weight Capacities
Every pallet has three different weight capacity ratings depending on how it is being used. Choosing the wrong rating can lead to product damage, safety hazards, or collapsed racking.
Static Load
Weight a pallet can support when stationary on a flat surface. Highest capacity rating. Used for long-term storage on warehouse floors.
Dynamic Load
Weight a pallet can support while being moved by a forklift or pallet jack. Lower than static due to stress from movement, acceleration, and uneven surfaces.
Racking Load
Weight a pallet can support when placed on warehouse racking beams, supported only at its edges. The lowest capacity rating since the center of the pallet is unsupported.
Capacity Quick Reference Chart (48" x 40" GMA Pallet)
| Pallet Grade | Static Load | Dynamic Load | Racking Load | Best For |
|---|---|---|---|---|
| New (Premium) | 2,800 lbs | 2,500 lbs | 2,200 lbs | Export, pharma, automated systems |
| Grade A (Like-New) | 2,800 lbs | 2,500 lbs | 2,200 lbs | Retail, food, racking storage |
| Grade B (Standard) | 2,500 lbs | 2,200 lbs | 1,800 lbs | General warehousing, domestic shipping |
| Grade C (Economy) | 2,000 lbs | 1,800 lbs | Not recommended | One-way shipping, floor storage only |
| Heavy Duty (Custom) | 5,000+ lbs | 4,000+ lbs | 3,500 lbs | Machinery, automotive, industrial |
Fork Entry Types Explained
Fork entry configuration determines how forklifts and pallet jacks can access the pallet. The right choice depends on your warehouse layout, racking system, and handling equipment.
2-Way Entry
Forks can only enter from two sides (the ends). Stringer pallets without notches are 2-way by default. The stringers block entry from the sides.
Assembly lines, conveyor systems, and operations where pallets always face the same direction.
Partial 4-Way Entry
Forks can fully enter from two sides and partially enter (via notches cut into the stringers) from the other two sides. The most common configuration for stringer pallets in North America.
General warehousing, retail distribution, and most standard supply chain applications.
Full 4-Way Entry
Forks can fully enter from all four sides. Achieved with block pallet construction where blocks replace continuous stringers, creating openings on all sides.
Automated warehouses, high-density racking, international shipping, and operations requiring maximum flexibility.
EUR / EPAL Pallet Sizes
If you ship internationally to Europe, you will likely need European standard pallets. The EPAL (European Pallet Association) manages the quality standards for Euro pallets, which are used in a managed pool system across the continent. We can source or build these to exact specification for your export shipments.
Most common in Europe. The universal standard for European logistics. Weight: ~25 kg. Load capacity: 1,500 kg dynamic, 4,000 kg static. Managed by EPAL (European Pallet Association).
Common in UK and Finland. Widely used for UK retail distribution and Scandinavian logistics. Comparable to GMA pallet dimensions.
Used in beverage industry across Europe. Same dimensions as EUR 2 but with reversed orientation for specific racking and truck loading patterns.
Retail display pallet, exactly half of a EUR 1. Used for in-store merchandising, promotional displays, and small-batch distribution throughout European retail chains.
Quarter-size European display pallet for point-of-sale and convenience retail. Easily moved by hand. Gaining popularity in automated micro-fulfillment centers.
ISO 6780 standard pallet used globally. Same footprint as EUR 1 but with different construction standards. Recognized by international shipping organizations worldwide.
Asian & Australian Pallet Standards
If your supply chain extends to Asia-Pacific markets, you need to understand the regional pallet standards used in Japan, China, South Korea, Australia, and New Zealand. These sizes are optimized for Asian shipping containers and warehouse dimensions.
The most common pallet in Japan, South Korea, and much of East Asia. Square format is compatible with shipping containers and Asian warehouse standards.
The primary pallet used in Australia and New Zealand. Managed by CHEP in the Australian pooling system. Square design maximizes container loading efficiency.
Used in both Australian and North American supply chains. The 42x42 format is common in the telecom and paint industries in the US and general logistics in Australia.
