Pallet Size Guide

Step 1: Measure Length

Place your tape measure along the stringer (the longest structural board). Measure from the outside edge of one lead board to the outside edge of the opposite lead board. This is the pallet length. For a standard GMA pallet, this should read 48 inches. The length is always stated first in a pallet size designation (e.g., 48" x 40" means 48" long x 40" wide).

The length runs parallel to the stringers (or the longest dimension).

Step 2: Measure Width

Measure across the deck boards, perpendicular to the stringers. This is the pallet width. For a standard GMA pallet, this should read 40 inches. Width determines how the pallet fits in truck beds, racking systems, and containers. Two standard 48x40 pallets fit side by side in a 53-foot trailer with room for a center aisle.

The width runs perpendicular to the stringers (or the shorter dimension).

Step 3: Measure Height

Measure from the bottom of the bottom deck boards to the top of the top deck boards. Standard pallet height is approximately 6 to 6.5 inches, though it can vary depending on the thickness of the deck boards and stringers or blocks used. Height matters for racking clearance, total stack height in warehouses, and container loading calculations.

Height affects how many layers you can stack in racking or container.

Step 4: Verify Fork Entry

Check the opening height between the top and bottom decks where fork tines enter. Standard fork entry height is approximately 3 to 3.5 inches. Ensure the opening is clear of obstructions like protruding nails, displaced boards, or debris. For 4-way entry pallets, verify fork access from all four sides.

Fork entry must accommodate your specific forklift or pallet jack tines.

Step 5: Count Deck Boards

Count the number of top deck boards and note their approximate width and spacing. This information is important for determining whether the pallet is suitable for your products. Five boards with wider spacing may work for sturdy boxes but not for small items or bags. Seven boards with close spacing provides more uniform support.

More deck boards = better support for small or irregular items.

Step 6: Check Board Thickness

Measure the thickness of the deck boards and stringers. Standard deck boards are typically 0.5" to 0.75" thick. Stringers are usually 1.5" x 3.5" (actual dimensions). Thicker components indicate a heavier-duty pallet with higher load capacity. Board thickness is especially important to verify when matching or replicating an existing pallet design.

Thicker boards = higher load capacity but also heavier weight.

The maximum weight a pallet can safely support while being moved by a forklift or pallet jack. This accounts for the forces experienced during transport, turning, lifting, and setting down. Dynamic loads are subject to acceleration, vibration, and impact forces that reduce the effective capacity compared to static loads. Always factor in safety margins — most guidelines recommend loading to 80% of rated capacity.

The maximum weight a pallet can support when stationary on a flat surface. Static load capacity is typically 2x the dynamic rating because there are no movement forces to consider. This applies when pallets are stacked on the floor or on each other. The load must be evenly distributed across the full deck surface for rated capacity to apply. Concentrated loads or point loads can cause failure even at lower total weights.

The maximum weight a pallet can support when placed on pallet racking, where only the edges are supported. This is typically the lowest rating — about 60-70% of the dynamic load — because the middle of the pallet is unsupported and must bridge the gap between the racking beams. Always verify racking specs for your specific pallet and racking configuration. Overloading racking loads is one of the most dangerous mistakes in warehousing.

Entry Type: 2-Way vs 4-Way

2-way entry pallets can only be accessed from two sides by forklifts or pallet jacks. 4-way entry pallets (notched stringers or block design) can be accessed from any side, offering much more flexibility in warehousing and loading. Block pallets are always 4-way; stringer pallets can be 2-way or notched for partial 4-way. Choose 4-way entry for maximum warehouse efficiency and automated system compatibility.

Deck Board Spacing

The gap between top deck boards affects how well the pallet supports different load types. Closer spacing (1" or less) provides better support for smaller items, drums, and bags. Wider spacing (2-4") is acceptable for uniform, sturdy loads like boxes and crates but may allow small items to fall through. When in doubt, request close-boarded or fully-decked pallets for maximum versatility.

ISPM-15 Treatment

International Standards for Phytosanitary Measures No. 15 (ISPM-15) requires that wood packaging materials used in international trade be heat treated or fumigated to prevent pest transmission. Heat-treated pallets are marked with the IPPC stamp. This is mandatory for exporting goods to most countries. Plastic pallets are exempt from ISPM-15. We provide ISPM-15 heat treatment services and stock pre-treated pallets for export customers.

Moisture Content

Wood moisture content affects weight, structural integrity, and susceptibility to mold and decay. General-use pallets should have moisture content below 19%. Pallets for food, pharmaceutical, or cleanroom applications should be below 12-15%. Kiln-dried pallets have the lowest moisture content and are the most dimensionally stable. High moisture content causes warping, swelling, and promotes mold growth in storage.

Wing Pallet vs Flush Pallet

A flush pallet has deck boards that are flush with the outer edges of the stringers — the deck and stringers end at the same line. A wing pallet has deck boards that extend beyond the stringers, creating overhanging "wings." Wing pallets provide additional surface area for loads without increasing the structural footprint, which can be useful for maximizing truck space or supporting oversized products.

Reversible vs Non-Reversible

A reversible pallet has the same number and configuration of deck boards on both the top and bottom, so either side can be used as the load surface. Non-reversible pallets have more top deck boards than bottom boards, with the top designed to support the load and the bottom designed for fork entry and floor contact. Reversible pallets offer more flexibility and longer life since they can be flipped when one side wears.