Standard Pallet Sizes and Pallet Dimensions

Different regions and industries have adopted specific pallet sizes based on local infrastructure, container dimensions, and historical trade patterns. While the 48” x 40” pallet dominates in North America, accounting for approximately 30% of all new pallets produced annually, other sizes serve specialized purposes or regional preferences. Understanding these variations is essential for companies engaged in international trade or multi-regional distribution.

GMA Pallet Specifications (48” x 40”)

The Grocery Manufacturers Association (GMA) pallet measuring 48 inches by 40 inches has become the de facto standard for North American logistics, representing the most common footprint in warehouses, distribution centers, and retail operations. This size was specifically designed to maximize space efficiency in standard 53-foot trailers and align with common warehouse racking configurations. The GMA pallet typically features a stringer design with perpendicular deck boards, constructed from either hardwood or softwood materials, and offers both 2-way and 4-way entry options for forklift and pallet jack access.

Why Pallet Dimensions Matter for Logistics

Pallet dimensions directly impact your bottom line by determining how many units fit in a trailer, container, or warehouse bay. A 53-foot trailer can accommodate 26 standard 48” x 40” pallets in a single-stacked configuration, maximizing cube utilization at approximately 93% efficiency. Non-standard pallet sizes can create wasted space, reduce load capacity, and increase cost-per-unit shipped. Additionally, warehouse racking systems, automated storage and retrieval systems (AS/RS), and material handling equipment are all designed around standard dimensions—using non-conforming pallets can lead to compatibility issues, safety concerns, and operational inefficiencies that compound throughout your supply chain.

Key Measurement Specifications

Understanding pallet measurements requires more than knowing the overall footprint—deck board spacing, overhang, stringer height, and entry clearances all affect equipment compatibility and load stability. Overall dimensions refer to the outer edges of the deck boards, while actual usable surface area may be slightly less due to chamfered edges or board spacing. Deck board spacing (typically 0.5” to 1.5” gaps) affects how products rest on the pallet and whether strapping will securely hold loads. Entry openings must accommodate forklift tines (typically 5.5” wide) with adequate clearance, while pallet height determines compatibility with automated conveyors, shrink-wrap machines, and low-clearance doorways in temperature-controlled environments.

North American Standard Pallet Sizes

Pallet standardization in North America has evolved to optimize supply chain efficiency, warehouse operations, and transportation logistics. While dozens of pallet sizes exist for specialized applications, the industry has gravitated toward several dominant standards that align with trailer dimensions, warehouse racking systems, and automated handling equipment. Unlike international standards such as the EUR pallet (47.24” x 31.5” or 1200mm x 800mm) commonly used in Europe, or the ISO standard pallets designed for global shipping containers, North American pallets prioritize domestic truck trailer optimization over international container compatibility.

The most prevalent standard in North America is the GMA pallet at 48” x 40”, which accounts for approximately 30% of all new pallets produced annually. However, regional preferences, industry-specific requirements, and product characteristics have led to the adoption of alternative sizes including square pallets and various rectangular configurations. These standards facilitate interoperability across the supply chain, reduce handling costs, and maximize trailer cube utilization when properly selected for specific applications. The dominance of imperial measurements in North American pallet sizing reflects the region’s truck-centric distribution model, where 53-foot trailers serve as the primary constraint for dimensional standardization.

Pallet Structure and Types

Understanding pallet construction is essential for optimizing your warehouse operations and logistics efficiency. Pallets are built using two primary structural designs: block pallets and stringer pallets. The fundamental difference lies in how the top deck is supported—either by blocks positioned throughout the base or by parallel boards called stringers running in one direction. This structural variation directly impacts load capacity, handling equipment compatibility, and overall durability, making it a critical consideration when selecting pallets for your operation.

