Industries
Pallets for paint and coatings
Reviewed
The paint and coatings industry commonly uses the 42 x 42 in (1067 x 1067 mm) square pallet, a size listed in both ISO 6780 and ANSI MH1, plus 48 x 48 in for drums. Paint loads are cases of cans and stacks of pails, so the spec should focus on deck coverage, gap size and weight.
Common pallet sizes
| Size | Metric | Typical use |
|---|---|---|
| 42 x 42 in | 1067 x 1067 mm | Paint cans, pails and cases; also telecom |
| 48 x 48 in | 1219 x 1219 mm | Four 55-gallon drums of resin, solvent or bulk coating |
| 48 x 40 in | 1219 x 1016 mm | Retail shipments into distribution centers |
| 44 x 44 in | 1118 x 1118 mm | Drums and chemical loads |
The 42 x 42 is one of the six footprints in ISO 6780 (as 1067 x 1067 mm), which makes it one of the few square sizes recognized internationally. Paint going to home-improvement and big-box retailers ships on the retailer's required footprint; The Home Depot, for example, specifies GMA-style pallets.
Construction and spec notes
A typical 42 x 42 paint pallet
A common starting point is a stringer pallet with 3 notched stringers of 1-1/2 in stock, SPF or similar softwood, and 5/8 to 3/4 in decks. palletdesign.ai's 42 x 42 template starts from that layout. Adjust from there for the load:
- Deck coverage and gaps. Gallon cans, 5-gallon pails and quart cases sit on small round or rectangular bases. Wide gaps let pail rims and can edges drop or rock, so specify a maximum top-deck gap or more boards. See deck board spacing.
- Deck thickness. Pails stacked several high put heavy ring loads on the top boards. Thicker boards (3/4 in) or narrower gaps spread them.
- Stringers. A fourth stringer shortens deckboard spans under heavy pail loads.
Pails and drums
Pails behave like small drums: each one bears on its rim, not its whole base. Plastic pails can also buckle when stacked. The Pallet Design System added drum and pail unit-load analysis in version 6.6 and plastic pail buckling in 6.8, so a PDS licensee can analyze the pallet and the pails together. For 55-gallon drums, use a 48 x 48 in drum pallet with tight gaps or a solid deck.
Entry, racking and stacking
Paint distribution centers rack product and ship stretch-wrapped unit loads. Specify:
- Entry: partial four-way (notched stringers) or full four-way (block)
- Rack orientation and beam span
- Floor-stack and trailer-stack height
Keep capacity statements tied to the support condition, and treat them as indicative until confirmed with a PDS analysis or a test to ASTM D1185 or ISO 8611.
Lumber and treatment
SPF and southern yellow pine are common for square paint pallets; mixed hardwood is heavier and stiffer. State the moisture content. If product ships outside the country, specify ISPM 15 heat treatment and the ISPM 15 mark.
Buyer requirements
Paint sold through home-improvement retail follows the retailer's pallet program. For example, The Home Depot requires a PDS analysis (latest version) or an ASTM D1185 test, a safe load stacked 3 high, a minimum capacity of 2,800 lb (3,500 lb for heavy products), and excludes low-density species classes 7 and 14. See Home Depot pallet requirements and confirm with the current vendor guide.
What to put in the RFQ
- Footprint (42 x 42 in, or the retailer's size)
- Container: can or pail size, weight, count per layer, layers
- Maximum top-deck gap, deck thickness, number of stringers
- Maximum load, racking span and orientation, stacking height
- Entry and handling equipment
- Lumber species, moisture content, heat treatment
- Retailer program and any required PDS or test report
Start from the pallet RFQ guide.
Questions
- What size pallet is used for paint?
- 42 x 42 in (1067 x 1067 mm) is the size most associated with paint. Drums go on 48 x 48 in pallets, and retail shipments often use 48 x 40 in.
- How do I stop paint pails from tipping on a pallet?
- Reduce the top-deck gaps or add boards so each pail rim sits on wood, and use stretch wrap or tier sheets between layers.
- Does Home Depot require a PDS report for pallets?
- Home Depot asks for a PDS analysis or an ASTM D1185 test, with a minimum capacity of 2,800 lb (3,500 lb for heavy products). Confirm with the current Home Depot vendor guide.