Pallet Sizes Guide

Understanding standard and custom pallet dimensions for your business

Standard Pallet Sizes

48 x 40 inches

GMA Standard

The most common pallet size in North America. Perfect for retail and grocery distribution. Fits standard truck and warehouse configurations.

42 x 42 inches

Telecommunications

Commonly used in paint and telecommunications industries. Square design provides excellent stability for heavy loads.

48 x 48 inches

Drums & Barrels

Ideal for drums, barrels, and other cylindrical containers. Square footprint allows for efficient stacking.

40 x 48 inches

Military & Cement

Used by military and cement industries. Similar to GMA but with reversed dimensions.

48 x 20 inches

Half Pallet

Perfect for retail displays and smaller shipments. Takes up half the space of standard pallets.

48 x 36 inches

Beverage Industry

Commonly used for beverage distribution. Optimized for bottled goods transport.

International Pallet Sizes

1200 x 800 mm

EUR Pallet

European standard pallet. Widely used throughout Europe and increasingly in international trade.

1200 x 1000 mm

EUR 2 Pallet

Larger European pallet for bulky goods. Common in European warehousing and distribution.

1100 x 1100 mm

Asian Standard

Standard size in many Asian countries. Metric equivalent of 42x42 inches.

Custom Pallet Sizes

Tailored to Your Needs

We manufacture custom pallet sizes to meet your specific requirements. Whether you need unique dimensions for specialized equipment or optimized sizes for your warehouse layout, we can help.

Custom size considerations:

Product dimensions and weight
Warehouse racking systems
Transportation vehicle specifications
Handling equipment compatibility
Storage space optimization

Size Categories

Standard Full-Size Pallets

Dimensions approximately 48x40 to 48x48 inches. Most common category used throughout warehousing, distribution, and retail operations. Compatible with standard forklift equipment and truck configurations.

Half Pallets

Typically 48x20 or 24x40 inches, exactly half the footprint of full pallets. Perfect for retail displays, smaller shipments, or products that don't require full pallet quantities. Easy to handle manually.

Quarter Pallets

Approximately 24x20 inches, quarter size of standard pallets. Ideal for end-cap displays, promotional items, or very small product quantities. Maximizes retail floor space efficiency for point-of-sale merchandising.

Oversize Pallets

Larger than standard dimensions, typically 60x60 inches or more. Used for bulk materials, large machinery parts, or applications requiring maximum surface area. Require specialized handling equipment and transportation.

Square Pallets

Equal length and width dimensions like 42x42 or 48x48 inches. Provide optimal stability for cylindrical products, drums, and symmetric loads. Four-way entry simplifies handling from any direction.

Narrow Pallets

Width less than 40 inches, often 30-36 inches wide. Designed for narrow aisles, specific rack configurations, or products with elongated shapes. Space-efficient for high-density warehouse storage systems.

Industry-Specific Sizes

Grocery and Retail (48x40")

GMA standard size optimized for grocery distribution and retail supply chains. Fits efficiently in delivery trucks and store backrooms. Most widely available and compatible size throughout North American retail.

Automotive Industry (48x45")

Specific dimensions accommodate automotive parts packaging and assembly line logistics. Compatible with automotive industry material handling equipment and racking systems standardized across manufacturers.

Beverage Industry (48x36")

Optimized for bottled beverages, cans, and liquid products. Dimensions work well with beverage packaging configurations and distribution center layouts specific to drink manufacturers.

Chemical and Paint (42x42")

Square design ideal for drums, pails, and chemical containers. Provides stable base for cylindrical products common in chemical, paint, and petroleum industries requiring secure handling.

Dairy Industry (40x48")

Dimensions suited to milk crates, cheese blocks, and dairy product packaging. Rotated orientation of GMA standard optimized for dairy cooler and refrigerated warehouse configurations.

Pharmaceutical (42x42" or 40x48")

Sizes meeting pharmaceutical industry requirements for clean room compatibility and automated systems. Often require plastic or specially treated wood for hygiene standards compliance.

Custom Sizing Options

Product-Optimized Dimensions

Design pallet size to match your product footprint exactly, minimizing wasted space and maximizing load efficiency. Custom sizing reduces packaging costs and improves cube utilization in storage and transportation.

Rack-Optimized Sizing

Size pallets to fit your specific racking system with optimal clearances. Maximizes warehouse storage density by eliminating unused space between pallets and rack beams or uprights.

Container-Optimized Dimensions

Design pallet size to maximize container utilization for ocean freight. Proper sizing can fit additional pallets per container, significantly reducing per-unit shipping costs for export operations.

Equipment-Specific Sizing

Custom dimensions accommodate unique material handling equipment, automated systems, or production line configurations. Ensures compatibility with conveyors, automated guided vehicles, or specialized handling machinery.

Multi-Use Sizing

Design pallets compatible with multiple applications, facilities, or customer requirements. Balanced dimensions work across various systems while optimizing overall supply chain efficiency.

