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Size guide

Measure twice.
Order once.

Nearly every expensive pallet mistake is a dimension mistake: a deck that overhangs a rack beam, a footprint that wastes nine inches of trailer width, a bay that was designed around a pallet nobody stocks any more. This is the reference we wish buyers had before they called.

Sizes charted
10 NA + 6 ISO
Fit patterns
Trailer & container
Deep dives
Four articles
Stock footprint
48 × 40 in

Quote request

Check a footprint before you commit

Give us a rack opening or a trailer plan and the load weight. We'll confirm whether a stock size fits or whether you genuinely need a custom build.

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48×4042×4248×481200×8001200×100036×361140×114048×4042×4248×481200×8001200×100036×361140×1140

North America

Ten footprints cover almost everything shipped in the US

And one of them covers about a third of it on its own. If you are designing a new pack, there is rarely a good reason to leave this list.

The 48×40 deep dive
Share figures are industry estimates for the United States; our own intake mix is roughly 72% GMA.
FootprintMetric (mm)Known asTypical useShare
48" × 40"1219 × 1016GMA / grocery standardGroceries, general distribution~30% of all US pallets
42" × 42"1067 × 1067Square 42Telecom, paint, drums~4%
48" × 48"1219 × 1219Drum pallet55-gallon drums, barrels~3%
40" × 48"1016 × 1219Rotated GMAMilitary, construction~3%
48" × 42"1219 × 1067Chemical / produceChemicals, produce~2%
40" × 40"1016 × 1016Dairy squareDairy, beverage~2%
48" × 45"1219 × 1143AutomotiveAuto parts~2%
44" × 44"1118 × 1118Drum & chemicalDrums, chemicals~1.5%
36" × 36"914 × 914BeverageBeverage, retail display~1.5%
48" × 20"1219 × 508Half palletRetail displays, DSD~1%
The six ISO 6780 footprints. Note that none is an exact metric twin of 48×40 — a recurring source of export grief.
ISO (mm)ImperialRegionNote
1200 × 100047.2" × 39.4"Europe, AsiaThe closest ISO neighbour to GMA
1200 × 80047.2" × 31.5"Europe (EUR/EPAL 1)The classic Euro block pallet
1140 × 114044.9" × 44.9"Australia, AsiaSquare, common in shipping containers
1100 × 110043.3" × 43.3"AsiaJapanese / regional standard
1067 × 106742.0" × 42.0"North America, AsiaISO form of the square 42
1016 × 121940.0" × 48.0"North AmericaGMA expressed in ISO terms

International

Why your export pallets never quite fit

48×40 inches is 1219×1016 mm. The nearest ISO size is 1200×1000 mm. That 19 mm and 16 mm difference is enough to ruin a container plan.

If you ship into Europe regularly, standardising on 1200×800 mm (EPAL) or 1200×1000 mm rather than fighting the GMA footprint through a container is almost always cheaper. We stock and build both.

Read the Euro / EPAL guide for the licensing, marking and repair rules — they are stricter than most US shippers expect.

Fit patterns

How many actually go in the trailer

Per-layer counts for the loading patterns we see every day. Multiply by your safe stack height, not by your optimism.

Interior widths vary by trailer build. Always confirm with your carrier before planning a pattern.
EquipmentInterior widthPatternPer layerNote
53 ft dry van100–102"48×40 straight26 palletsTwo rows of 13, 40" face out
53 ft dry van100–102"48×40 pinwheel28 palletsAlternating orientation, tighter fit
48 ft dry van98–100"48×40 straight24 palletsTwo rows of 12
20 ft container92.5"1200×800 EUR11 palletsOr 9–10 × GMA
40 ft container92.5"1200×800 EUR24 palletsOr 20–21 × GMA
40 ft HC container92.5"1200×1000 ISO20 palletsDouble-stack if load allows

Clearances

The four measurements people forget

Footprint is the easy part. These are the numbers that actually decide whether a pallet works in your building.

