Wood Pallets

Stringer Pallets

The most common pallet type in North America, stringer pallets use two or three parallel boards (stringers) running between the top and bottom deck boards to provide structural support. Stringers are typically made from 2x4 or 3x4 lumber. The standard stringer pallet offers 2-way forklift entry from the ends, though many are produced with notched stringers that allow partial 4-way entry for forklift tines. Stringer pallets are favored for their simplicity, ease of repair, and cost-effectiveness. They are the default choice for the grocery, retail, and general merchandise industries. When a stringer pallet is damaged, individual boards or stringers can be replaced quickly and cheaply, making them highly economical over multiple use cycles. The GMA (Grocery Manufacturers Association) standard 48x40 pallet is the most iconic example of a stringer pallet, and it accounts for roughly 30% of all new pallets produced in the United States each year.

Block Pallets

Block pallets represent a more advanced design that uses cylindrical or rectangular blocks of solid wood (typically 4 to 12 blocks per pallet) positioned between the top and bottom deck boards, connected by both parallel and perpendicular boards. This construction provides true 4-way entry, meaning forklifts and pallet jacks can access the pallet from all four sides without restriction. Block pallets are structurally stronger than stringer pallets and distribute weight more evenly, making them ideal for heavier loads and automated warehouse systems. They are the standard in European and international logistics (the EUR pallet is a block pallet), and are increasingly popular in the United States for industries that require high throughput and automated handling. While they cost more to manufacture and are slightly more complex to repair, their superior versatility and durability often justify the premium, especially in closed-loop supply chains where pallets are reused many times.

Hardwood Pallets

Hardwood pallets are constructed from dense deciduous species such as red oak, white oak, hard maple, hickory, beech, and birch. These woods have a Janka hardness rating typically above 1,000 lbf, which translates to exceptional resistance to impact, compression, and wear. Hardwood pallets can support significantly heavier loads than their softwood counterparts and resist damage from forklift tines, heavy machinery, and rough handling. They are the preferred choice for automotive parts, metal products, industrial equipment, and any application where the pallet will endure punishing conditions over many use cycles. A well-maintained hardwood pallet can last 10 to 20 years in a closed-loop system. The downside is weight -- hardwood pallets are substantially heavier, which increases freight costs -- and they cost more upfront. However, their longevity and repairability make them the most cost-effective choice for many heavy-duty applications when measured on a per-trip basis.

Softwood Pallets

Softwood pallets are made from coniferous species such as Southern Yellow Pine (SYP), Spruce-Pine-Fir (SPF), Douglas Fir, and various other pine and spruce species. These woods are lighter, more readily available, and less expensive than hardwoods, making softwood pallets the high-volume workhorse of the pallet industry. Southern Yellow Pine is particularly popular in the southeastern United States due to its excellent strength-to-weight ratio and abundance. Softwood pallets are ideal for one-way shipping, export applications (they accept heat treatment easily for ISPM-15 compliance), and any scenario where pallet weight affects transportation costs. While they are less durable than hardwood pallets under extreme conditions, modern softwood pallet designs using optimized board thicknesses and fastener patterns can achieve impressive load capacities. Most softwood pallets can be reused 3 to 7 times before requiring repair, and the wood is easily recycled into mulch, animal bedding, or biomass fuel at end of life.

Combo / Mixed-Wood Pallets

Combo pallets use a strategic combination of hardwood and softwood components to optimize both cost and performance. A typical configuration uses hardwood stringers or blocks for structural strength and softwood deck boards for lighter weight and lower cost. This hybrid approach provides better load-bearing capacity than an all-softwood pallet at a lower price point than an all-hardwood pallet. Combo pallets are an excellent middle-ground solution for businesses that need more durability than standard softwood but do not want to pay the full premium for hardwood. They are particularly popular in the food and beverage, pharmaceutical, and consumer goods industries. Cleveland Pallet Co. stocks a large inventory of combo pallets in all standard sizes, and we can build custom combo configurations to match your exact specifications for load weight, stacking requirements, and budget.

