Deck gap
A deck gap is the open space between two neighboring deckboards. With the end boards flush and interior boards equally spaced, the gap is (deck length minus total board width) divided by (number of boards minus 1): a GMA-style 48x40 top deck works out to (48 - 28.5) / 6 = 3.25 in.
Also called board spacing, deckboard spacing, gap
Reviewed
How to calculate deck gaps
Gap = (deck length - sum of board widths) / (boards - 1)
| Top deck on a 48 in length | Boards | Gap |
|---|---|---|
| 2 x 5-1/2 + 5 x 3-1/2 in (GMA style) | 7 | 3.25 in |
| 2 x 5-1/2 + 6 x 3-1/2 in | 8 | about 2.36 in |
| 2 x 5-1/2 + 7 x 3-1/2 in | 9 | 1.75 in |
The bottom deck of a stringer pallet uses a different rule: interior boards cluster between the notches, so gaps there are smaller (3.75 in on a GMA-style bottom) with larger openings over the notches.
How big should deck gaps be?
There is no single rule; it depends on the load. palletdesign.ai flags top gaps over 5 in because cartons and bags may sag through, and over 2.5 in under drums, where chimes can drop into gaps. Tighter gaps mean more boards, more board feet and more nails.
Why gaps matter
Gaps under carton walls reduce box stacking strength, and wide gaps let bags bulge and tear. See deck coverage, deckboard and the deck board spacing guide.
Questions
- What is the standard gap between pallet boards?
- On a GMA-style 48x40 top deck the gap is 3.25 in. Other designs vary with the board count and widths.
- How do I reduce pallet deck gaps?
- Add a top deckboard or use wider boards. On a 48 in deck, going from 7 to 9 boards of the same widths shrinks the gap from 3.25 to 1.75 in.
Related
- Deck coverageDeck coverage is the share of a pallet deck's area covered by boards. A GMA-style 48x40 top deck covers about 59%: 28.5 in of boards over a 48 in length.
- 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.
- 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.
- 48 × 40 pallet48 × 40 in (1219 × 1016 mm) pallet specs with drawings: stringer pallet 59 lb, block pallet 96 lb, skid 79 lb. Nail counts, board feet and parts lists for each build.
- DeflectionDeflection is how far a pallet sags under load. Typical limits are about 2% of span in racking (about 0.75 in on a 44 in span) and 0.5 in for automated systems.