How to design a wood pallet, step by step

Designing a pallet is a sequence of decisions, each one constrained by the one before it. Get the requirements right and most of the geometry follows. Skip them and you end up with a pallet that is either overbuilt (expensive) or fails in the rack.

This guide walks through the full process using the most common North American pallet, the 48 x 40 in (1219 x 1016 mm) GMA-style stringer pallet, as the running example. Each step links to a deeper guide.

Step 1: Write down the requirements

Everything else depends on these. The Uniform Standard for Wood Pallets asks the user to state three groups of conditions: the load, the support, and the performance expected.

The unit load design guide covers how the load and its packaging interact with the pallet.

Step 2: Choose the footprint

The footprint is length x width, with the length stated first and defined as the stringer length. It should match the product and the equipment, not the other way round. Start from the product footprint, avoid overhang, and check trailer and rack fit. For most US grocery and consumer goods the answer is 48 x 40. See choosing a pallet size and pallet dimensions explained.

Step 3: Choose the class and entry

There are two pallet classes:

• A stringer pallet uses continuous beams (stringers) under the deck. It is cheaper and lighter. Plain stringers give two-way entry; notched stringers give partial four-way entry (forklifts from all sides, pallet jacks from the ends only).
• A block pallet sits on 9 blocks and gives full four-way entry. It is heavier and costs more, and it is the construction used by the big rental pools.

The stringer vs block guide compares them side by side. For the running example, notched stringers give partial four-way entry.

Step 4: Lay out the top and bottom decks

Pick the deckboard count, thickness and widths, then space them. The usual rule is lead boards flush with the ends and interior boards equally spaced:

gap = (pallet length minus the sum of board widths) / (number of boards minus 1)

For the example, 2 lead boards at 5-1/2 in plus 5 interior boards at 3-1/2 in total 28.5 in, so the gap is (48 - 28.5) / 6 = 3.25 in. Deck thickness is 5/8 in. The bottom deck uses 5 boards: two 5-1/2 in leads plus three 3-1/2 in interior boards clustered between the notches so they do not block fork entry. More in deck board spacing.

Step 5: Size the stringers or blocks

Stringers carry the load in a rack, so their size and count govern racked capacity. The GMA-style pallet uses 3 stringers, 1-3/8 x 3-1/2 x 48 in, notched 1-1/4 in deep and 9 in long, 6 in from each end. Overall height is 5/8 + 3-1/2 + 5/8 = 4.75 in. Heavier loads call for a fourth stringer, a deeper stringer, or a denser species. For block pallets you size the blocks, the stringerboards and the bottom deck style instead.

Step 6: Set the fastener schedule

The Uniform Standard's Table 5 sets the minimum nails per deckboard-to-stringer joint by board width: 2 up to 5-1/4 in wide, 3 from 5-1/4 to 7 in, 4 from 7 to 8 in. For the example:

• Top: 2 lead boards x 3 stringers x 3 nails = 18, plus 5 interior boards x 3 x 2 = 30, so 48
• Bottom: 2 x 3 x 3 = 18, plus 3 x 3 x 2 = 18, so 36
• Total: 84 nails

Nail length must give at least 1-1/4 in of penetration into the stringer, so a 5/8 in deck needs at least a 1-7/8 in nail; 2-1/4 in helically threaded nails are common. See the pallet nail schedule.

Step 7: Specify the lumber

Choose the species (or species mix), grade, moisture condition and any treatment. Mixed hardwood, southern yellow pine and SPF are common. Green lumber is cheapest; kiln-dried is lighter and resists mold; export shipments need ISPM-15 heat treatment. See pallet lumber.

Step 8: Check it

Before drawing, check:

• Geometry: boards do not overlap, bottom boards clear the notches, at least 2 in of stringer remains above each notch, gaps suit the load (keep them tight for drums and point loads).
• Fasteners: nails per joint meet Table 5; penetration is adequate.
• Capacity: the load is within the pallet's capacity for each support condition. Racked capacity is usually the limiting case. See pallet load capacity, racking pallets and pallet deflection.
• Weight and cost: compute board feet, weight and an estimate. The example is 13.5 board feet and about 59 lb in green mixed hardwood. See board feet, pallet weight and pallet cost.

Simple checks catch most mistakes, but a certified load rating comes from a Pallet Design System (PDS) analysis or a physical test to ASTM D1185 or ISO 8611.

Step 9: Produce the drawing, parts list and RFQ

A buildable design needs a to-scale drawing (top, front and side views with dimensions and nail positions), a bill of materials, a cut list and the fastener spec. Then send it to mills with a clear request for quote. See how to read a pallet drawing and how to write a pallet RFQ.

palletdesign.ai runs these steps from a plain-language description: it proposes a construction, checks it against the Uniform Standard nail rules and geometry, and outputs the drawing, parts list, nail count, weight and an indicative cost.

The running example, summarized