Overhang, Overload, and Other Pallet Sizing Mistakes
Most buyers pick a pallet size based on what they've always used, or what their current supplier carries in stock. That works until it doesn't. When loads start failing, overhang and overloading are two of the most common reasons. Here's how to size a pallet correctly.
How much overhang is too much
The standard answer is one inch on any side. That's the general guideline from most carriers and industry standards, and it exists for a reason. When a load overhangs the pallet, the overhanging weight is unsupported. The edge of the pallet becomes a fulcrum. In transit, vibration and braking forces amplify that stress.
The damage pattern for overhang loads is predictable: crushed corners, compression marks on the bottom layer of cartons, and loads that arrive leaning or partially collapsed.
If your cartons consistently overhang a 48x40, you have two options: reconfigure the load to fit within the footprint, or switch to a pallet that matches your load dimensions. Common alternatives include:
- 42x42 — good for square carton configurations
- 48x48 — wider footprint for loads that spread
- Custom sizes — available when stock sizes don't fit the load
Overloading and the static vs. dynamic rating
Every pallet has two weight ratings: static and dynamic. Static is what the pallet can support sitting still. Dynamic is what it can handle while being moved, forked, and shipped. Most buyers know their pallet's static rating. Fewer know the dynamic one.
| Rating type | What it means | When it applies |
|---|---|---|
| Static | Weight the pallet supports while stationary | Storage, racking |
| Dynamic | Weight the pallet handles while being moved or shipped | In transit, forklift handling |
| Dynamic ratings are typically 60-70% of static ratings. A pallet rated 2,500 lbs. static may only handle 1,500 lbs. in transit. | ||
If your load is near the rated capacity of the pallet you're using, check which rating you're comparing to. A lot of buyers look at static ratings and apply them to dynamic applications. That's how pallets fail under loads that seem like they should be fine. More on pallet weight ratings.
Pallet height and stacking
Pallet height affects stability in a racking system and determines how loads stack in a trailer. The standard GMA pallet is 5.5 inches tall, but deck board thickness and notching can vary. If you're stacking loads in transit or in storage, verify that the top deck of the pallet can handle the stack pressure from above. Are standard pallets stackable?
When a standard pallet isn't enough
Sometimes the right answer is that a standard pallet, in any size or grade, isn't the right solution. Heavy machinery, irregular shapes, fragile equipment, and export freight often need a custom or engineered pallet, or in some cases a crate. When a standard pallet isn't enough.
The cost of a better pallet or a custom build is almost always less than the cost of a failed shipment.
When we quote a pallet order, we ask about the load: what's going on it, how much it weighs, and how it ships. If we think the spec you're considering is wrong for your application, we'll say so.
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