Reversible Pallets

Reversible pallets are constructed with identical top and bottom deck configurations, meaning either side can serve as the load-bearing surface. This design essentially doubles the usable life of the pallet, since when one side becomes worn or damaged, the pallet can simply be flipped over and used from the other side. Reversible pallets are particularly valuable in industries that subject pallets to heavy wear, such as concrete products, masonry, and steel distribution. They are also popular in export shipping where the pallet may not return. The symmetrical design provides excellent stability for stacking and reduces the risk of errors in loading. Reversible pallets can be built in either stringer or block configurations, and in any combination of hardwood or softwood species. While they use more lumber than a standard single-face pallet, the extended lifespan and dual-use capability often deliver a lower total cost of ownership.

Wing Pallets (Overhang Pallets)

Wing pallets, also called overhang pallets or flush pallets with wings, feature top deck boards that extend beyond the edges of the stringers or blocks. This overhang, or "wing," provides additional surface area for supporting loads that are wider than the pallet base. Wing pallets are essential in the beverage industry, where cases of bottles or cans are stacked in configurations that require maximum deck coverage. They are also widely used in the paper, printing, and packaging industries for supporting rolls, sheets, and bundled goods. The wings can extend on two sides (single-wing) or all four sides (double-wing), with overhang distances typically ranging from 1 to 3 inches per side. Wing pallets must be designed carefully, as the overhanging portions are unsupported and can break under excessive point loads. Our team can advise on the optimal wing dimensions for your specific product and stacking pattern.

Heat-Treated (HT) Export Pallets

Heat-treated pallets have been processed in accordance with ISPM-15 (International Standards for Phytosanitary Measures No. 15), which requires the wood core temperature to reach at least 56 degrees Celsius (132.8 degrees Fahrenheit) for a minimum of 30 continuous minutes. This treatment eliminates insects, larvae, and pathogens that could be transported across international borders in raw wood packaging materials. Heat-treated pallets are stamped with the internationally recognized IPPC (International Plant Protection Convention) mark, which includes the country code, producer number, and the HT (Heat Treatment) designation. Without this stamp, wood pallets will be refused at customs in most countries worldwide. Cleveland Pallet Co. operates USDA-approved heat treatment kilns on-site, and we can process pallets in any quantity with fast turnaround times. We maintain strict chain-of-custody documentation to ensure your shipments pass customs inspection without delay.

Top Deck Boards

The top deck boards are the horizontal planks that form the load-bearing surface of the pallet. Products are placed directly on these boards, so their spacing, width, and thickness are critical for load support. Standard top decks use 5 to 7 boards on a 48x40 pallet. Wider boards and tighter spacing provide more support for small-footprint items, while wider gaps reduce weight and lumber cost. Top deck boards typically range from 5/16" to 3/4" in thickness and 3.5" to 5.5" in width. The lead boards (the two outermost boards) are often wider than the interior boards to provide better edge support and prevent product overhang.

Bottom Deck Boards

Bottom deck boards run perpendicular to (or in the same direction as) the stringers on the underside of the pallet. They provide stability, prevent the stringers from rocking, and create a flat surface that interfaces with racking systems, conveyor belts, and warehouse floors. Most stringer pallets have 3 bottom deck boards (two outer and one center), while block pallets typically feature 3 to 5 bottom boards. Bottom deck board dimensions are usually similar to top deck boards, though they can be thinner on lighter-duty pallets. Proper bottom deck board placement is essential for compatibility with automated material handling equipment.

Stringers

Stringers are the long, thick boards (typically 2x4 or 3x4 dimensional lumber) that run the length of a stringer pallet between the top and bottom decks. They are the primary load-bearing structural members. A standard stringer pallet uses three stringers -- one on each side and one in the center. The center stringer prevents the top deck boards from deflecting under load. Stringers can be notched (cut-outs on the sides) to allow partial 4-way entry for forklift tines. The notch is typically 9 inches wide, 1.5 inches deep, and positioned at specific intervals along the stringer length.