The type of pallet you choose affects everything from forklift maneuverability to storage density and shipping costs. Block pallets typically offer four-way entry access and higher load capacities, making them ideal for heavy-duty applications and automated warehouse systems. Stringer pallets, being the most common design in North America, provide a cost-effective solution for standard warehousing needs, though they may have entry restrictions depending on whether notches are cut into the stringers. Understanding these structural differences helps businesses make informed decisions that align with their handling equipment, storage systems, and budget constraints.

Pallet Type Comparison Table

Block Pallets

Block pallets feature a robust construction with solid blocks—typically nine or twelve—positioned between the top and bottom deck boards, creating a stable foundation that distributes weight more evenly across the entire structure. These blocks are usually made from solid wood, engineered wood, or plastic, and they’re strategically placed at the corners, edges, and center of the pallet to maximize strength and stability. The design allows forklift tines or pallet jack forks to enter from all four sides, providing superior maneuverability in tight warehouse spaces and making them compatible with automated storage and retrieval systems. Block pallets excel in heavy-duty applications, offering load capacities that can exceed 7,500 lbs for static loads, and they’re particularly popular in industries requiring maximum durability such as manufacturing, automotive, and international shipping where ISPM-15 compliant heat-treated wooden pallets are required. However, these advantages come at a cost—block pallets are significantly more expensive than stringer designs ($25-$50 vs. $10-$25), heavier to handle (50-75 lbs), and more complex to repair when damaged, making them less practical for businesses with limited budgets or operations that primarily handle lighter loads where the extra capacity isn’t necessary.

Stringer Pallets

Stringer pallets are constructed with three parallel pieces of timber—called stringers—that run the length of the pallet and support the top deck boards, creating the most economical and widely used pallet design in North America. The stringers are positioned along the two edges and the center of the pallet, with deck boards nailed perpendicular across them to form the load-bearing surface. Standard stringer pallets offer two-way entry, meaning forklifts can only access them from the front and back, though many manufacturers add notches (also called forklift slots) cut into the stringers to enable four-way entry with proper equipment. This design is favored for its cost-effectiveness, with prices ranging from $10-$25 per pallet, making it ideal for businesses with high pallet turnover, one-way shipping applications, and operations that don’t require the heavy load capacities of block pallets—typically handling dynamic loads of 1,500-2,800 lbs depending on wood grade and construction quality.

Two-Way vs. Four-Way Pallets

Entry configuration is one of the most practical considerations when selecting pallets, as it directly determines which handling equipment can efficiently move your loads and how quickly warehouse operations can flow. Two-way pallets allow forklift tines or pallet jack forks to enter only from two opposite sides—typically the front and back—because the support structure blocks access from the other two sides. Four-way pallets, on the other hand, permit entry from all four sides, offering maximum flexibility for forklift operators who can approach the pallet from any direction without repositioning. This seemingly simple difference has significant implications for warehouse efficiency: four-way access reduces maneuvering time by 15-30%, improves space utilization in narrow aisles, and is essential for automated systems and high-density storage configurations where precise positioning matters.

Entry Configuration Comparison

Material Options (Wood, Plastic, Metal)

Pallet materials have evolved significantly beyond traditional wood, with each option offering distinct advantages for specific applications, environments, and industries. Wood remains the dominant material, accounting for approximately 90% of the US pallet market due to its affordability ($10-$25 for stringer, $25-$50 for block), repairability, and natural shock absorption that protects goods during transit. Plastic pallets, though more expensive initially ($50-$150), provide exceptional durability with lifespans of 10+ years, resist moisture and chemicals, meet strict hygiene standards for pharmaceutical and food industries, and maintain consistent weight and dimensions—critical factors for automated systems. Metal pallets, typically constructed from steel or aluminum, command premium prices ($150-$400) but offer unmatched strength for extreme load capacities (up to 10,000 lbs), fire resistance for hazardous material storage, and longevity in harsh industrial environments, though their weight and potential for rust can be limiting factors.