Never let the deck overhang the beam

A pallet must bear on the rack beams through its stringers or blocks, not through an overhanging deck board. Overhang is the leading cause of catastrophic pallet failure in racking, because the load path runs through a ⅝-inch board rather than a structural member.

Measure your beam-to-beam span and subtract: you want the stringer direction to sit fully within it, with the deck flush or inside the beam face.

CheckRule of thumb
Deck beyond beam0 in — never acceptable
Load beyond deck≤ 1 in per side
Beam span, 48×40≥ 96" for two pallets
Flue space, back to back≥ 6"

Two-way, partial four-way, full four-way

A standard stringer pallet admits forks on two sides only. Notching the stringers creates partial four-way entry — forks from all four faces, pallet jacks from two. Block pallets give true four-way access for both.

If your operation uses pallet jacks in aisles, this single decision matters more than grade.

TypeForkliftPallet jack
Stringer, unnotched2 sides2 sides
Stringer, notched4 sides2 sides
Block pallet4 sides4 sides

Count down from the beam, not up from the floor

Usable load height is beam-to-beam clearance minus pallet height minus a safety gap. A standard recycled GMA deck is about 5½ inches tall; allow a further 4 inches of clearance for fork entry and settlement.

For floor stacking, the limiting factor is usually the bottom pallet's static load rating rather than ceiling height — see load & capacity ratings.

The constraint nobody measures until it fails

Freight lifts, mezzanine gates, cold-store doors and roll-up shutters all impose a maximum loaded footprint and height. A 48×40 pallet with a 1-inch load overhang on each side needs 50 inches of clear opening, plus mast clearance.

If any of your route includes a lift, measure it first and tell us. It occasionally makes a half-pallet or a 36×36 the right answer.

Deep dives

Four long reads for whoever owns the spec

Pages inside this guide, written for the person who actually has to sign off a pallet standard.

Quick answers

Conversions and common confusions

Elsewhere on the site

Conversions & clearances

The arithmetic nobody wants to do twice

Inches to millimetres is exact: multiply by 25.4. Everything else below is the subtraction that decides whether a pallet fits your building.

Exact conversions for common pallet dimensions

Rounding 1219 mm to 1200 mm is the single most common cause of a failed container plan.
InchesMillimetresWhere it appears
20"508.0 mmRetail half-pallet depth
36"914.4 mmBeverage / DSD footprint
40"1016.0 mmGMA width
42"1066.8 mmSquare 42, chemical
44"1117.6 mmDrum pallet
45"1143.0 mmAutomotive
48"1219.2 mmGMA length
5½"139.7 mmGMA deck height
⅝"15.9 mmNominal board thickness
2½"63.5 mmStandard fastener length

Rack clearance arithmetic

Beam-to-beam clear span
Measure inside faces
Two 48×40 pallets side by side
96" of pallet
Minimum beam span for two
≥ 96", plus entry clearance
Deck beyond the beam face
0" — never acceptable
Load beyond the deck edge
≤ 1" per side
Flue space, back to back
≥ 6" in most codes
Usable load height
Beam clearance − 5½ in − 4 in
Loaded 48×40 through a doorway
≥ 50" clear opening

Measure the building first, the equipment second, the trailer third and the product last. Everybody does it backwards.

Six measurements to take before ordering

  • Beam-to-beam clear span, inside faces
  • Beam depth front to back, and usable bearing surface
  • Clear height from beam top to the underside of the beam above
  • Flue space between back-to-back bays
  • Fork spread and mast clearance of the truck serving the bay
  • The narrowest doorway, lift or gate on the route

Cross-reference

Which footprint each industry actually runs

Compiled from sixteen years of order history. If your sector is here and you are using something else, there is usually a reason — but it is worth knowing you are the exception.