Blocks

Blocks are cuboid or cylindrical sections of solid wood used in block pallets instead of (or in addition to) stringers. A standard block pallet uses 9 blocks arranged in a 3x3 grid pattern -- four corner blocks, four edge blocks, and one center block. Blocks are typically 3.5" x 3.5" x 3.5" or 4" x 4" x 4" and are made from hardwood, softwood, or engineered composite materials. The block design creates open channels on all four sides of the pallet, enabling true 4-way fork entry. Blocks can be made from solid lumber cut-offs, reducing waste in the manufacturing process.

Notches

Notches are rectangular cut-outs made in the stringers of a stringer pallet. Their purpose is to create openings that allow forklift tines or pallet jack forks to enter from the sides (the non-entry faces) of the pallet. Without notches, a stringer pallet can only be accessed from the two ends. With notches, it becomes a partial 4-way entry pallet. Standard notch dimensions are 9" wide x 1.5" deep, spaced symmetrically along the stringer. While notches greatly increase versatility, they also reduce the structural strength of the stringer at the notch point, which is why notched stringer pallets have a lower load capacity than non-notched equivalents.

Chamfers

A chamfer is a beveled or angled cut made on the leading edge of the bottom deck boards. Chamfers serve as a guide for forklift tines and pallet jack forks, making it easier and faster to slide the forks under the pallet. Without chamfers, fork tips can catch on the square edge of the bottom board, causing damage to the pallet or product and slowing down operations. Lead-edge chamfers are standard on high-quality pallets and are especially important in high-speed warehousing and distribution environments. The typical chamfer angle is 30 to 45 degrees, and the chamfer length is 1 to 2 inches.

Fasteners (Nails)

Pallet fasteners -- almost exclusively nails -- are the connectors that hold the entire pallet together. Standard pallet nails are helically threaded (screw-shank) or ring-shank, which resist pullout forces far better than smooth-shank nails. The most common pallet nail size is 2.25" to 2.5" in length and 0.113" to 0.131" in diameter. Each pallet uses anywhere from 60 to 120 nails depending on design. The nailing pattern -- the specific arrangement and quantity of nails at each board-to-stringer or board-to-block connection -- is carefully engineered to balance holding strength, cost, and ease of repair. Pneumatic nail guns are used in production for speed and consistency.

Lead Boards

Lead boards are the outermost top and bottom deck boards on each end of the pallet. They are subjected to more stress than interior boards because they are the first point of contact for forklift tines and must resist the prying and lifting forces at the pallet edge. For this reason, lead boards are often wider (5.5" or 6" versus 3.5" for interior boards) and may be made from thicker or higher-grade lumber. On some heavy-duty pallets, lead boards are reinforced with additional nails or even metal strapping. The condition of the lead boards is one of the most important factors in pallet grading -- severely damaged lead boards typically disqualify a pallet from premium or grade-A status.

Deckboard Spacing

The gaps between top deck boards are not arbitrary -- they are an engineered specification that affects load support, air circulation, weight, and lumber consumption. Standard spacing on a GMA 48x40 pallet ranges from 2.5" to 3.5" between interior boards. Tighter spacing provides better support for small items and bags but adds weight and cost. Wider spacing reduces material usage and weight but may allow small items to fall through. For specialized applications such as pharmaceuticals or small electronics, we can build pallets with zero-gap (tight-deck) top surfaces. Deckboard spacing also affects airflow during heat treatment, fumigation, and cold storage.