The choice of material should align with your specific operational requirements, regulatory compliance needs, and total cost of ownership rather than just initial purchase price. Wood pallets require ISPM-15 heat treatment or fumigation for international shipping to prevent pest transmission, adding processing time and cost but remaining the most economical choice for domestic one-way shipments. Plastic pallets eliminate splinters, contamination risks, and insect concerns, making them ideal for cleanroom environments, export without treatment requirements, and closed-loop supply chains where pallets are returned and reused hundreds of times—ultimately providing better ROI despite higher upfront costs. Metal pallets excel in specialized applications like automotive manufacturing, steel mills, and situations requiring maximum fire safety or load capacity, though their weight (70-100 lbs vs. 35-50 lbs for wood) increases handling difficulty and shipping costs for empty pallet returns.

Material Comparison Table

Factors Affecting Weight Limits

Several environmental and operational factors can dramatically reduce a pallet’s safe load capacity below its rated specifications. Pallet condition plays a critical role—visible damage such as cracked stringers, broken deck boards, or missing fasteners can reduce capacity by 20-60%. Environmental conditions including moisture exposure, temperature extremes, and prolonged outdoor storage weaken wood fibers and make plastic pallets brittle. Load distribution is equally important; improper weight placement creates dangerous point loads that can cause failure even with weights well below the rated capacity, so loads should always be centered and evenly distributed across the pallet surface. Additionally, industry-specific requirements may impose stricter limits—food and pharmaceutical industries often mandate lower capacities for hygiene-rated pallets, while export pallets may need derating to account for extended transit times and handling by multiple carriers.

International Pallet Standards

Pallet standardization emerged from the need to optimize global shipping container space, streamline warehouse operations, and facilitate efficient cross-border trade. Different regions developed their own standards based on local shipping practices, truck dimensions, and industrial requirements. While this regional variation can create challenges for international logistics, it reflects the diverse needs of different markets and transportation systems. The most widely recognized standards include European EUR pallets, ISO specifications, Asian market sizes, and specialized chemical industry pallets.

Understanding these standards is crucial for businesses engaged in international trade, as selecting the wrong pallet size can result in wasted container space, increased shipping costs, and compatibility issues at destination warehouses. Standard pallets typically range from 40×32 inches to 48×48 inches, with load capacities varying from 2,500 to 5,000 pounds depending on construction and intended use. The right pallet choice depends on your destination market, product type, transportation method, and whether you prioritize compatibility with forklifts, automated systems, or specific container dimensions.

European Pallets (EUR-1, EUR-3)

European pallets, manufactured under the EPAL (European Pallet Association) certification system, are the dominant standard across Europe and increasingly used globally. The EUR-1, measuring 47.2×31.5 inches (1200×800 mm), is the most common type, featuring a 4-way entry design that allows forklift access from all sides and a typical height of 5.7 inches (144 mm). The EUR-3 pallet, at 39.4×47.2 inches (1000×1200 mm), is essentially a reversed dimension version used for specific loading requirements. These pallets are constructed from kiln-dried wood with specific board thicknesses and nail patterns regulated by EPAL, ensuring consistent quality and interchangeability across the European logistics network. Both types are designed to fit efficiently into European truck trailers and standard 20-foot and 40-foot shipping containers, with EUR-1 pallets being particularly optimized for European distribution.

ISO Standard Pallets

The International Organization for Standardization (ISO) established six standard pallet dimensions (ISO 6780) to promote global trade efficiency and optimize shipping container utilization. The most widely adopted are ISO Pallet 1 at 47.2×39.4 inches (1200×1000 mm), which dominates in Europe and Asia, and ISO Pallet 2 at 47.2×31.5 inches (1200×800 mm), identical to the EUR pallet. North America primarily uses the 48×40-inch pallet (not an ISO standard) due to its optimization for 48-foot truck trailers, while Asian markets favor the 43.3×43.3-inch (1100×1100 mm) ISO Pallet 6 for square container loading. ISO standards were developed to maximize the number of pallets that fit into standard 20-foot and 40-foot shipping containers while maintaining structural integrity and load stability across different transportation modes.