Primary footprint first, then what we also ship into that sector. Export columns assume ISPM-15 heat treatment.
IndustryPrimary footprintAlso commonExport footprintTypical grade
Grocery distribution48×40 GMA48×20 half1200×800 EUR#1 / A
Beverage & DSD36×3648×40, 40×401200×1000 ISOA
Food manufacturing48×40 GMA42×421200×800 EURA / #1
Chemicals & drums48×4842×42, 44×441200×1000 ISO#1, new for racking
Automotive45×4548×45, custom1200×1000 ISONew or hybrid
PharmaceuticalCustom / new48×40 GMA1200×800 EURNew, documented
Retail display48×20 half24×20 quartern/aA, branded
Agriculture & produceVentilated bins48×40 #21200×1000 ISO#2 in field, #1 in store
Building products48×40 GMA60×48, custom skidsCrates#1 / #2
Machinery & heavy point loadsCustom skids48×48Export cratesNew, engineered
Paper & printing48×40 GMA40×481200×800 EUR#1, dry only
Cold chain48×40 GMAPlastic at the zone boundary1200×1000 ISO#1, companions only

Footprint share of our own intake

48" × 40" GMA
72%
42" × 42"
6%
48" × 48"
5%
36" × 36"
4%
48" × 20" half
3%
1200 × 800 EUR
3%
Everything else
7%

Twelve-month weighted figures. Odd sizes arrive as they arrive — ask before planning around them.

Signs you have inherited the wrong footprint

  • Your rack bays have visible empty steel at each end
  • Pallets overhang a beam anywhere in the building
  • Trailer layers leave a gap you cannot use
  • Nobody can say why the size was chosen
  • Only one supplier in the region can fill it
  • Your own cores have no resale value

Yard reference

Every number we publish, in one place

The same appendix appears at the foot of our reference pages so you never have to leave an article to check a figure. All of it is revised annually and matches the constants used by the Carbon Ledger.

Stock specification

Stock footprint
48" × 40" (1219 × 1016 mm)
Deck height, GMA stringer
5½" (140 mm)
Deck height, block pallet
5¾" (146 mm)
Deck height, EPAL 1
144 mm
Board thickness, nominal
⅝" (16 mm)
Top deck boards, #1 grade
6–7
Bottom deck boards, #1 grade
4–5
Stringers per pallet
3, notched or solid
Species
Mixed hardwood, oak-dominant
Mass, recycled 48×40
33–42 lb / 15–19 kg
Mass, new 48×40
37–48 lb / 17–22 kg
Mass, EPAL 1
22–25 kg / 49–55 lb
Moisture ceiling at dispatch
≤ 19%
Fasteners
Helical-thread 2½"

Typical values for our 48×40 recycled stock. Exact board counts vary by grade and batch.

Order terms

Metro delivery minimum
100 pallets
Pickup minimum (selling to us)
50 pallets
Drop-off minimum
None, during yard hours
Out-of-region freight
Full trailer
Quote validity
14 days
Standing-order pricing
Fixed for the quarter
First order terms
Prepaid or card
Account terms
Net 30, approved
Buy-back payment
Cheque or ACH, 10 business days
Sample before contract
20 pallets, free
Grade dispute remedy
Same-day re-grade, replace or credit
Reserved stock
Up to 8 weeks against a confirmed order

Standing-order customers get fixed quarterly pricing.

The yard, in facts

Address
9869 Meeks Blvd, St. Louis, MO 63132
Founded
2009
Zero landfill since
March 2017
Grading lanes
Four, plus new and heat-treated
Named defects on the wall
Thirteen
Covered storage
Two roofed bays
Dock doors
Four at 48 in, plus drive-on
Weighbridge
On site, certified
Trailers owned
Nine, plus two flatbeds
Trailer staging spaces
Twelve
Pallets handled last year
412,000
Hardwood kept in circulation
4,780 tons
Decks repaired weekly
≈ 3,000
Intake leaving as pallets
94%
Mean further lives per deck
4.7

Counted at the weighbridge and the grading line.