Southern Yellow Pine is the single most widely used pallet wood in the United States. Grown abundantly across the southeastern states, SYP offers an outstanding strength-to-weight ratio that makes it ideal for general-purpose pallets. It has a Janka hardness of approximately 870 lbf, which is high for a softwood, giving it reasonable resistance to denting and surface damage. SYP accepts nails well without splitting, is easy to cut and process, and kiln-dries or heat-treats efficiently. Its widespread availability keeps costs low and supply consistent year-round. The primary drawback is that SYP is more susceptible to fungal decay and insect damage than hardwoods, which makes proper storage and treatment important for longevity.

Red Oak is one of the premier hardwood species used in heavy-duty pallet construction. With a Janka hardness of approximately 1,290 lbf, red oak provides exceptional resistance to impact, compression, and wear. Pallets made from red oak are the go-to choice for automotive parts, metal stampings, machinery, and any product where the pallet will be subjected to extreme loads or rough handling over many use cycles. Red oak is widely available in the eastern United States and is often sourced as a byproduct of the furniture and flooring lumber industries. Its open grain structure means it can absorb moisture more readily than some other hardwoods, so it should be stored in dry conditions when possible.

Hard Maple (also called Sugar Maple or Rock Maple) is among the hardest and strongest domestic wood species, with a Janka hardness of 1,450 lbf. Pallets made from hard maple are virtually indestructible under normal handling conditions and can withstand the heaviest loads in the most demanding environments. Maple is denser than oak, which means even higher resistance to denting, splitting, and surface damage from forklift tines. Its tight, closed grain structure resists moisture absorption better than oak, making it suitable for food-contact and pharmaceutical applications where contamination risk must be minimized. Hard maple pallets are premium products and are priced accordingly, but for applications that demand maximum strength and cleanliness, they are unmatched.

SPF is a grading designation that encompasses several closely related softwood species -- primarily White Spruce, Engelmann Spruce, Lodgepole Pine, and various true firs -- that share similar structural properties. SPF is the dominant pallet lumber in the northern United States and Canada. It is lighter than Southern Yellow Pine, which can reduce freight costs, and it machines cleanly with minimal splintering. SPF has a Janka hardness of about 490-590 lbf depending on species mix, making it softer than SYP but still adequate for standard pallet applications. It is an excellent choice for lightweight pallets, export packaging, and any application where minimizing pallet weight is a priority. SPF pallets are widely used in the paper, printing, and food packaging industries.

White Oak is distinguished from Red Oak by its closed, tylosis-rich grain structure that makes it naturally resistant to moisture, rot, and decay. With a Janka hardness of approximately 1,360 lbf, white oak is slightly harder than red oak and significantly more durable in wet or outdoor environments. These properties make white oak pallets the preferred choice for outdoor storage, cold storage facilities, and any application where pallets may be exposed to rain, snow, humidity, or standing water. White oak also has natural resistance to insect attack, further extending its service life. While less commonly available than red oak (much of the white oak harvest goes to the cooperage industry for bourbon barrels), white oak pallets command a premium in applications where moisture resistance is critical.

Douglas Fir is a heavyweight softwood with a Janka hardness of approximately 660 lbf, placing it between typical softwoods and lower-range hardwoods in terms of strength. Grown primarily in the Pacific Northwest, Douglas Fir produces strong, straight-grained lumber that is highly valued for structural applications. Pallets made from Douglas Fir offer a compelling combination of strength and moderate weight, making them popular in the construction, manufacturing, and agricultural industries on the West Coast. Douglas Fir has excellent nail-holding capacity and resists splitting better than many softwoods. It is also one of the most aesthetically attractive pallet woods, with a distinctive reddish-brown color, though appearance is rarely a factor in pallet selection. Availability can be limited and more expensive in the Midwest and East Coast due to transportation distances.

Poplar (also known as Tulipwood or Yellow Poplar) occupies a unique niche in pallet manufacturing. Technically classified as a hardwood because it comes from a deciduous tree, poplar has a Janka hardness of only 540 lbf, which is softer than most true softwoods used in pallets. However, poplar is extremely lightweight, inexpensive, widely available, and easy to work with. It is commonly used for deck boards on lightweight pallets and as a filler wood in combo pallets where the stringers provide the structural strength. Poplar pallets are popular in the export market because their low weight minimizes freight costs and they accept heat treatment well. The wood has a pale, clean appearance that some food and pharmaceutical companies prefer.