Asian Pallet Sizes

Asian pallet standards reflect the region’s focus on square dimensions that optimize container space and facilitate multi-directional loading in compact warehouses. The 43.3×43.3-inch (1100×1100 mm) pallet is the dominant standard across Japan, South Korea, and Taiwan, offering superior stability for automated handling systems common in Asian manufacturing facilities. China uses a mix of standards including 47.2×47.2 inches (1200×1200 mm) for heavy industrial goods and increasingly adopts the 1100×1100 mm standard for export-oriented manufacturing. These square configurations allow for more flexible stacking patterns and work well with the automated guided vehicles (AGVs) and robotic systems prevalent in Asian electronics and automotive manufacturing, though they can be less material-efficient than rectangular pallets for certain product types.

CP Pallets for Chemical Industry

Chemical Pallets (CP) represent a specialized standardization system developed specifically for the safe and efficient transportation of chemical products, drums, and intermediate bulk containers (IBCs). The CP system includes nine standardized sizes (CP1 through CP9) ranging from 31.5×47.2 inches (800×1200 mm) to 47.2×51.2 inches (1200×1300 mm), each designed to accommodate specific container types and loading patterns common in chemical logistics. These pallets must meet strict safety requirements including chemical-resistant materials, absence of protruding nails, and often feature heat-treated wood (HT) or plastic construction to prevent contamination. CP1 (39.4×47.2 inches / 1000×1200 mm) and CP3 (44.9×44.9 inches / 1140×1140 mm) are the most common, optimized for 200-liter drums and cubic IBCs respectively, with load capacities typically ranging from 3,300 to 4,400 pounds depending on the specific CP designation and construction.

Pallet Grades and Conditions

Understanding pallet grades is essential for making cost-effective purchasing decisions that match your operational needs. The pallet industry uses a standardized grading system—Grade A (new), Grade B (reconditioned), and Grade C (recycled)—to classify pallets based on their condition, structural integrity, and remaining lifespan. Each grade serves different applications and budgets, from pristine export-ready pallets to economical single-use options.

Selecting the appropriate grade directly impacts your shipping costs, product safety, and supply chain efficiency. While Grade A pallets command premium prices ranging from $15-30 per unit, they’re often required for international shipping and high-value goods. Grade B pallets ($8-15) offer the best value for domestic operations, while Grade C pallets ($3-8) suit light-duty or one-way shipments. Understanding these distinctions helps businesses balance quality requirements against budget constraints.

Grade A (New Pallets)

Grade A pallets are manufactured from virgin lumber with no previous use, featuring consistent dimensions, no structural defects, and full ISPM 15 heat treatment certification for international shipping. These pallets meet the strictest industry standards and are mandatory for export to countries requiring phytosanitary compliance, as well as for industries like food service, pharmaceuticals, and electronics where contamination risks must be eliminated. Their premium construction ensures maximum load capacity of 4,600 lbs for static loads and 2,500 lbs for dynamic loads, making them ideal for heavy machinery, chemical drums, and high-value inventory that cannot risk pallet failure during transit.

Grade B (Reconditioned Pallets)

Grade B pallets are professionally inspected and repaired used pallets with replaced deck boards, reinforced stringers, and renewed structural integrity that meets safety standards for most domestic applications. The reconditioning process involves replacing damaged components with matching lumber, removing protruding nails, and ensuring the pallet can safely handle 85-95% of original load capacity—typically 3,600-4,100 lbs for static loads. These pallets offer the optimal balance between cost and reliability for businesses running regular distribution operations, warehouse storage, and retail supply chains where ISPM 15 certification isn’t required, delivering 5-8 years of service life at nearly half the cost of new pallets.

