palletdesign.ai

Glossary

Solid deck

Also called: closed deck, solid top, no-gap deck

Reviewed

Definition

A solid deck is a pallet deck with no gaps between the deckboards, made either from boards butted edge to edge or from a single plywood or OSB panel. It is used for small cartons, bags, drums and loose items that would sag into or drop through a spaced deck.

On this page
  1. Ways to build a solid deck
  2. When a solid deck is worth it
  3. Trade-offs

Ways to build a solid deck

Method Notes
Boards butted edge to edge uses the most lumber; green boards can open small gaps as they dry
Panel deck (plywood or OSB) one flat sheet, fewer pieces to nail

When a solid deck is worth it

  • Small or soft packages that sag into a spaced deck
  • Drums and pails, whose chimes can drop into gaps (palletdesign.ai warns when top gaps exceed 2.5 in under drums)
  • Loose parts or display pallets that need a continuous surface
  • Loads that must not get marked by board edges

Trade-offs

A board-built solid deck adds lumber, weight and cost compared with a spaced deck such as the GMA-style 48x40 (7 boards, 3.25 in gaps). A solid deck also does not drain. See deck gap and solid deck pallet.

Questions

When do you need a solid deck pallet?
When the load would sag into or fall through gaps: small cartons, bags, drums, pails or loose parts.

Sources