Hickory is the hardest and strongest commercially available North American wood species used in pallets, with a Janka hardness of approximately 1,820 lbf. Hickory pallets are reserved for the most extreme applications -- ultra-heavy loads, aggressive handling environments, and situations where pallet failure is absolutely unacceptable. The wood is incredibly dense, shock-resistant, and flexible, meaning it absorbs impacts without cracking or breaking. Hickory is commonly used in pallets for the steel, foundry, and heavy manufacturing industries. The downside is that hickory is difficult to work with, very heavy, and not consistently available in pallet-grade lumber. It also costs significantly more than any other common pallet wood. For most applications, oak or maple provide sufficient strength at lower cost, but when only the strongest wood will do, hickory is the answer.

Hand-Nailed Construction

The traditional method of pallet assembly, where workers manually position lumber components on a jig or fixture and drive nails using pneumatic nail guns. Hand-nailing allows maximum flexibility for custom sizes and non-standard configurations. It is the primary method used in pallet repair operations and small-batch manufacturing. Experienced hand-nailers can produce 80-120 pallets per day. While slower than automated methods, hand-nailing provides the most control over fastener placement and is essential for repair work where damaged boards must be replaced individually. Cleveland Pallet Co. uses hand-nailing for all custom orders and repair work.

Automated Nailing Machines

Modern pallet manufacturing facilities use automated nailing machines that can produce 300-500+ pallets per hour. These machines use computer-controlled pneumatic nail guns that drive all fasteners simultaneously in a pre-programmed pattern. Workers load lumber onto a conveyor system, and the machine automatically positions and nails the components with precision. Automated production ensures consistent quality, optimal nailing patterns, and high throughput. The machines can be reconfigured for different pallet sizes and designs, though changeover time limits their flexibility for very small production runs.

Band-Saw / Dismantler Processing

Recycled pallet production starts with dismantling used pallets to recover usable lumber. Band-saw dismantlers cut through the nails connecting deck boards to stringers, preserving the wood. Recovered boards are inspected, sorted by size and quality, and fed into the manufacturing process as raw materials for new or rebuilt pallets. This method maximizes material recovery and is a cornerstone of the recycled pallet industry. Advanced dismantlers use carbide-tipped blades that can process 200+ pallets per hour while maintaining tight tolerances on recovered board dimensions.

Heat Treatment Processing

For ISPM-15 compliance, pallets must be heat-treated in a controlled kiln to reach a core temperature of 56 degrees C for 30 minutes. Modern heat treatment chambers are gas-fired or steam-heated and equipped with multiple temperature probes that continuously monitor the wood core temperature throughout the cycle. The entire process, from loading to unloading, typically takes 4-8 hours depending on wood thickness and initial moisture content. Pallets are stamped with the IPPC mark immediately after treatment while strict chain-of-custody protocols prevent contamination.

CNC and Precision Cutting

Computer Numerical Control (CNC) machines are used to produce precisely dimensioned pallet components, including notches in stringers, chamfers on lead boards, and custom-shaped deck boards. CNC processing ensures exact repeatability across thousands of identical parts, which is critical for pallets that must interface with automated handling systems, robots, and precision racking. CNC-cut stringer notches have smoother, more consistent surfaces that reduce forklift tine wear and improve fork entry speed. While CNC processing adds cost, it is essential for high-performance pallets used in pharmaceutical, electronics, and automotive applications.

