02 / BUILD
Pallet builds: how it's put together and how forks get in
A pallet's build is how it is put together and how forks get in. The main split is stringer versus block, and within that, two-way versus four-way entry.
01 The four terms
- Stringer
- A frame of three or more parallel timbers under the deck. The long boards under a stringer pallet are the stringers.
- Block
- A frame of parallel and perpendicular members with blocks at the corners, middle and edges, so forks enter from any side.
- Two-way
- Forks enter from two opposite sides only.
- Four-way
- Forks enter from all four sides.
02 A quick comparison
| Build | Fork entry | Stiffness | Typical use |
|---|---|---|---|
| Stringer | Two sides, unless notched | Good for light and mid loads | Cartons, consumer goods |
| Block | Four sides | High | Heavy, racked, drum and tote loads |
| Two-way | Two sides | Depends on frame | Straight-line docks |
| Four-way | Four sides | Usually heavier and sturdier | Tight aisles, mixed handling |
03 More on each build
For a head-to-head read, see block or stringer.
04 Terms that get mixed up
- Two-way versus partial four-way
- A stringer pallet with notched stringers lets forks in from the other two sides, but not at full width. Ask whether 'four-way' means true block entry or notched stringers.
- Reinforced
- A heavier build with extra boards or blocks; the trade quotes 55 to 66 lb empty.
- Deck coverage
- How much of the top is solid board. Small cartons and bagged goods need more.
- Companion stringer
- A second timber added beside a split stringer during repair.
05 Treatment is separate
Heat treatment does not depend on the build. A block pallet or a stringer pallet can be heat treated, and either can be left untreated. Decide treatment by destination and by buyer, not by structure.
06 Order of decisions
Pick the size first, then the build, then entry, then treatment, then grade, then quantity. Following that order stops a choice made early from forcing a costly change later.
07 Materials beyond wood
Plastic pallets of HDPE or recycled PET can last more than 100 trips and may have molded-in RFID chips, though some creep under long heavy loads. Paper pallets are two flat corrugated pieces weighing 4.5 kg, exempt from ISPM 15. Aluminum is stronger than wood and plastic, lighter than steel, and used for air freight. Wood remains the most widespread for its strength, low cost and repairability.
08 Four-way pallets
A four-way pallet can be lifted from any side, and it is usually heavier, bigger and more durable than a two-way. It earns its extra weight in tight aisles and in docks that handle pallets from every direction.
What you pay and what you get
| Gain | Cost |
|---|---|
| Fork access from every side | More lumber and weight |
| Easier handling in tight aisles | Higher price per pallet |
| Less turning of pallets | More freight weight per load |
Where it fits
Recycling and mixed-handling docks, 3PL warehouses where one pallet may be handled by five different trucks, and heavy square loads such as 48 x 48 all ask for four-way. The pallets stay on the move, and a pallet that cannot be picked up from the side it was set down on slows the whole shift.
Checking a four-way pallet
- Insert a fork from each side, if you can, without lifting.
- Check that the openings are wide enough for your forks.
- Check the blocks or notches for cracks.
- Look for repairs near the openings.
A common mistake
Ordering four-way pallets for a line that only ever enters from one side means paying for blocks that never earn their keep. Ordering two-way for a mixed route means rotating pallets by hand at each stop.
Rack and floor
On a floor, four-way entry is a convenience. In a rack, the beams run in one direction and the pallet is usually fixed in orientation, so four-way entry matters less there than at the dock and in the trailer.
Entry and rack capacity
Interlake Mecalux notes that automated warehouses usually run a single pallet type, that rack capacity depends on the support configuration, and that OSHA rule 29 CFR 1910.176 requires secure storage at safe heights. Some four-way stringer pallets exist, it adds, though they are less common than block pallets.
Q Questions
Which build is cheapest?
A plain stringer pallet usually, because it uses the least lumber. Price depends on the spec you send.
Can I change the build later?
You can order another build next time, but pallets already in the rack stay as they are.
Do four-way pallets cost more?
They use more material, so usually yes. The request is where the price is stated.
Is every block pallet four-way?
Yes in the usual layout, as the blocks leave openings on all four sides.
Does four-way carry more?
Not necessarily. It gives more ways in, not a higher rating.
Src Sources
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