Grade C (Recycled Pallets)

Grade C pallets show visible wear including weathering, staining, and minor structural damage but remain functional for light-duty applications with loads under 3,200 lbs. These budget pallets may have split deck boards, worn stringers, or cosmetic imperfections that don’t compromise basic functionality, making them suitable for single-use shipments, in-house material handling, DIY projects, or temporary storage where pallet appearance and longevity aren’t critical factors. While they typically last only 1-3 years under regular use, their $3-8 price point makes them economical for businesses with one-way shipping needs or operations where pallets won’t be returned or reused.

Applications by Industry

Different industries have distinct pallet requirements based on their unique operational needs, product characteristics, and regulatory standards. While the 48” x 40” GMA pallet serves as the general standard in North America, sectors like military, food and beverage, chemicals, and retail each demand specific dimensions, materials, and features to optimize their supply chains. Understanding these industry-specific applications helps businesses select the right pallet type to ensure product safety, compliance, and cost efficiency.

The variation in pallet standards across industries reflects the diverse challenges each sector faces, from heavy-duty military equipment requiring reinforced platforms to pharmaceutical products demanding contamination-free environments. Geographic considerations also play a role, as companies operating internationally must navigate regional standards while maintaining compatibility with global logistics networks. This section explores how different industries adapt pallet specifications to meet their specialized requirements.

Military and Cement

Military operations and cement manufacturing both require exceptionally robust pallets capable of handling extreme weights and harsh conditions. The military standard pallet measures 88” x 108” (compared to the civilian 48” x 40”), designed specifically to fit military cargo aircraft and support loads up to 10,000 lbs. Cement industries typically use either heavy-duty block pallets or the standard 48” x 40” GMA configuration reinforced with additional stringers, with weight capacities ranging from 4,500 to 5,000 lbs to accommodate cement bags typically weighing 2,200 to 4,400 lbs per pallet. Both sectors prioritize hardwood construction and expendable designs due to the punishing nature of their applications and the impracticality of pallet return systems.

Military and Cement Industry Pallet Specifications:

Food and Beverage

The food and beverage industry predominantly uses the 48” x 40” GMA (Grocery Manufacturers Association) pallet, which has become the de facto standard across North American supply chains, with an estimated 30% of all pallets in circulation being this size. Hygiene and regulatory compliance drive material selection, with many companies transitioning from heat-treated wood (ISPM 15 compliant) to plastic pallets that resist moisture, bacteria growth, and contamination while supporting loads between 2,500 and 5,000 lbs. The cold chain requirements for refrigerated and frozen goods further influence pallet choice, as materials must withstand temperature fluctuations from -20°F to 100°F without warping or degrading, ensuring product integrity from warehouse to retail shelf.

Food and Beverage Pallet Standards:

Chemical and Pharmaceutical

Chemical and pharmaceutical industries demand the highest pallet standards due to strict contamination control, regulatory compliance, and product safety requirements. Plastic pallets dominate this sector, with 48” x 40” and 42” x 42” configurations being most common, as they offer non-porous surfaces that prevent chemical absorption, resist corrosion, and can be thoroughly sanitized to meet Good Manufacturing Practice (GMP) and Good Distribution Practice (GDP) standards. These industries often require specialized features like spill containment lips, anti-static properties for volatile materials, and smooth surfaces compatible with cleanroom environments, with weight capacities typically ranging from 2,500 to 5,000 lbs to accommodate chemical drums, pharmaceutical totes, and sensitive equipment valued at $50,000 to $500,000 per shipment.

Chemical and Pharmaceutical Pallet Requirements:

Retail and General Logistics

The retail and general logistics sector established the 48” x 40” GMA pallet as the universal standard, accounting for approximately 30% of all pallets in circulation and serving as the reference point for warehouse racking, truck dimensions, and material handling equipment across North America. This standardization emerged from major retailers like Walmart, Target, and grocery chains demanding consistent dimensions to optimize their distribution networks, with the 48” x 40” footprint fitting perfectly two-across in a standard 96” wide trailer and accommodating standard 42” aisles in warehouses. European operations typically use the Euro pallet at 47.2” x 31.5” (1200mm x 800mm), while Asian markets favor 43.3” x 43.3” (1100mm x 1100mm) dimensions, creating a global patchwork that companies must navigate through pallet pooling services like CHEP and PECO, which charge rental fees ranging from $6 to $15 per pallet cycle depending on region and service level.