Repair and Remanufacturing

Pallet repair is a highly skilled process that involves inspecting each used pallet, identifying damaged components, removing the damaged boards or stringers, and replacing them with compatible lumber. Experienced repair technicians assess whether a pallet is economically repairable (typically, if more than 40% of components need replacement, it is more cost-effective to dismantle and recycle). Repairs use the same fasteners and nailing patterns as new construction to maintain structural integrity. Companion boards (additional boards nailed alongside a cracked stringer) are a common technique for restoring stringer strength without full replacement. Our repair facility processes thousands of pallets per week.

Static Load Capacity

Static load capacity is the maximum weight a pallet can support when resting on a flat, solid surface (such as a warehouse floor or ground-level storage pad) with no movement. This is the highest of the three load ratings because the weight is evenly distributed across the entire bottom surface of the pallet. A standard-grade 48x40 GMA stringer pallet typically has a static load rating of 4,000-6,000 lbs, depending on wood species, board thickness, and condition. Heavy-duty hardwood pallets can support static loads of 8,000-10,000+ lbs. Static load ratings assume the load is uniformly distributed across the deck surface. Point loads or concentrated weights will reduce the effective capacity significantly.

Dynamic Load Capacity

Dynamic load capacity is the maximum weight a pallet can safely support while being lifted and moved by a forklift or pallet jack. This rating is lower than static capacity because the pallet is supported only at the fork entry points (typically two stringers or block rows), creating bending stresses across the deck. A standard 48x40 GMA pallet has a dynamic load rating of approximately 2,500-2,800 lbs. Factors that reduce dynamic capacity include fork speed, uneven loads, damaged components, worn forklift tines, and rough floor surfaces. Always lift pallets slowly and smoothly to minimize dynamic stresses. Never drag, push, or slide a loaded pallet across a floor, as this creates forces the pallet was not designed to withstand.

Racking Load Capacity

Racking load capacity is the maximum weight a pallet can support when placed on pallet racking with support only at the two racking beams (typically spanning the 40-inch dimension). This is the lowest and most conservative load rating because the pallet is essentially a beam spanning between two supports, with the entire load creating bending stress. A standard 48x40 GMA pallet has a racking load rating of approximately 1,500-2,500 lbs. Racking capacity is heavily influenced by beam span, wood species, board thickness, and the number and spacing of stringers or blocks. Always verify that your pallet grade is rated for racking use, and never exceed the rated capacity. Racking failures are among the most dangerous warehouse incidents.

Carbon Sequestration

Wood is a natural carbon sink. Trees absorb CO2 from the atmosphere as they grow, and that carbon remains locked in the wood fiber throughout the pallet's useful life. A standard 48x40 wood pallet stores approximately 3.5 pounds of carbon dioxide equivalent. With roughly 2 billion wood pallets in circulation in the U.S. alone, the pallet pool represents a massive carbon reservoir of approximately 7 billion pounds of sequestered CO2. When pallets are eventually recycled into mulch or compost, much of that carbon is returned to the soil rather than the atmosphere, completing a natural carbon cycle.

Sustainable Forestry

The vast majority of wood used in pallet manufacturing comes from sustainably managed forests. The U.S. grows more timber than it harvests each year -- net forest growth has exceeded harvest by more than 40% since the 1950s. Pallet manufacturers primarily use low-grade lumber, sawmill byproducts, and wood that is not suitable for higher-value applications like furniture or construction. This means pallet production utilizes wood that might otherwise go to waste, maximizing the value extracted from every harvested tree. Many pallet producers, including Cleveland Pallet Co., prioritize sourcing from forests certified by the Sustainable Forestry Initiative (SFI) or Forest Stewardship Council (FSC).

Repairability and Reuse

Unlike plastic or metal pallets that must be discarded or returned to the manufacturer when damaged, wood pallets can be repaired locally using basic tools and readily available lumber. A single board replacement can extend a pallet's life by years, and the average wood pallet goes through 7-15 use cycles before reaching end of life. This repairability dramatically reduces the demand for new materials and the energy required for manufacturing replacements. The decentralized nature of pallet repair (there are over 3,000 pallet recycling facilities in the U.S.) also minimizes transportation distances, further reducing the carbon footprint.

