Solid deck
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.
Also called closed deck, solid top, no-gap deck
Reviewed
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.
Related
- Panel deckA panel deck is a pallet deck of plywood or OSB instead of boards. The Uniform Standard requires face grain across the stringers and pieces 24 in wide or more.
- 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.
- Solid deck pallet: no gaps between deckboardsA solid deck pallet has deckboards butted edge to edge with no gaps. On a 48x40, twelve 4 in boards cover the deck. When the extra lumber pays off, and specs.
- Drum pallet: 48 x 48 pallets for four 55-gallon drumsA drum pallet is usually a 48x48 in wood pallet for four 55-gal drums, with 3/4 in top boards, 4 stringers and tight deck gaps so drum chimes can't drop in.
- StaplePallet staples are two-legged wire fasteners, often adhesive-coated. The Uniform Standard requires a crown of at least 3/8 in, set across the grain.
- Strap slotA strap slot is a recess in the top of a stringer or under the top deck that lets strapping or banding pass under the deck to secure the load to the pallet.
Sources
- Crate Pro: pallet terminology
- Uniform Standard for Wood Pallets (NWPCA, now Woodpack Global), 2012 edition