Glossary
Load overhang
Also called: pallet overhang, product overhang, underhang
Reviewed
Definition
Load overhang is when the product or cartons on a pallet extend beyond the pallet's edges. It leaves the overhanging carton walls without support, which reduces their stacking strength and exposes them to damage from forks, racks and neighboring loads. The opposite, underhang, leaves bare deck around the load.
Why overhang hurts
- Box strength: corrugated boxes carry most of their stacking load through their walls and corners. When a wall hangs past the deck edge it has nothing under it, so the box is weaker than its rating.
- Damage: overhanging cases catch on rack uprights, trailer walls and other loads
- Instability: wrap and straps pull overhanging edges inward and can crush them
Overhang vs deck overhang
| Term | What sticks out |
|---|---|
| Load overhang | the product, past the pallet edge |
| Deck overhang (wing) | the pallet deck, past its own stringers |
How to avoid it
- Choose a pallet footprint that fits the carton pattern, or change the pattern to fit the pallet
- Specify overhang limits in the unit load spec (PDS and LoadSync unit load details include overhang)
- When the product footprint is fixed, design a custom pallet size to match it
palletdesign.ai lets you set a custom footprint to match the load. See choosing a pallet size and unit load design.
Questions
- Is it OK for boxes to hang over a pallet?
- It is best avoided. Overhanging box walls lose support, which lowers stacking strength and makes damage more likely.