Pallet Size Guide
The complete reference for pallet dimensions. Find the right size for your application, industry, and region.
North American Standard Sizes
The Grocery Manufacturers Association (GMA) 48×40 pallet is the most widely used in North America, accounting for about 30% of all pallets produced.
| Size (in) | Size (mm) | Name | Common Use | Market Share |
|---|---|---|---|---|
| 48" × 40" | 1219 × 1016 | GMA | Grocery, retail, general | 30% |
| 42" × 42" | 1067 × 1067 | Telecom | Telecom, paint, drums | 6% |
| 48" × 48" | 1219 × 1219 | Square | Drums, containers, auto | 6% |
| 48" × 42" | 1219 × 1067 | Chemical | Chemical, military | 5% |
| 40" × 40" | 1016 × 1016 | Dairy | Dairy, square loads | 3% |
| 48" × 36" | 1219 × 914 | Beverage | Beverage, canning | 2% |
| 36" × 36" | 914 × 914 | Small Square | Beverage, small loads | 1% |
| 48" × 20" | 1219 × 508 | Half Pallet | Retail display, POP | 1% |
International Standard Sizes
International pallets follow ISO 6780 standards. If you're shipping globally, choosing the right regional pallet size can prevent costly repalletizing at the destination.
| Size (mm) | Size (in) | Designation | Primary Region |
|---|---|---|---|
| 1200 × 800mm | 47.2" × 31.5" | EUR 1 | Europe |
| 1200 × 1000mm | 47.2" × 39.4" | EUR 2 | Europe / Asia |
| 1000 × 1200mm | 39.4" × 47.2" | EUR 3 | Europe / Asia |
| 1140 × 1140mm | 44.9" × 44.9" | Australian | Australia |
| 1100 × 1100mm | 43.3" × 43.3" | Asian | Asia / Pacific |
| 1067 × 1067mm | 42" × 42" | Telecom | N. America / Europe |
Choosing the Right Size
Match Your Product
Choose a pallet that matches your box dimensions to minimize overhang and maximize load stability.
Check Your Racking
Your warehouse racking is designed for specific pallet sizes. Mismatched pallets can cause collapses.
Consider Destination
For international shipments, use the destination region's standard size to avoid costly repalletizing.
Industry-Specific Size Recommendations
Different industries have established preferred pallet sizes based on product dimensions, handling requirements, and supply chain standards. Here is a quick reference to help you choose the right size for your sector.
| Industry | Primary Size | Secondary Size | Notes |
|---|---|---|---|
| Food & Beverage | 48×40 GMA | 48×48 | GMA standard required by most grocers; 48×48 for drums and barrels |
| Retail / E-Commerce | 48×40 | 40×48 (reverse) | Standard for distribution; reverse orientation used for in-store display |
| Automotive | 48×45 | 60×48 | Larger parts need oversized pallets; custom sizes are common |
| Pharmaceutical | 48×40 | 40×32 (half) | Standard for warehouse; half pallets for pharmacy floor displays |
| Chemical | 48×40 (drums) | 48×48 (IBC totes) | Plastic pallets recommended for spill containment and washdown |
| Agriculture | 48×40 | 48×48 / Oversized | Oversized pallets common for produce bins and field crates |
Weight Capacity by Size & Construction
A pallet's load capacity depends on its size, construction type, wood species, and condition. The values below represent typical capacities for new hardwood pallets in good condition.
| Size | Construction | Dynamic Load | Static Load |
|---|---|---|---|
| 48×40 | Stringer | 2,500 lb | 5,000 lb |
| 48×40 | Block | 4,000 lb | 8,000 lb |
| 48×48 | Stringer | 2,200 lb | 4,500 lb |
| 48×48 | Block | 3,800 lb | 7,500 lb |
| 42×42 | Stringer | 2,000 lb | 4,000 lb |
| 36×36 | Stringer | 1,800 lb | 3,500 lb |
| Custom Heavy-Duty | Reinforced Block | Up to 6,600 lb | Up to 14,000 lb |
Dynamic vs. Static Load
Dynamic load is the maximum weight a pallet can carry while being moved by a forklift or pallet jack. Static load is the maximum weight when the pallet is stationary on a flat surface or racking.
