Top deck

How the top deck is specified

A top deck is described by its style and its board list:

• Style: Deckboard, Deckboard/Stringerboard, Panel, or Panel/Stringerboard (the last two for block pallets)
• Boards: count, thickness, width and length for each width group, e.g. 5 at 5/8 x 3-1/2 x 40 plus 2 at 5/8 x 5-1/2 x 40
• Spacing rule: usually end boards flush with the pallet ends and interior boards equally spaced
• Extras: wing overhang, strap slots, chamfers (rare on top)

With ends flush and equal spacing, the gap is (pallet length minus total board width) divided by (boards minus 1). For the GMA-style layout: (48 - 28.5) / 6 = 3.25 in.

Why the top deck matters

The top deck supports the product directly, so gap size decides whether cartons, bags or drum chimes are well carried. It also governs capacity when the pallet is racked across its width, because the deckboards then span between the outer stringers. palletdesign.ai uses the top deck section for its indicative rack-across-width check. Deck coverage and deck gap are the two numbers buyers most often adjust.

Top deck vs bottom deck

The bottom deck usually has fewer boards (5 on a GMA-style 48x40) and openings for fork notches and pallet-jack wheels. A reversible pallet has identical decks.