Colorado, These are the Pallet Specs You Need for Safe Pallet Rack Design

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What You Need to Know About Pallets to Design a Pallet Racking System

Do you know that the pallet is at the core of pallet racking design? Likely you do, but with a large variety of pallet types, materials, sizes, etc., we are here to lay out all the details you need to understand to ensure your rack system’s safe, efficient function.

The Apex Colorado team has compiled this comprehensive guide to help you recognize critical features and specs –let’s start with the basics.

Pallet Basics

There are various pallet styles, designs, and materials used today. However, most pallets fit a basic size and shape called the GMA-style or GMA pallet, named after the Grocery Manufacturers Association (GMA) that created a “pallet standard” that is widely regarded.

GMA-Style Pallet Parameters 

  • Wood
  • Stringer-style
  • 40” w x 48” d x 6 1/2” h
  •  7 top & 5 bottom boards – minimum ½” thick
  • 4-way forklift entry
  • Minimum load capacity of 2500 lbs
  • Top boards – 5 1/2″ x 40″ on each end & five 3 1/2″ x 40″ boards in the center
  •  Bottom boards – 5 1/2″ x 40″ on each end & three 3 1/2″ x 40″ boards between

Wooden pallets 40” w x 48” d x 6 1/2” h are called GMA-style pallets. They are designed so that a forklift can access them from the end or side, enabling the pallet to be placed in a storage bay or pallet lane parallel or perpendicular to the opening of the rack.

Stringer Pallets

How To Measure A GMA-Style Pallet

  •     Pallet width – 40” wide, which refers to the direction of the deck boards
  •     Pallet depth – 48” deep which refers to the direction of the stringers
  •     Pallet orientation – Refers to the orientation of the stringers relative to the direction of the pallet in a lane or bay

To measure a GMA-style (stringer) pallet, measure across the width of the deck boards, down the length of the stringer, and then from the top boards to the bottom of the pallet.

2-Way vs. 4-Way Pallet Design

GMA-style pallets with notches in the stringers that enable forklift access from the sides and the ends are called 4-way pallets. Pallets that don’t have stringer board notches are called 2-way pallets because they can only be accessed from either end.

Pallet Orientation

Most often, pallet orientation is 40” w x 48” d for a standard pallet rack design. This orientation gives the forklift operator a wide space to secure the pallet with the forks and gives you a greater number of pallet positions.

If you’re designing rack bays for more than one pallet deep, you can orient the pallet 48” w x 40” d to get more depth in your design. This design works well for inventory with a low SKU count of high-volume items; however, you will sacrifice the total number of lanes. Also, the narrow fork openings make it harder for the forklift operator to secure the pallets onto the forks and can cause beam damage as a result.

Common Pallet Types

Block – traditionally, 4 to 12 blocks are used between the top and bottom boards with parallel and perpendicular boards to hold the pallet together. Block pallets allow 4-way forklift access

Skid – a stringer pallet without bottom deck boards

Square – 42” x 42” & 48” x 48” are common square pallet sizes

Pod – plastic pallet with protruding feet (pods)

Solid top plastic pallet with a smooth top surface to prevent inventory or storage case damage. Allows for 4-way forklift access.

Honeycomb –  lightweight and eco-friendly corrugated paper pallets for one-way use.

Metal Frame – various designs and sizes. It is critical to note the weld condition and any protrusions that can hinder safety for forklift operators or within dynamic storage systems.

Metal Frame Pallet, Plastic Pod Pallet, and Paper Honeycomb Pallet

A Closer Look At Pallet Quality & Material

Poor condition wood pallet

The quality of a pallet is important for warehouse, inventory, and worker safety. Good quality pallets are less likely to cause injury or damage due to protruding nails, broken boards, unbalanced loads, etc.

Wood Pallets

Select Grade A (or minimum Grade B) quality pallets. Grade A pallets are the highest quality and do not have damaged stringers. Grade B pallets show wear and can have repaired stringer damage. Note that reconditioned pallets might have inconsistencies because of maintenance. 

Metal & Plastic Pallets

Look for broken or protruding welds that create an uneven surface and can trigger point loads. Similarly, plastic pallets can have pod feet versus a flat bottom surface. Pallet decking is a great way to minimize these types of pallet challenges. It provides safe and solid support for standard and non-standard pallets alike.

Pod Pallet DeckingBenefits of Pallet Rack Decking

  • Easy installation into step beam
  • Supports compromised and damaged pallets
  • Enhances warehouse safety
  • Provides full-surface shelf coverage
  • Allows non-palletized storage
  • Secures odd-sized pallets

Outfitting a pallet racking system with decking gives you more safety and flexibility in using your pallet racking system and provides a greater opportunity to maximize capacity. 

Don’t Leave Warehouse Design To Chance

Apex Colorado is your local warehouse solutions expert team. We have all of your pallet racking design needs covered. We design simple Selective pallet rack systems and high-density Drive-In, Push-Back, and Pallet Flow for all your inventory needs. We also offer professional installation, rack maintenance, and repairs. Call us today to discuss your inventory storage and pallet rack system needs. We will work closely with you to configure the solution best suited to your needs.