Grades, side by side

Load figures are observed operating capacities for a 48×40 footprint under a uniformly distributed load. Apply your own safety factor — 1.5 for dynamic handling, 2.0 for long-term racked storage. Price index: 100 = new hardwood.
GradeTop / bottom boardsRepairs allowedStaticDynamicRackedPrice index
A / Premium7 / 5None visible4,600 lb2,800 lb1,800 lb42–52
#1 Grade6–7 / 4–5Full-length companions4,000 lb2,500 lb1,500 lb30–40
#2 Grade5–6 / 3–4Plugs and companions3,200 lb1,800 lbNot advised20–28
Core / MixedAs arrivedUnsortedUnratedUnratedNo12–20
New hardwood7 / 5n/a5,000+ lb3,000 lb2,200 lb100
Heat-treated #16–7 / 4–5Companions, re-treated4,000 lb2,500 lb1,500 lb38–48

Carbon model constants

Sources: industry LCA literature plus our own weighbridge and fuel records. Substitute your own figures — the Carbon Ledger shows the arithmetic.
FactorValueBasis
New hardwood pallet, embodied12.6 kg CO₂eCradle-to-gate, regional oak
Recycled deck, processed1.0 kg CO₂eRepair, handling, yard energy
Net credit per reuse cycle11.6 kg CO₂eDifference of the two above
Heat treatment, per deck0.9 kg CO₂eOur chamber, measured
Average pallet mass15 kg / 33 lb12-month weighted mean
Road freight0.11 kg CO₂e / ton-mileOwn fleet fuel records
Landfill volume, broken deck0.12 yd³Uncompacted, measured
Mature tree sequestration21.8 kg CO₂e / yrIllustration only
Break-even haul distance≈ 950 milesBeyond this, reuse credit is cancelled
Run the numbers on your own volumes →

ISPM-15 heat treatment

Core temperature
56 °C minimum
Hold time
30 continuous minutes
Probe points
Three per batch, deepest board
Batch capacity
≈ 420 pallets
Mark elements
IPPC symbol, country, facility, HT
Marks required on
Two opposite sides, legible
Bark
Prohibited on every component
Records retained
24 months
Invalidated by
Repair with untreated wood
Dunnage & bracing
In scope — must also be treated

Batch logs retained 24 months. A treated pallet repaired with untreated wood must be re-treated and re-marked.

Service rings from Meeks Blvd

Beyond roughly 950 miles, freight emissions cancel the carbon benefit of reuse. We will say so and recommend a nearer yard.
RingDistanceExample marketsDelivery windowPickup window
One0–60 miSt. Louis, St. Charles, Metro EastNext business day48 business hours
Two60–180 miColumbia, Springfield IL, Cape Girardeau2–4 business daysWithin the week
Three180–300 miKansas City, Memphis, IndianapolisWeekly scheduled runBy arrangement
Beyond300+ miQuoted case by caseBy arrangementFull trailers only

Species in our intake, and how they behave

Densities and Janka figures are published wood-science values; the behaviour column is sixteen years of our own grading notes. Our intake is oak-dominant mixed hardwood.
SpeciesGroupDensity (lb/ft³)Janka hardnessBehaviour in a pallet
White oakHardwood471,350 lbfOur backbone: holds fasteners superbly, heavy, very durable
Red oakHardwood441,290 lbfSlightly more porous than white; excellent deck boards
HickoryHardwood511,820 lbfHardest of our intake; superb stringers, splits if nailed dry
MapleHardwood441,450 lbfClean, pale, dimensionally stable; good for upcycled tops
AshHardwood411,320 lbfTough and flexible; forgiving under impact
PoplarHardwood29540 lbfLight hardwood, weaker fastener grip, fine for one-way
Southern yellow pineSoftwood35690 lbfCommon in new softwood builds; resinous, holds nails well
Spruce / firSoftwood27510 lbfLightest option; loosens soonest under repeated handling

Moisture targets by application

Dryness is the single biggest determinant of recycled pallet quality — more than grade, species or board count.
ApplicationTarget moistureWhy
Food distribution≤ 19%Mould risk, not strength; covered storage mandatory
Pharmaceutical / clean areas≤ 15%Documented dryness, often new material
General warehouse and racking≤ 19%Fastener grip and creep resistance
Cold chain≤ 15% at dispatchCondensation cycling through the dew point
Export, heat-treated≤ 19%Post-chamber typical; bark-free is the hard rule
Upcycled furniture stock8–12%Conditioned indoors two weeks before machining
Field and agricultural useNo targetWeather governs; buy #2 and expect it

