Industries
Pallets for the automotive industry
Reviewed
The footprint most associated with automotive parts is 48 x 45 in (1219 x 1143 mm), a size also used under bulk bins and gaylords; 48 x 40 in is used for aftermarket and retail shipments. Automotive loads are heavy, often concentrated, and move in closed loops, so durability and a clear spec matter more than lowest price.
Common pallet sizes
| Size | Metric | Typical automotive use |
|---|---|---|
| 48 x 45 in | 1219 x 1143 mm | Bulk bins, gaylords and returnable containers for parts |
| 48 x 40 in | 1219 x 1016 mm | Aftermarket parts into retail and distribution |
| 48 x 48 in | 1219 x 1219 mm | Drums of fluids and lubricants |
| 60 x 48 in, 72 x 48 in | 1524 x 1219, 1829 x 1219 mm | Long or oversized components, racks and assemblies |
| 1200 x 1000 mm | 47.24 x 39.37 in | Parts shipped to and from Europe and Asia |
Many automotive programs use the part supplier's or the assembly plant's own container footprint. When a bin or container sits on the pallet, size the pallet to the container base, not the other way round.
Construction and spec notes
Load types
Automotive pallets carry some of the hardest loads in general manufacturing:
- Bulk bins and gaylords of small parts: heavy, and the weight is spread over the container base.
- Castings, forgings and machined parts in dunnage: dense, with the weight on small contact areas. Model these as concentrated or line loads, not as a uniform load.
- Assemblies on fixtures or in crates: often bolted down, which suggests a skid or a pallet with a heavy top deck.
Describe the load as it actually bears on the deck. A 2,000 lb bin on four feet loads a pallet very differently from 2,000 lb of cartons.
Construction choices
- Block pallets give full four-way entry and work well with automated handling. Stringer pallets with 4 or 5 stringers suit heavy one-way loads.
- Thicker decks and more fasteners for concentrated loads. The Uniform Standard's minimum is 2 nails per joint on boards up to 5-1/4 in wide and 3 on boards up to 7 in; heavy automotive designs often go beyond that.
- Strap slots where parts are banded to the pallet. See strap slot.
- Flatness. Automated storage and conveyors need a flat, square pallet with limited deflection. Virginia Tech cites 0.5 in or less for automated systems. The Uniform Standard allows 1/4 in corner-to-corner flatness at assembly.
Returnable loops
Interplant and supplier-to-plant loops reuse the same pallets many times, so durability drives cost. Specify reusable construction, a handling severity, a repair policy and the expected number of trips. Metal and plastic pallets are also used for long-life automotive loops, while wood is widely used for one-way and export shipments.
The Automotive Industry Action Group publishes RC9 for testing returnable containers and pallets. If your customer references it, put the requirement in the RFQ so the supplier can quote the testing.
Racking, stacking and treatment
State the rack span and orientation, and the floor or trailer stacking height. Treat capacity from palletdesign.ai's beam check as indicative; a certified rating comes from a PDS analysis or a test to ASTM D1185 or ISO 8611. Export parts need ISPM 15 heat-treated pallets with the mark on the pallet.
What to put in the RFQ
- Footprint, and the container or bin the pallet must carry
- Load description: container base size, weight, and whether the load is uniform, line or concentrated
- Maximum load, racking span and orientation, stacking height
- Entry and handling: forklift, pallet jack, conveyor, automated storage
- Flatness and deflection limits for automation
- Reusable or single-use, expected trips, repair policy
- Customer test standard (for example AIAG RC9) or PDS report
- Strap slots, marking, ISPM 15 treatment
Questions
- What size pallet is used in the automotive industry?
- 48 x 45 in (1219 x 1143 mm) is the size most associated with automotive parts, and it is also a common base size for bulk bins and gaylords. 48 x 40 in is used for aftermarket and retail shipments.
- What is AIAG RC9?
- RC9 is an Automotive Industry Action Group document for testing returnable containers and pallets. Check with your customer whether it applies to your program.
- Are block or stringer pallets better for automotive parts?
- Block pallets give full four-way entry and suit automated handling and returnable loops. Heavy stringer pallets with 4 or 5 stringers are common for one-way shipments of dense parts.