Types of pallets: dimensions and classification
The word “pallet” on a booking can describe very different handling units: a standard Euro pallet carrying cartons, a wider industrial base loaded with drums, or a purpose-built support for machinery. If only the quantity is agreed, loading may reveal that the cargo takes up more width than expected, the pallet is unsuitable for the receiver's racking, or the actual weight exceeds the declared figure.
Choosing correctly requires the base dimensions, construction, load rating and receiver's requirements. The finished handling unit must then be measured with its packaging in place. This guide covers common pallet types, verified specifications and practical examples to help prepare information for transporting packaged goods.
Common pallet dimensions in millimetres
The footprint is the floor area occupied by an empty pallet. Pallet height excludes the goods, cartons, collars and protective lid. All linear dimensions in the table are in millimetres. A particular model's specifications should not be applied to every pallet that looks similar.
Type or model | Footprint in mm | Pallet height in mm | Key distinction |
|---|---|---|---|
EPAL 1 Euro pallet | 1200 × 800 | 144 | Standardised wooden pallet within the EPAL system |
EPAL 2 | 1200 × 1000 | 162 | Industrial model with a perimeter base frame |
EPAL 3 | 1200 × 1000 | 144 | Different construction from EPAL 2 despite the same footprint |
EPAL 6 half pallet | 800 × 600 | 144 | Compact model for smaller handling units |
FIN Finnish pallet | 1200 × 1000 | Per specification | Confirm the standard and actual construction |
Common North American format | Approximately 1219 × 1016 | Model dependent | Footprint alone does not determine height or load capacity |
Pallet footprint diagrams
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Square pallets measuring 1200 × 1200 mm can also be used in industrial logistics, but describing that footprint as the universal American standard is incorrect. Check the manufacturer's drawing for the North American format; 1219 mm is a rounded metric dimension.
FIN should not be used as a generic name for every 1200 × 1000 mm base. Different industrial models share this footprint, including EPAL 2 and EPAL 3. Identical length and width do not establish that the deck, lower supports or permitted load are the same.
A Euro pallet and a pallet with a Euro footprint
A wooden pallet measuring 1200 × 800 mm does not become an EPAL pallet simply because of its dimensions. Identification requires checking its markings, construction and origin. EUR and EPAL identify their respective systems; they should not be applied informally to homemade packaging or treated as names for any rectangular pallet.
The EPAL 1 technical specification gives a height of 144 mm, an approximate tare weight of 25 kg and a safe working load of 1500 kg. These figures apply to that model under its appropriate conditions of use. They do not establish that a damaged pallet is fit for service or that any arrangement of heavy machinery can be placed on it.
A one-way pallet can be sufficient for a particular shipment if its construction suits the cargo and handling conditions. However, accepting one-way packaging for transport does not mean that a warehouse will accept it in place of a specified pallet system. Obtain the receiver's requirements before packing the goods.
Material and construction affect the choice
Wooden pallets are selected by deck layout, supports, timber condition and route requirements. For sacks, gaps between boards and the absence of sharp projections matter; for cartons, the bottom layer needs adequate support. Board thickness alone does not establish the suitability of the complete structure.
Plastic pallets may suit returnable packaging systems and processes with defined cleaning requirements. However, “plastic” does not automatically mean suitable for food products, low temperatures or rack storage. Check the particular material and model specifications.
Metal pallets and purpose-built frames are used where the cargo needs engineered support points or dedicated securing arrangements. Lightweight cardboard or pressed-material pallets also require a defined operating environment. Their response to loading and moisture cannot be assumed to match a wooden Euro pallet.
Construction features include two-way or four-way fork entry, open or solid decks, and different bottom runners. Check compatibility with the receiver's pallet truck, conveyor and racking as well as its forklift. A pallet that can be lifted by one type of equipment may not suit the complete handling chain.
The CP family is used in the chemical industry. For example, EPAL CP3 and CP9 both have a 1140 × 1140 mm footprint, but their construction differs. Choose the CP model for the sacks, drums or other packaging involved. The CP designation alone does not establish compliance with every dangerous goods transport requirement.
Load capacity depends on how the pallet is used
A pallet specification may show several ratings. Static load relates to defined stationary support conditions. Dynamic load relates to the handling conditions specified by the manufacturer. Racking load relates to storage on particular supports with a defined span. These values are not interchangeable: the largest catalogue figure is not the permitted weight for every operation.
For comparison, EPAL's official specifications list these approximate tare weights and safe working loads: EPAL 2, 35 kg and 1250 kg; EPAL 3, 30 kg and 1500 kg; EPAL 6, 9.5 kg and 750 kg. A larger footprint or a heavier empty pallet does not guarantee a higher permitted payload.
Load distribution needs a separate check. Cartons resting across much of the deck and a metal machine standing on four small feet place different demands on the boards. Concentrated loads need agreed support arrangements and, where necessary, a specially engineered base. A cargo weight below a published rating is not sufficient evidence on its own.
Illustrative example. A 900 kg machine stands on four narrow supports. Even if its total weight is below the pallet's stated working load, the contact points, centre of gravity, resistance to overturning and lifting arrangement still need checking. Adding more stretch film does not solve a structural weakness in the base.