Retail and Logistics Standard Pallets by Region:

Choosing the Right Pallet Size

Selecting the appropriate pallet size is a critical decision that directly impacts your bottom line through transportation costs, warehouse efficiency, and product damage rates. The wrong pallet size can lead to wasted truck space, incompatible racking systems, and increased handling time, potentially costing businesses thousands of dollars annually. While the standard 48” × 40” GMA pallet dominates North American logistics, understanding the full range of pallet dimensions available ensures you’re making the most cost-effective choice for your specific supply chain needs.

The decision isn’t one-size-fits-all. Your ideal pallet size depends on multiple factors including your product characteristics, shipping destinations, warehouse infrastructure, and transportation methods. By carefully evaluating these elements and understanding how different pallet dimensions perform across your entire operation, you can optimize material handling, reduce damage, maximize trailer utilization, and improve overall supply chain efficiency. The following sections break down the key considerations to help you make an informed decision.

Standard Pallet Sizes Comparison

Factors to Consider

When choosing a pallet size, start by evaluating your product’s weight, dimensions, and fragility to ensure proper load distribution and stability. Consider the industries and regions you serve—grocery distributors typically use 48” × 40” GMA pallets, while companies shipping to Europe need 47.2” × 31.5” EUR pallets for seamless integration with European supply chains. Your shipping destinations matter significantly; if you’re exporting internationally, using ISO-standard 48” × 48” pallets ensures compatibility with global shipping containers and handling equipment. Additionally, assess your stacking requirements and load height restrictions, as some warehouses and retail locations have specific limitations that could affect your pallet choice and overall product configuration.

Truck Load Optimization

Pallet dimensions directly determine how many units fit in a trailer, which dramatically affects your per-unit shipping costs. A standard 53-foot trailer can accommodate 26 standard 48” × 40” pallets in a single layer, achieving approximately 91% floor space utilization, while 48” × 48” pallets only fit 24 units with similar efficiency. Poor pallet sizing can waste 15-20% of available trailer space, translating to $150-$300 in additional costs per shipment when you’re forced to use extra trucks. By selecting pallet dimensions that maximize your specific trailer types, you can reduce the number of shipments needed, lower freight costs, and improve your logistics sustainability by minimizing empty space and unnecessary trips.

Truck Loading Capacity by Pallet Size

Note: Capacities shown are for single-layer floor loading. Most shipments accommodate double stacking, effectively doubling these quantities based on product weight and stability.

Warehouse Compatibility

Your warehouse infrastructure—including racking systems, forklifts, pallet jacks, and aisle widths—must accommodate your chosen pallet size to ensure smooth operations and worker safety. Standard selective racking is designed for 48” × 40” pallets with 42-inch deep beams, while European pallets require different configurations that could necessitate costly rack modifications. Forklift compatibility is equally critical; you’ll need adequate aisle widths of 12-13 feet for standard counterbalance forklifts handling 48” pallets, though narrow aisle reach trucks can operate in 8-10 foot aisles. Mismatched pallet sizes can reduce storage density by 20-30%, force inefficient product placement, and create safety hazards when pallets overhang racking or don’t fit properly on handling equipment, ultimately slowing down your receiving, putaway, and picking operations.

Standard Pallet FAQs

When it comes to shipping, warehousing, and logistics, understanding standard pallet dimensions is essential for efficient operations. Pallets serve as the foundation of modern supply chains, allowing goods to be moved, stored, and transported with ease. Whether you’re a warehouse manager, business owner, or logistics professional, knowing the specifications of standard pallets can help you optimize space, reduce costs, and ensure compliance with industry standards.

