How to Determine Specifications for a Custom Pallet or Crate

Dimensions, Weight, & Load Requirements

Accurate specifications allow a pallet or crate to be built correctly the first time.

Custom packaging is designed around the load. The more clearly the load requirements are defined, the more accurately the support structure can be matched to it.

Below are the key details that determine construction.

  1. Overall Dimensions

    Start with the full dimensions of the item being shipped:

    • Length

    • Width

    • Height

    Measurements should reflect the complete footprint of the equipment, including any protrusions, mounting brackets, or attached components.

    Clear dimensions ensure:

    • Proper base support

    • Adequate stability

    • Appropriate crate clearance, if required

    If multiple units are being shipped together, include spacing or stacking configuration.

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  2. Total Weight

    Provide the total weight of the load.

    Weight determines:

    • Deck board thickness

    • Number and type of stringers or runners

    • Reinforcement requirements

    • Fastener specifications

    If the weight is approximate, indicate that clearly.

    For more on how weight affects pallet design, see: How Much Weight Can a Pallet Really Handle? Load Limits Explained.

  3. Load Distribution

    Total weight is only part of the equation.

    How that weight is distributed matters just as much.

    Important considerations include:

    • Does the equipment rest on narrow steel channels or small mounting feet?

    • Is the weight evenly distributed or concentrated at specific points?

    • Is the unit top-heavy or asymmetrical?

    Concentrated load points often require blocking or additional support members to prevent deflection during handling.

  4. Handling Requirements

    How will the pallet or crate be handled?

    Specify:

    • Forklift access (2-way or 4-way entry)

    • Pallet jack compatibility

    • Crane lifting points

    • Stacking requirements

    • Warehouse racking storage

    A pallet that will be stored in racking must be designed differently than one that will remain floor-loaded.

    For more detail, see: Are Your Pallets Safe for Racking? Rackable vs. Non-Rackable Pallets Explained.

  5. Shipping Method & Destination

    Freight conditions influence construction decisions.

    Indicate whether the shipment will move via:

    • LTL freight

    • Flatbed

    • Ocean container

    • Air freight

    International shipments typically require heat-treated lumber compliant with ISPM-15 standards.

    For more information, see: Export Pallets & Crates: ISPM-15, Heat Treatment, & Shipping Requirements.

  6. Protection Requirements

    Determine whether the load requires:

    • Basic structural support only

    • Partial enclosure

    • Full crate enclosure

    • Internal bracing

    • Protection for exposed components

    If you’re unsure whether a pallet or crate is more appropriate, see: When Do You Need a Crate Instead of a Pallet?

Common Specification Mistakes

Clear specifications help avoid unnecessary cost or risk.

Frequent issues include:

  • Not accounting for load concentration

  • Ignoring center of gravity

  • Overlooking forklift entry requirements

  • Underestimating total shipment weight

  • Overbuilding beyond what the application requires

The objective is proper structural support — not maximum material use.

Request a Quote

If you have dimensions and weight available, we can review your specifications and provide pricing based on your exact requirements.

If certain details are unknown, we can help determine what is necessary.

Request a Quote

Or call us at (630-765-5476