Pallet

A pallet is a flat transport structure that supports goods in a stable, stackable unit for handling by forklifts, pallet jacks, and automated warehouse systems. Most pallets are made of wood, though plastic, metal, and corrugated versions exist for specialized applications. The pallet is so fundamental to logistics that warehouse design, truck dimensions, container capacity, and racking systems are all built around its standard footprint.

Standard Pallet Sizes

In the United States, the Grocery Manufacturers Association (GMA) pallet measures 48 inches by 40 inches. This is the dominant size in domestic commerce, used by roughly 30% of all pallets in circulation. It fits perfectly into a 53-foot trailer (two pallets wide, 26 to 30 pallets per full truckload depending on height and weight) and is the basis for most warehouse racking configurations.

Other standard sizes include 42 x 42 inches (common in telecommunications and paint industries), 48 x 48 inches (used for drums and barrels), and the EUR/EPAL pallet at 1200 x 800 millimeters (roughly 47 x 31 inches), which is the standard in European logistics. When importing goods from Europe or Asia, pallet size mismatches can create problems. A container loaded with EUR pallets will not fill a 53-foot domestic trailer efficiently because the footprint does not align with U.S. truck and dock dimensions.

Pallet Types

Stringer pallets use two or three parallel boards (stringers) running the length of the pallet to support the deck boards. They are the most common type in the U.S. and are less expensive to manufacture, typically costing $6 to $12 new for a standard 48 x 40 unit.

Block pallets use blocks of solid wood at the corners and center points, with both top and bottom deck boards. They can be accessed by a forklift from all four sides (four-way entry), making them easier to handle in tight warehouse aisles. Block pallets cost $12 to $25 new and are more durable than stringer pallets.

Plastic pallets are used in food, pharmaceutical, and cleanroom environments where wood contamination (splinters, mold, insects) is a concern. They weigh 30% to 50% less than wood pallets and can be washed and sanitized. Prices range from $30 to $80 per pallet, which limits their use to closed-loop supply chains where the pallet is returned and reused rather than discarded.

ISPM-15 and International Shipping

Wood pallets used in international shipping must comply with ISPM-15 (International Standards for Phytosanitary Measures No. 15). This regulation requires wood packaging materials to be heat-treated or fumigated with methyl bromide to kill insects and pathogens. Treated pallets carry a stamp showing the treatment method and the country of origin. Non-compliant pallets can be refused at the destination port, and the entire shipment may be quarantined or returned.

For importers receiving containerized goods on non-ISPM-15 pallets, the cargo must be re-palletized at the port or warehouse before further domestic transport. This adds $2 to $5 per pallet in labor and material costs, plus the cost of the compliant replacement pallets.

Pallet Weight and Load Capacity

A standard GMA wood pallet weighs 30 to 48 pounds depending on construction. Its static load capacity (weight it can hold while stationary on the floor) is typically 2,500 to 3,000 pounds. Dynamic load capacity (weight while being moved by a forklift) runs lower at 2,000 to 2,500 pounds. Racking load capacity (weight when supported only at the edges on a rack beam) drops further to 1,500 to 2,000 pounds.

Overloading pallets is a common warehouse safety issue. A pallet rated for 2,500 pounds of dynamic load that gets stacked with 3,200 pounds of product can fail when lifted, dropping cargo onto the warehouse floor or worse, onto a worker. Prep centers handling FBA inbound shipments must verify pallet weights before stacking and shipping, as Amazon’s fulfillment centers have specific pallet weight limits (typically 1,500 pounds per pallet for standard receiving).