Fasteners — two percent of the cost, most of the service life

Specify the fastener and the count per board-stringer intersection, not just the board count.
FastenerLengthShankWithdrawal resistanceWhere we use it
Helical-thread nail2½"Twisted, thread-cuttingHigh, survives moisture cyclingStandard on every new build and repair
Annular-ring nail2¼"–2½"Barbed ringsHighestLead boards and heavy racked specifications
Smooth-shank nail2"–2½"PlainLow, drops as wood driesNot used — the reason old pallets loosen
Screw-shank nail2½"Coarse helixHighBlock pallets and thick stringers
Staple1¾"Crown wireLow in hardwoodNot used here; acceptable in softwood one-way pallets

Standards that actually govern a pallet

Only ISPM-15 is legally mandatory, and only for export. Everything else is a specification you can choose to be held to.
StandardIssued byCoversWhy it matters to you
ISPM-15IPPC / FAOPhytosanitary treatment of wood packagingMandatory for export; 56 °C core for 30 minutes, marked
ISO 6780ISOPrincipal pallet footprintsDefines the six international sizes, including 1200×800
ISO 8611ISOPallet test methods and performanceThe basis of static, dynamic and racked load figures
ASTM D1185ASTMTest methods for pallets and skidsNorth American equivalent test battery
GMA specificationGrocery Manufacturers Assoc.48×40 four-way notched stringer palletWhat 'GMA' means when stated properly
EPAL / UIC 435EPALLicensed European block palletExchange-pool eligibility, marks and licensed repair
MH1ANSI / MHIPallet terminology and dimensionsThe vocabulary used on our build sheets
NWPCA uniform standardNWPCARecycled pallet grading practiceThe nearest thing the recycled market has to a rulebook

Handling and rack dimensions

Measure your own equipment before specifying a pallet. These are the values that decide whether a footprint works in your building.
DimensionTypical valueNote
Fork length42"–48"Must not protrude beyond the far side of a 48" pallet
Fork width4"–6"Wider forks spread load across deck boards
Fork thickness1½"–2"Determines minimum pallet entry height
Fork spread, GMA entry24"–27" centresBetween the stringers of a three-stringer pallet
Pallet-jack wheel path6½" clearWhy notched stringers do not admit jacks
Minimum entry height3½"A crushed bottom deck blocks the forks entirely
Rack beam span, two pallets≥ 96" clearFor two 48×40 pallets, 40" face out
Flue space, back to back≥ 6"Most fire codes; check your jurisdiction

The life of one deck, stage by stage

Durations are medians from our line records and the Passport programme; the population is survivor-biased and we say so.
StageTypical durationWhat happensCarbon position
Timber to palletWeeksSawn, nailed, often shipped wet12.6 kg CO₂e embodied
First life2–4 yearsHardest service; lead board usually failsCredit begins at reuse
First repair2 minutesLead board replaced with salvaged stock+1.8 further lives on average
Second to fifth life6–12 yearsGrading, companions, re-nailing, re-grading11.6 kg CO₂e avoided per cycle
Structural retirement—Stringers rotted or deck beyond rebuildStored carbon still retained
RepurposedDecadesCollars, crates, table tops, claddingCarbon stays in the material
Fiber1–3 yearsMulch or bedding, then soilReleased slowly
ThermalImmediateBoiler-grade chipReleased at once — last resort

Total cost of a pallet programme, indexed

Index 100 = reactive spot buying. Observed across our managed accounts; your mix will differ, and we will model it against your own invoices for free.
Cost lineSpot buyingManaged programmeComment
Pallet purchase priceIndex 10078–86Grade matched to the job, not to panic
Emergency purchases6–11% of spend≈ 0%Reserved stock removes the Friday scramble
Disposal and haulageIndex 1000–20Cores are bought, not binned
Internal labour on woodIndex 10045–60Sorting at source, scheduled collection
Product damage from palletsIndex 10060–80Fewer failures from under-specified decks
Admin and reconciliationIndex 10030One netted invoice a month
Reporting effortIndex 10010Diversion and CO₂e arrive automatically
Net first-year change—−18% to −34%Observed across our managed accounts