Wood Species Matters
Hardwood pallets (oak, maple) can carry 20-30% more weight than softwood pallets (pine, spruce). All ratings above assume standard hardwood construction. Softwood pallets should be derated accordingly.
Board Count & Moisture
More deck boards distribute weight across a wider area, increasing capacity. Excess moisture (above 20%) weakens wood fibers and can reduce load ratings by up to 30%. Always use properly dried lumber.
Stacking & Storage Guidelines
Proper stacking and storage protect your products, your workers, and your pallets. Follow these guidelines to maximize warehouse efficiency and safety.
Maximum Stack Height
- Stringer pallets: Maximum 3 high when floor-stacked. Stringers have less four-way entry, reducing stability at height.
- Block pallets: Maximum 4-5 high depending on load weight. Full four-way entry provides better stability for taller stacks.
- General rule: Never stack higher than the load can maintain plumb (vertical alignment). Leaning stacks must be restacked immediately.
Racking Beam Spans
- 48×40 pallets: Require 96" (8 ft) beam span for two pallets side by side, or 42-44" clear opening for single-deep.
- 48×48 pallets: Require 50-52" clear beam opening. Verify racking is rated for the wider pallet before use.
- Important: Always confirm beam and upright capacity ratings with your racking manufacturer before loading.
Container & Trailer Loading
- 40 ft container: Fits 20 pallets of 48×40 using the pinwheel loading pattern (alternating orientation). Straight loading fits only 18.
- 53 ft trailer: Fits 26 pallets of 48×40 in a single layer (13 rows of 2). Double-stacking can yield up to 52 pallets if weight allows.
- Tip: Always verify gross weight limits. A fully loaded 53 ft trailer is limited to approximately 44,000 lb of cargo.
Overhang & Floor Storage
- Racking overhang: Maximum 1" overhang on each side when pallets are placed on racking beams. Greater overhang risks product falls and beam damage.
- Floor storage overhang: Maximum 2" overhang permitted for floor-stacked pallets. Loads must remain stable and not protrude into aisle ways.
- Floor vs. racking: Floor storage is simpler but uses more space. Racking maximizes vertical space but requires properly sized pallets.
How to Measure a Pallet
Accurate pallet measurements ensure proper fit in racking, trucks, and containers. Here is the standard method used across the industry.
Length x Width Format
Pallets are always described as Length x Width. The length is the dimension along the stringers (the long boards running underneath). The width is the dimension along the deck boards (the top boards you place products on).
For example, a "48 x 40" pallet has 48-inch stringers and 40-inch deck boards.
Where to Measure
Always measure from outside edge to outside edge. Place your tape measure at the very end of one side and extend it to the opposite outer edge. Do not measure from the inside of any notch or chamfer.
Take measurements at two points along each dimension and use the larger number to account for any warping.
Pallet Height
The standard pallet height is 6 inches (including top deck, stringers/blocks, and bottom boards). However, actual heights vary:
- Low-profile pallets: 4.5" - 5" (used for retail display and low-clearance applications)
- Standard pallets: 5.5" - 6.5" (most common for shipping and warehousing)
- Heavy-duty pallets: 6" - 7" (thicker lumber for extreme weight requirements)
Common Measurement Mistakes
- Reversing L x W: Confusing length (stringer) with width (deck board) is the most common error. This can result in pallets that don't fit your racking.
- Measuring inside notches: Stringer pallets have forklift notches cut into them. Never measure from inside the notch — always measure the full outside dimension.
- Ignoring warping: Used pallets may be warped or have damaged boards. Always measure at multiple points and note any deflection greater than 1/2".
- Forgetting height: Height matters for container loading and racking clearance. Always measure and report the total pallet height along with length and width.
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