Pallet types
Double-face pallet: top and bottom decks
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A double-face pallet has both a top deck and a bottom deck. Most are non-reversible: the GMA-style 48 x 40 has 7 top boards but only 5 bottom boards, grouped to clear the stringer notches. A reversible double-face pallet has identical decks and can be used either way up.
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What is a double-face pallet?
A double-face pallet has a deck on both sides of its stringers or blocks. The bottom deck spreads the pallet's load onto whatever is beneath it (a floor, a rack beam, another load) and ties the stringers or blocks together, which is why nearly all general-purpose pallets are double-face.
The Uniform Standard splits double-face pallets into two deck styles:
- Double-face non-reversible: the bottom deck is lighter than the top, usually fewer boards. This is the default.
- Double-face reversible: the two decks are the same and either can carry the load. See reversible pallets.
How a double-face pallet is built
On the common GMA-style 48 x 40 in stringer pallet:
| Deck | Boards | Layout |
|---|---|---|
| Top deck | 7 boards of 5/8 in: two 5-1/2 in leads, five 3-1/2 in interior | Ends flush, interior boards equally spaced, 3.25 in gaps |
| Bottom deck | 5 boards of 5/8 in: two 5-1/2 in leads, three 3-1/2 in interior | Interior boards clustered in the middle, clear of the notches |
| Fasteners | 48 top + 36 bottom = 84 | 3 per lead-board joint, 2 per interior joint |
The bottom interior boards are grouped between the notches so forklift tines can enter from the sides. Bottom lead boards are often chamfered so pallet-jack wheels ride over them.
Block pallets are double-face too. Their bottom can be a perimeter, unidirectional or cruciform pattern (see perimeter base pallets).
When to use a double-face pallet
- Almost any general freight pallet: grocery, retail, beverage, chemicals.
- Floor stacking. The bottom deck spreads the load onto the pallet or goods below. In one published PDS example, the same 48 x 40 pallet had a safe load of 5,223 lb stacked one high on the floor against 1,558 lb racked across its length, which shows how much the support condition matters.
- Rack storage, where the bottom deck adds bearing on the beams.
- Pallet-jack handling, which needs a bottom deck for the wheels to roll off.
When not to use one
- When the pallet will be bolted to a machine or used as a crate base, a skid is simpler.
- When every board and nail counts on a one-way load that is not stacked, a single-face design saves material.
Non-reversible vs reversible
| Non-reversible | Reversible | |
|---|---|---|
| Bottom deck | Fewer boards than top | Same as top |
| Material | Less | More |
| Notches | Compatible (bottom boards cluster clear of notches) | Usually unnotched, since a full bottom deck covers the notch zones |
| Entry | Partial 4-way possible | Usually 2-way |
| Use | General freight | Heavy use, loads on either face |
How to specify a double-face pallet
- Deck style: double-face non-reversible or reversible.
- Top deck: count, thickness, widths.
- Bottom deck: count, thickness, widths and layout (clustered or evenly spaced).
- Chamfers on bottom lead boards if pallet jacks are used.
- Stringer or block sizes and notch details.
- Fasteners per joint for top and bottom decks.
- Load, stacking height and racking direction.
palletdesign.ai draws both decks to scale and lists every board in the cut list, so the difference between a 5-board and a 7-board bottom shows up directly in the board feet and nail count.
Questions
- What does double-face non-reversible mean?
- The pallet has top and bottom decks, but the bottom deck is lighter, usually with fewer boards, so only the top face carries the load.
- Why does a GMA pallet have fewer bottom boards?
- Five bottom boards are enough to spread load and tie the stringers, and grouping them in the middle keeps the notches clear for side fork entry.
- Is a block pallet double-face?
- Yes. Block pallets have a top deck and a bottom base, which may be a perimeter, unidirectional or cruciform pattern.