Inspect the pallet before loading it
Commercial descriptions such as “premium grade”, “first grade” or “used no more than three times” are not a universal technical classification. Light-coloured wood does not prove strength, and darkening alone does not establish unfitness. EPAL has its own condition criteria; new pallets and classes A, B and C are distinguished by a combination of features. Requirements for a particular quality class should be agreed between the parties.
During the initial inspection, check for missing boards or blocks, damage to load-bearing components, protruding fasteners and contamination that could transfer to the goods. Do not conceal these defects under packaging. Separate the pallet from stock ready for loading and arrange assessment or replacement.
There is no universal rule allowing a crack of a particular length on every pallet. Its location, the component affected, the fasteners and the relevant system criteria all matter. For EPAL, use the current official quality classification; repairs governed by the system are carried out by licensed repair companies. For example, the class C criteria allow a slightly twisted block protruding no more than 10 mm, but do not allow exposed nail tips. These examples do not replace assessment against the full criteria.
Fitness for use and obligations to return packaging are separate matters. The allocation of returns, refusal records and shortage charges is explained in the dedicated article on Euro pallet exchange.
ISPM 15 markings on wooden pallets
International shipments require a check of the destination country's phytosanitary rules for wood packaging. Wood packaging within the scope of ISPM 15 requires the appropriate treatment and official marking. For example, relevant wood packaging entering the EU from third countries is subject to treatment, debarking and IPPC marking requirements.
The standard contains exemptions, including packaging made entirely from wood no thicker than 6 mm or qualifying processed wood materials such as plywood. A plywood deck with raw-wood supports should not automatically be treated as a wholly exempt construction. Check the packaging materials and destination requirements for the particular shipment.
The IPPC mark concerns phytosanitary treatment. It does not state load capacity, establish EPAL membership or replace inspection for damage and contamination. An unofficially applied stamp does not establish that the treatment procedure has been followed either.
Measure the handling unit after packing
The transport booking should state the length, width and full height of the loaded pallet. Include projecting cartons, collars, wrapping and any other external elements. Measure height from the underside of the pallet to the highest point of the finished packaging, rather than from the top deck to the goods.
Overhang example. The base measures 1200 × 800 mm, but the cartons extend 50 mm beyond every side. The actual handling unit occupies 1300 × 900 mm. At a total height of 1500 mm, its volume is 1.755 m³. Without the overhang, the same height would give 1.44 m³. That is an increase of approximately 21.9%, although the pallet count has not changed.
Overhang also makes it harder to position the unit beside other cargo and leaves packaging edges less protected. For groupage freight delivery, the logistics specialist therefore needs each unit's actual dimensions, not just the pallet name. The tariff implications of volume are explained in the guide to calculating volumetric weight.
Product weight and loaded pallet weight
Pallet tare weight is only one part of the transport weight. Add the pallet and all packaging materials to the weight of the goods. The approximate 25 kg figure for EPAL 1 is useful for preliminary planning, but the actual result depends on the individual pallet, its moisture content and the packaging used.
Illustrative calculation. A pallet carries 24 cartons, each containing 12.5 kg of goods net: 300 kg in total. The cartons and protective materials weigh 12 kg, and the measured pallet tare is 25 kg. The complete handling unit weighs 337 kg; four identical units weigh 1348 kg. If each unit is 1500 mm high including the pallet, with no overhang, the total volume of the four units is 5.76 m³.
Documents should make clear what is included in the stated net and gross figures. Transport planning needs the complete handling-unit weight. Before cargo consolidation, agree a consistent measurement method with all suppliers so that one booking does not combine product-only weights from one sender with packed weights from another.
Planning vehicle and warehouse space
For curtain-sided road transport, check the pallet count against the internal body dimensions, unit orientation, complete weight and load distribution. An illustrative layout for a body with a usable length of 13 600 mm and width of 2450 mm places three 800 mm bases across the width, occupying 2400 mm, and eleven 1200 mm rows along its length, occupying 13 200 mm. Geometrically, that gives 33 positions without overhang; it does not guarantee an acceptable load.
If each unit weighs 900 kg, the total is 29 700 kg. Compare that figure with the particular vehicle combination's permitted payload and axle arrangement. Allow the space needed for securing and consider the unloading sequence as well. The separate guide to loading metres or LDM explains how occupied vehicle length is assessed.
For ocean container shipping, check the plan against the selected container's internal space, door opening, permitted weight and securing arrangement. A curtain-sided trailer loading plan cannot simply be transferred to a container.
For international air freight, total height, weight and the carrier's agreed restrictions matter. Reducing empty pallet weight is useful only if the required strength is maintained. Confirm stackability separately: a strong base does not establish that the top layer of cartons can support another loaded pallet.
Information to provide for a palletised shipment
Before booking transport, prepare the number of handling units, their actual dimensions in mm, each unit's complete weight, pallet type and packaging photographs. Include stackability, the centre of gravity for complex items, the loading method and the receiving warehouse's requirements. For wooden packaging, check the markings required for the route.
Send these details to Save Pro Solutions with the collection and delivery locations and the cargo readiness date. They help establish the appropriate transport and any repacking requirement before a vehicle is dispatched, while changing the pallet is still easier than reworking an already loaded shipment.