This FAQ section answers the most common questions about pallet sizes, weight capacities, heights, materials, and truck loading capacities. From the ubiquitous 48×40 inch GMA pallet to specialized sizes used in different industries and regions, we’ll cover everything you need to know about pallet dimensions and their practical applications in your operations.

What is the most common pallet size in the US

The most common pallet size in the United States is 48 inches by 40 inches, known as the GMA (Grocery Manufacturers Association) pallet or standard North American pallet. This size became the industry standard because it efficiently utilizes truck and warehouse space while accommodating the widest range of products. The 48×40 inch dimension allows for optimal loading in 53-foot trailers, where they can be arranged in rows of two across the width of the trailer. This pallet size is used across multiple industries including retail, grocery, pharmaceutical, and general manufacturing, making it the most versatile and widely available option in North America.

Standard Pallet Sizes by Region

How much weight can a standard pallet hold

A standard 48×40 inch wooden pallet can typically hold between 3,000 and 4,600 pounds, though capacity varies significantly based on how the load is supported. The three main load types are static loads (pallet resting on the ground), dynamic loads (pallet being moved by forklift or pallet jack), and racking loads (pallet stored on warehouse racking). Static loads generally have the highest capacity at 5,500 pounds or more, while racking loads—which put the most stress on the pallet structure—typically max out around 2,500 pounds. Always check the pallet’s rating stamp or consult with your supplier to ensure you’re within safe weight limits, as overloading can lead to pallet failure, product damage, and workplace safety hazards.

Pallet Weight Capacity by Load Type

How tall is a standard pallet

A standard wooden pallet typically stands between 5.5 and 6 inches tall, measured from the ground to the top deck surface where products rest. This height accounts for the bottom deck boards, stringers or blocks that create the fork pockets, and the top deck boards. While the pallet itself is relatively short, the total height of a loaded pallet is crucial for shipping and warehousing—most trailers have internal heights of 110 to 114 inches, and loaded pallets should not exceed 96 inches in total height (including the pallet) to allow for safe stacking and transport. Some warehouses and distribution centers impose even stricter height limits of 72 to 84 inches to maximize vertical storage capacity and maintain safe handling clearances.

Pallet Height Specifications

What materials are pallets made from

Pallets are manufactured from four primary materials: wood, plastic, metal, and composite materials, each offering distinct advantages for different applications. Wood pallets are the most common, accounting for roughly 90% of the US market due to their low cost ($10–$25 per pallet), repairability, and recyclability, though they’re susceptible to moisture damage and pest infestation. Plastic pallets ($50–$150) are increasingly popular in food, pharmaceutical, and export industries because they’re lightweight, weather-resistant, and easy to sanitize, while metal pallets ($150–$400) are reserved for heavy-duty applications requiring maximum durability and fire resistance. Composite pallets, made from wood fiber and plastic blends, offer a middle ground with better moisture resistance than wood at a lower cost than pure plastic, making them ideal for one-way shipping and specific industry needs like automotive parts transport.

Pallet Material Comparison

How many pallets fit in a truck

A standard 53-foot trailer can accommodate 26 standard 48×40 inch pallets when floor-loaded in a single layer, arranged in 13 rows of two pallets side-by-side. If you turn the pallets sideways (known as “pinwheeling”), you can sometimes fit 28-30 pallets, though this sacrifices some stability and ease of unloading. When double-stacking is possible—depending on product weight, durability, and trailer height—you can potentially transport 52 pallets in a single load. Smaller trucks have proportionally reduced capacities: a 48-foot trailer holds 24 pallets floor-loaded, a 28-foot trailer fits 14 pallets, and a 26-foot box truck accommodates 12 pallets. Keep in mind that weight restrictions (typically 42,000–45,000 pounds of cargo) may limit your actual capacity before you reach the physical space limit, especially when shipping dense products like beverages or building materials.

Truck Pallet Capacity Guide