Deck coverage
Deck coverage is the share of a pallet deck's area that is covered by boards, the rest being gaps. It equals total board width divided by deck length: a GMA-style 48x40 top deck (two 5-1/2 in and five 3-1/2 in boards) covers 28.5 of 48 in, about 59%, and its bottom deck about 45%.
Also called deck surface coverage, percent coverage
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How to calculate deck coverage
Deck coverage = sum of board widths / deck length x 100.
| Deck (GMA-style 48x40) | Boards | Board width total | Coverage |
|---|---|---|---|
| Top | 2 x 5-1/2 + 5 x 3-1/2 in | 28.5 in | about 59% |
| Bottom | 2 x 5-1/2 + 3 x 3-1/2 in | 21.5 in | about 45% |
| Solid deck | boards edge to edge | 48 in | 100% |
Why coverage matters
- Product support: higher coverage supports small cartons and bags better and reduces how far they sag into gaps
- Box strength: cartons stand on the deckboards, so gaps under box walls weaken the bottom layer
- Cost and weight: every extra board adds board feet, nails and pounds
- Drainage and airflow: gaps let water drain and air circulate, which matters for green wood and some products
Deck coverage vs load coverage
Deck coverage describes the pallet. Load coverage describes how much of the deck the product occupies, which PDS captures as "Uniformly Distributed, Full Pallet Coverage" versus partial loads. See deck gap and deck board spacing.
Questions
- What is the top deck coverage of a GMA pallet?
- About 59%: seven boards totaling 28.5 in of width across a 48 in deck.
Related
- Deck gapA deck gap is the open space between adjacent deckboards. A GMA-style 48x40 has 3.25 in top gaps: (48 - 28.5 in of boards) / 6 spaces with ends flush.
- Top deckThe top deck is the load-carrying surface of a pallet: the top deckboards or panel fastened to the stringers or blocks. A GMA 48x40 has 7 top boards.
- Solid deckA solid deck pallet has no gaps between top deckboards, or uses one panel. It carries small cartons, bags and drums that would sag into or drop through gaps.
- Pallet deck board spacing: how to calculate the gapsPallet deck board spacing: gap = (length - total board width) / (boards - 1). A 48x40 GMA top deck with 7 boards has 3.25 in gaps. Worked examples and limits.
- Deck matA deck mat is the top deckboards and stringerboards of a block pallet pre-assembled as one unit, usually with clinched nails, before being nailed to the blocks.
- DeckboardA deckboard is a board in a pallet's top or bottom deck, laid across the stringers or stringerboards. Typical size is 5/8 x 3-1/2 x 40 in.