End-of-Life Recycling

When a wood pallet finally reaches the end of its useful life as a shipping platform, it does not become waste. End-of-life pallets are broken down and the wood is recycled into a range of valuable products: landscape mulch, animal bedding, compost, particleboard, biomass fuel for electricity generation, and erosion control materials. Even the metal nails are magnetically separated and recycled as scrap steel. The wood pallet industry recovers and recycles approximately 95% of all end-of-life pallets in the United States, making it one of the most successful recycling programs in any industry.

Low Manufacturing Energy

Manufacturing a wood pallet requires significantly less energy than producing a plastic or metal pallet. The embodied energy of a new wood pallet is approximately 750-1,000 BTUs, compared to 15,000-25,000 BTUs for a comparable plastic pallet and 20,000-30,000 BTUs for an aluminum pallet. Recycled wood pallets have even lower embodied energy since the raw material has already been processed. The pallet manufacturing process itself is primarily mechanical (sawing, nailing) rather than thermal or chemical, which means fewer emissions and less pollution.

Biodegradability

In the unlikely event that a wood pallet does end up in a landfill or natural environment, it will biodegrade naturally over time. Wood is composed of cellulose, hemicellulose, and lignin -- all organic compounds that are broken down by fungi, bacteria, and other decomposers. A discarded wood pallet will decompose within 2-5 years under typical conditions, compared to hundreds of years for plastic pallets. As the wood decomposes, it returns nutrients to the soil and does not release toxic chemicals or microplastics into the environment. This biodegradability provides a final environmental safety net that synthetic materials cannot match.

Store Pallets Indoors When Possible

Indoor storage protects pallets from rain, snow, UV radiation, and temperature extremes that accelerate wood degradation. If indoor storage is not feasible, cover pallet stacks with tarps or plastic sheeting and ensure the storage surface is well-drained. Pallets stored outdoors in wet conditions can absorb moisture rapidly, increasing their weight by 20-30% and reducing their structural strength by 15-25%. Moisture also promotes fungal growth, mold, and insect infestation, all of which shorten pallet life and can contaminate the products placed on them.

Stack Pallets Properly

Empty pallets should be stacked neatly in uniform piles with all pallets facing the same direction. Maximum recommended stack height is 15-20 pallets for stringer pallets and 20-25 for block pallets. Stacks should be placed on level, firm surfaces to prevent leaning and collapse. Never stack pallets of different sizes together, as this creates unstable stacks. Ensure adequate spacing between stacks for forklift access and air circulation. Crooked or leaning stacks are a major safety hazard and one of the most common causes of warehouse injuries.

Inspect Before Use

Every pallet should be visually inspected before loading. Look for cracked or broken stringers, split or missing deck boards, protruding nails, signs of insect damage (small round holes, sawdust), mold or fungal growth, and chemical staining or odors. A damaged pallet that fails under load can cause product damage, workplace injuries, and supply chain delays. If a pallet shows any signs of structural compromise, set it aside for repair or recycling rather than putting it into service. The few seconds spent on inspection can prevent thousands of dollars in damage.

Handle Pallets Gently

The most common cause of pallet damage is rough handling by forklifts. Forklift tines that strike stringers, deck boards, or blocks cause cracks, splits, and breakage that reduce load capacity. Train forklift operators to approach pallets straight-on, insert forks fully before lifting, avoid dragging pallets across floors, and set loaded pallets down gently. Never push or bulldoze pallets across the ground. Smooth, careful handling can double the number of use cycles a pallet achieves before requiring repair.

Rotate Pallet Stock

Practice first-in, first-out (FIFO) pallet management to ensure older pallets are used before newer ones. Pallets left sitting unused for extended periods can develop moisture damage, insect problems, or structural deterioration. Regular rotation ensures that all pallets in your inventory are used consistently and that any developing issues are identified quickly. FIFO rotation also helps maintain ISPM-15 compliance, as heat treatment stamps can become unreadable over time due to weathering.