Common throughout mainland China. Designed to optimize loading in standard shipping containers used in Chinese export logistics.
Deck Board Spacing Guide
The spacing between deck boards affects load distribution, product support, and the types of goods you can safely palletize. Here is how to choose the right deck board configuration.
Full Deck (No Gaps)
Small items, bags, irregular shapes, powders, and loose fill materials that could fall through gaps.
Agriculture (grain bags), pharmaceuticals, small parts manufacturing, food processing.
Heaviest option. Adds 10-15 lbs to pallet weight. Provides maximum surface coverage.
Standard Spacing
Boxed goods, cased products, and palletized cartons. The most common configuration for general commerce.
Grocery, retail, general manufacturing, distribution, beverage.
The industry default. Good balance of weight, cost, and product support.
Wide Spacing
Large, rigid items with flat bottoms such as drums, large totes, and heavy machinery components.
Chemical, petroleum, heavy industrial, construction materials.
Lightest and most economical. Only suitable for rigid items with large footprints.
Material Thickness Guide
Understanding lumber dimensions helps you specify the right pallet strength for your application. Here is a breakdown of standard and heavy-duty component sizes.
| Component | Standard | Heavy Duty | Notes |
|---|---|---|---|
| Top Deck Boards | 5/8" (16mm) | 3/4" (19mm) | The boards on the top surface where goods are placed. Thicker boards distribute weight more evenly and resist point loads. |
| Bottom Deck Boards | 5/8" (16mm) | 3/4" (19mm) | Boards on the bottom providing ground contact and racking support. Quality of bottom boards is critical for racking applications. |
| Stringers (2x4) | 1.5" x 3.5" (38x89mm) | 1.5" x 5.5" (38x140mm) | The structural backbone running lengthwise. Stringer dimensions directly determine dynamic and racking load capacity. |
| Stringers (3x4) | 2.5" x 3.5" (64x89mm) | 2.5" x 5.5" (64x140mm) | Thicker stringers used in heavy-duty applications. The extra width increases surface area for notching and nail holding. |
| Blocks | 3.5" x 3.5" x 3.5" (89mm cube) | 4" x 4" x 6" (102x102x152mm) | Used in block pallets instead of stringers. Block size determines fork entry clearance and structural rigidity. |
| Lead Board Width | 5.5" (140mm) | 7.25" (184mm) | The outermost edge boards on the top deck. Wider lead boards provide better edge support and resist damage from strapping and forklift impacts. |
Pallet Anatomy 101
Understanding pallet construction helps you choose the right product for your needs. Here is a detailed breakdown of the two main pallet types.
Stringer Pallets
The most common pallet type in North America. Uses long boards (stringers) as the primary structural support. Typically less expensive than block pallets and available in 2-way or partial 4-way (notched) entry configurations.
Top Deck Boards
The boards on top where goods are placed. Typically 5-7 boards on a standard pallet, spaced 2-3 inches apart. Lead boards (outermost) are usually wider for edge support.
Stringers
The long structural boards (usually 2x4 or 3x4) running lengthwise between decks. The backbone of the pallet that determines its load capacity and structural integrity.
Bottom Deck Boards
The boards on the bottom providing ground contact and racking support. Usually 3 boards. Critical for racking applications where they bear the full load weight on beam edges.
Notches
Cutouts in the stringers allowing partial four-way fork entry. Standard notch dimensions are 1.5" deep x 9" wide. Notches reduce stringer strength by 10-15% but greatly increase handling flexibility.
Lead Boards
The outermost top deck boards, typically 5.5" to 7.25" wide. They provide edge support for products, resist forklift damage, and anchor strapping and stretch wrap.
Companion Boards
The interior deck boards between the lead boards, typically 3.5" to 5.5" wide. Their number and spacing determine the pallet's ability to support different product types.
Block Pallets
Premium pallet construction using blocks of wood instead of continuous stringers. Provides true 4-way fork entry from any direction. Preferred for automated systems, international shipping, and high-performance applications. Common in European and pharmaceutical supply chains.