Modular Sizing Systems

Create family of pallet sizes with common dimensions that nest or stack together. Half, quarter, and full sizes share design elements for simplified inventory management and versatile applications.

Measurement Guidelines

Standard Measurement Method

Pallet dimensions stated as length x width. Length is stringer dimension (direction forks enter on two-way pallets). Width is perpendicular measurement. Always measure at widest points including any overhang.

Tolerance Standards

Industry standard tolerances typically plus/minus 1/4 inch for wood pallets. Plastic pallets have tighter tolerances around 1/8 inch. Critical applications may require closer tolerances specified during manufacturing.

Height Considerations

Overall pallet height important for clearances in racks, automated systems, and doorways. Standard heights range 4-8 inches. Measure from ground to top deck surface for loaded product height calculations.

Fork Entry Clearance

Measure fork opening height and width to ensure compatibility with material handling equipment. Standard fork openings typically 3.5-4 inches high. Wider pallets may need reinforced bottom deck for adequate clearance.

Overhang Allowances

Products can overhang pallet edges slightly but excessive overhang causes handling problems and damage risk. General rule: keep overhang under 1-2 inches per side. Some automated systems allow zero overhang.

Weight Capacity vs Size

Larger pallets don't automatically mean higher weight capacity. Load capacity depends on construction, materials, and support configuration. Specify both size and load requirements for proper pallet engineering.

Stacking Guidelines

Maximum Stack Height

Stack height limitations depend on pallet size, construction, load weight, and stability. Smaller pallets typically allow higher stacks. Industry standards suggest limiting stack height to 6 feet for safety and stability.

Load Distribution

Keep heavy items on bottom layers, lighter items on top. Center heavy items over pallet center for stability. Overhang and uneven distribution causes dangerous stack lean and collapse risk.

Interlocking Patterns

Rotate layers 90 degrees or use interlocking patterns to improve stability. Proper stacking pattern prevents load shifting during transport and handling. Column stacking weakest configuration for most products.

Stretch Wrap Considerations

Adequate stretch wrapping critical for tall stacks. Wrap multiple layers together as single unit. For pallet sizes with high center of gravity, additional wrapping may be necessary for transport safety.

Size Matching for Stacking

Stack only identically sized pallets for stability and rack compatibility. Mixed sizes in stacks create unsafe conditions and handling difficulties. Separate different sizes in storage and during shipment.

Warehouse Height Restrictions

Consider warehouse ceiling height, sprinkler clearance requirements, and rack beam heights when determining stacking heights. Maintain required clearances per fire codes and safety regulations.

Compatibility Information

Forklift Compatibility

Standard forklifts accommodate pallets up to 48-60 inches typically. Oversized pallets require specialized equipment. Verify fork length adequate to support 3/4 of pallet depth for safe handling and stability.

Pallet Jack Compatibility

Manual and electric pallet jacks typically handle pallets 20-48 inches width. Narrow-aisle jacks accommodate smaller sizes. Jack fork length must extend 2/3 into pallet minimum for proper load support.

Truck and Trailer Fit

Standard 53-foot trailers fit specific pallet configurations efficiently. 48x40 pallets load 26 per tier (13 pairs). Alternative sizes may waste trailer space. Calculate floor layout before committing to custom sizes.

Racking System Compatibility

Verify pallet dimensions fit your rack beam spacing with adequate clearances. Pallets should be 3-4 inches less than rack opening width. Oversized pallets can't fit, undersized pallets risk falling through.

Automated System Requirements

Automated warehouses require precise pallet dimensions with tight tolerances. Conveyors, sorters, and AS/RS systems have strict size specifications. Always verify pallet sizes with automation equipment manufacturer.

International Shipping

International shipments work best with pallets fitting standard container dimensions. ISO container sizes dictate optimal pallet configurations. Consider destination country standards when selecting export pallet sizes.

Pallet Sizes FAQ

Can you cut pallets to custom dimensions?

Our remanufacturing line can trim or rebuild pallets to exact footprints.

Do you stock metric sizes?

Yes, 1200x800 and 1200x1000 millimeter pallets are available for international orders.

How do I pick the right size for containers?

We analyze container dimensions and product sizes to recommend the most efficient layout.

Can you share load charts?

Reference sheets outline load ratings, truck quantities, and racking compatibility by size.

How many pallets fit on a truck?

A 53-foot trailer fits about 26 stacks of 48x40 pallets; other sizes have custom counts.

Can one delivery include multiple sizes?

Yes, we block and label stacks so warehouses can separate them easily.

Do uncommon sizes cost more?

Special footprints require unique cuts and may carry a premium, noted up front.

How early should I order rare sizes?

Please allow two to three weeks so materials and production slots can be arranged.

Can I test a sample pallet?

We ship single samples for fit checks before a full run.

Do you build collapsible or nestable pallets?

Custom engineering projects can create foldable or nestable solutions for tight spaces.