End-of-line fiber products

Two percent of intake, screened rather than dumped.
Fiber productScreen sizeMade fromSold to
Landscape mulch, coarse1"–2"Ground hardwood pallet stockLandscapers, garden centres
Landscape mulch, fine⅜"–1"Screened second passRetail bagging, municipal beds
Animal bedding⅛"–⅜"Fine screen, metal-freeLivestock and poultry operations
Boiler-grade chipMixedMaterial failing every screen aboveIndustrial thermal users
Recovered steeln/aMagnetically separated fastenersLocal scrap processor

Conversions we use daily

Inches to millimetres is exact. Rounding 1219 mm to 1200 mm is how container plans fail.
FromToMultiply by
InchesMillimetres25.4 exactly
PoundsKilograms0.4536
Short tonsMetric tonnes0.9072
Cubic yardsCubic metres0.7646
Ton-milesTonne-kilometres1.4594
°F to °C—(°F − 32) × 5⁄9
Board feetCubic metres0.00236
lb/ft³kg/m³16.018

The thirteen named defects on our grading wall

  1. 01Cracked stringer through a nail line
  2. 02Stringer break longer than one board width
  3. 03Soft rot or fungal staining
  4. 04Missing deck board
  5. 05Split lead board
  6. 06Plug or scab repair
  7. 07Protruding or missing fastener
  8. 08Board thinner than specification
  9. 09Mixed board widths on one deck
  10. 10Pallet will not sit flat on a jig
  11. 11Visible chemical residue or paint
  12. 12Moisture above threshold
  13. 13Bark present on any component

A pallet is only downgraded for a defect a grader can name out loud. If it is not on this list, it is not a reason to move a pallet between lanes.

Glossary — thirty terms worth knowing

Core
A used pallet bought for grading — the currency of the industry.
Deck board
Any board on the top or bottom face of a pallet.
Lead board
The outermost deck board at each end; absorbs every fork entry.
Stringer
The long member running the length of a stringer pallet; usually three.
Stringer board
On a block pallet, the board that ties the blocks together.
Block
One of the nine supports in a block pallet.
Notch
The cut-out in a stringer that creates four-way fork access.
Chamfer
A bevel on a lead board's lower edge to ease fork entry.
Companion
A full-length board nailed alongside a damaged stringer. A strong repair.
Plug / scab
A short piece fixed over a break. A weaker repair; #2 grade here.
Re-nail
Restoring the fastener pattern on a loose but intact pallet.
Regrade
Moving a pallet between grade lanes after inspection.
Down-cut
Re-cutting a larger deck into a smaller footprint.
Static load
Capacity at rest on a flat, continuous surface.
Dynamic load
Capacity while being lifted and moved.
Racked load
Capacity spanning beams with no deck support. Always the smallest figure.
Unit load
Pallet, product and wrap considered as one structure.
Overhang
Load or deck projecting beyond its support. The leading cause of rack failure.
Flue space
The gap between back-to-back rack bays; six inches minimum in most codes.
GMA
The Grocery Manufacturers Association 48×40 specification.
EPAL
The licensing body for the European 1200×800 block pallet.
ISPM-15
The international phytosanitary standard for wood packaging.
HT
Heat treatment: 56 °C at core for 30 minutes.
IPPC mark
The wheat-sheaf stamp evidencing phytosanitary treatment.
Collar
Four hinged timber sides that turn a pallet into a container.
Top cap
A lightweight cover protecting the uppermost layer of a stack.
Dunnage
Timber used to fill voids, brace loads and spread point loads.
Fiber
Ground wood: mulch, animal bedding or boiler-grade chip.
Diversion rate
Share of intake kept out of landfill. Ours is 100%.
Reuse rate
Share of intake that leaves as a pallet. Ours is 94%.

Still wondering?

Eight questions that arrive most weeks. The full set lives on the FAQ page, and anything missing can go straight into the form at the top of this page.

Asked most weeks

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