Top Deck Boards
Same as stringer pallets — where goods are placed. Block pallets often have more deck boards for a smoother surface, since the block construction supports greater weight.
Blocks
6 or 9 blocks of wood replacing stringers. Typical dimensions are 4" x 4" x 6". The 9-block design (corners, midpoints, and center) provides the strongest and most balanced support.
Stringer Boards
Thinner boards connecting blocks, running between the top and bottom decks. These transfer load from deck boards to blocks and provide additional lateral stability.
Four-Way Entry
True four-way entry — forklifts can access from any direction with full fork penetration. This is the primary advantage of block pallets over stringer pallets in automated and high-throughput environments.
Bottom Deck
Block pallets typically have a more complete bottom deck (5+ boards) to distribute loads across racking beams evenly. This makes them superior for racking applications.
Chamfered Edges
Many block pallets feature chamfered (angled) edges on the lead boards and bottom boards to facilitate smooth fork entry and reduce splintering during repeated handling.
Pallet Stackability Ratings
Stackability is critical for warehouse storage density, trailer loading, and shipping container optimization. Here is how different factors affect pallet stacking performance.
Pallet Condition
New and Grade A pallets stack most reliably. Warped, twisted, or damaged pallets create unstable stacks that can topple, causing safety hazards and product damage. Always inspect pallets before stacking more than 2 high.
Load Symmetry
Even weight distribution across the pallet surface is essential for safe stacking. Concentrated or off-center loads shift the center of gravity and make upper pallets unstable. Use stretch wrap and edge protectors for asymmetric loads.
Product Rigidity
Rigid products like boxes and crates form stable columns for stacking. Flexible products like bags, pouches, and irregularly shaped items shift under vertical pressure, causing stack instability. Use pallet collars or interlocking patterns for soft goods.
Pallet Dimensions
Only stack pallets of identical dimensions. Mixing sizes creates overhangs that concentrate stress on the edges of lower pallets. Even 1-2 inch mismatches can cause board failures and stack collapses under heavy loads.
Construction Type
Block pallets generally stack better than stringer pallets because their 9-block design provides more uniform bottom support and better nesting with the pallet below. Block pallets also resist racking from stacking stress better.
Environmental Conditions
Wet or humid conditions soften wood fibers and reduce pallet strength. Outdoor-stored pallets absorb moisture, increasing weight by 15-25% and reducing load capacity by 10-20%. Always store pallets in dry conditions for maximum stacking performance.
Best Pallet Size by Industry
Not sure which size to order? Here are our expert recommendations based on years of serving each industry sector.
Grocery & Retail
The universal standard. Fits all retail racking and truck configurations. Ensure food-safe condition for perishables.
Beverage
Optimized for case pack layouts. The 48x36 fits most 12-pack configurations perfectly.
Automotive
Requires tight tolerances for automated systems. Block construction preferred for 4-way access on assembly lines.
Chemical / Pharmaceutical
ISPM-15 heat treatment required for exports. Chemical-free processing. Full documentation for regulatory compliance.
Agriculture
Reinforced construction for grain bags and produce. ISPM-15 for export crops. Moisture-resistant treatment recommended.
E-Commerce / Fulfillment
Standard GMA for warehouse racking. Smaller sizes for micro-fulfillment and last-mile distribution centers.
Construction / Building
Oversized for cement bags, lumber, and roofing materials. Maximum load capacity is critical.
Aerospace / Defense
Precision-engineered with foam inserts, tie-down points, and ESD protection. Full traceability documentation required.
Cold Chain / Frozen
Must withstand freeze-thaw cycles. Plastic pallets increasingly preferred for hygiene. Wood pallets must be kiln-dried.
Not Sure Which Size You Need?
Our team can help you select the optimal pallet size for your products, storage, and shipping requirements. We consider product dimensions, weight distribution, stacking patterns, racking compatibility, automation tolerances, and transportation mode to recommend the perfect fit. We have been helping Wichita businesses choose the right pallets for years — let us put that experience to work for you.
Email us at info@palletswichita.com or call for immediate assistance. We typically respond to size inquiries within 2 hours during business hours.