Keep Pallets Clean

Remove debris, shrink wrap remnants, strapping, and any foreign materials from pallets before storing or reusing them. Accumulated debris can trap moisture, hide damage, create slip hazards, and contaminate products. In food and pharmaceutical environments, cleanliness standards for pallets are especially strict. Pallets visibly contaminated with chemicals, food residue, or biological materials should be segregated and either cleaned thoroughly or recycled. Never use pallets that have been exposed to hazardous chemicals for food or consumer product applications.

Maintain Adequate Air Circulation

Wood pallets need air circulation to prevent moisture buildup and fungal growth. When storing pallets indoors, ensure the storage area has adequate ventilation. Do not place pallets directly against walls or in enclosed spaces without airflow. When stacking loaded pallets in cold storage, allow clearance between the pallet load and the walls, ceiling, and adjacent stacks for proper cold air circulation. Poor airflow can cause condensation on cold wood surfaces, leading to mold, product contamination, and structural weakening over time.

Use Appropriate Pallet Grades

Matching pallet grade to the application prevents both waste and failure. Using premium-grade pallets for one-way shipments wastes money, while using economy-grade pallets for heavy racking applications creates safety risks. Work with your pallet supplier to identify the minimum grade required for each application. At Cleveland Pallet Co., we grade all pallets to NWPCA standards and can recommend the most cost-effective grade for your specific load weights, handling conditions, and reuse requirements. Overspecifying pallet grade is one of the most common sources of unnecessary supply chain expense.

Document and Track Pallet Usage

For businesses that manage large pallet inventories, tracking pallet usage, damage rates, and lifecycle costs provides valuable data for optimizing your pallet program. Record the number of pallets received, used, repaired, and recycled each month. Track which suppliers, products, or routes generate the most pallet damage. This information helps you identify operational issues, negotiate better pricing, plan inventory levels, and maximize the return on your pallet investment. Even simple tracking using spreadsheets can reveal significant cost-saving opportunities.

Grade A (Premium)

Grade A pallets are in excellent condition with no broken boards, no cracked stringers, minimal cosmetic wear, and all fasteners properly seated. They may have slight surface scuffing from previous use but are structurally sound and aesthetically presentable. Grade A pallets are suitable for premium products, retail display, export shipments, and any application where appearance and structural integrity are paramount. They meet the highest load capacity specifications for their design and can be used in automated handling systems without risk of jamming or failure.

Grade B (Standard)

Grade B pallets are structurally sound and fully functional but show moderate signs of previous use. They may have minor cosmetic damage such as surface staining, scuff marks, or slight discoloration. Some boards may have been replaced during repair, resulting in mismatched wood colors. All structural components are intact and meet load capacity requirements. Grade B pallets are the most popular grade for general warehousing, distribution, and shipping applications where function matters more than appearance. They offer the best balance of quality and value for most businesses.

Grade C (Economy)

Grade C pallets are functional pallets with visible wear and cosmetic imperfections. They may have repaired boards, companion-boarded stringers, noticeable staining, or weathering. While they meet minimum structural requirements for standard loads, they are not recommended for heavy racking or automated systems. Grade C pallets are ideal for one-way shipments, ground-level storage, and applications where cost is the primary consideration. They represent the most affordable option for businesses that need functional pallets without premium pricing.

Combo / Mixed Grade

Combo grade pallets contain a mix of Grade B and Grade C pallets in a single load. This option provides the lowest per-pallet cost and is popular with businesses that use large quantities of pallets for one-way shipping or non-critical storage. The exact grade mix varies by availability, but typically skews 60-70% Grade B and 30-40% Grade C. Combo loads are inspected to ensure all pallets are structurally functional regardless of cosmetic condition. This is an excellent option for businesses that prioritize cost savings and can accept some variation in pallet appearance.