01 / SIZE
Standard pallet sizes, indexed
There is no single legal pallet size. The North American default is 48 x 40 inches, and five other footprints are common enough to quote by name: 48 x 48, 42 x 42, 48 x 45, 48 x 42 and the 800 x 1200 mm Euro pallet.
01 The index
| Size | Metric | Deck area | Industry |
|---|---|---|---|
| 48 x 40 | 1,219 x 1,016 mm | 13.3 sq ft | GMA standard |
| 48 x 48 | 1,219 x 1,219 mm | 16.0 sq ft | drums, totes |
| 42 x 42 | 1,067 x 1,067 mm | 12.3 sq ft | telecommunications, paint |
| 48 x 45 | 1,219 x 1,143 mm | 15.0 sq ft | automotive |
| 48 x 42 | 1,219 x 1,067 mm | 14.0 sq ft | chemical, beverage |
| 800 x 1200 mm | 1,200 x 800 mm | 10.3 sq ft | Euro |
More on each: 48 x 40, 48 x 48, 42 x 42, 48 x 45, 48 x 42 and the Euro pallet.
02 Why there are so many
Trade sources agree that no universally accepted standard for pallet dimensions exists. ISO accepts the 48 x 40 inch specification as the North American standard pallet size, and the 48 x 40 GMA pallet accounts for 30% of all new wood pallets produced in the United States, but chemical plants, bottlers and automakers each settled on their own footprints. A size is a product of the load, not a rule.
03 How to read the table
- Length is the first number, the direction forks usually enter on a stringer pallet.
- Deck area is length times width, a quick way to compare how much a size can carry.
- Metric is the same footprint in millimetres, useful for export paperwork.
04 Picking one
Start from the load, not the pallet. A product that packs nine 16 x 12 inch cartons per layer fits 48 x 40. Round drums and square totes sit better on 48 x 48. A beverage line built around 48 x 42 should stay with it. The spec builder walks through the choice.
05 Check the rack
Before ordering any size other than 48 x 40, measure the rack openings and the doors the pallet will pass through.
06 The ten North American ranks
| Rank | Footprint | Main users |
|---|---|---|
| 1 | 40 x 48 in | Grocery |
| 2 | 42 x 42 in | Telecom, paint |
| 3 | 48 x 48 in | Drums |
| 4 | 48 x 40 in | Military, cement |
| 5 | 48 x 42 in | Chemical, beverage |
| 6 | 40 x 40 in | Dairy |
| 7 | 48 x 45 in | Automotive |
| 8 | 44 x 44 in | Drums, chemical |
| 9 | 36 x 36 in | Beverage |
| 10 | 48 x 36 in | Beverage, shingles, paper |
07 ISO 6780 floor waste
| Footprint, mm | Wasted floor, 40 ft container | Main region |
|---|---|---|
| 1,016 x 1,219 | 3.7% | North America |
| 1,000 x 1,200 | 6.7% | Europe, Asia |
| 1,165 x 1,165 | 8.1% | Australia |
| 1,067 x 1,067 | 11.5% | North America, Europe, Asia |
| 1,100 x 1,100 | 14% | Asia |
| 800 x 1,200 | 15.2% | Europe |
08 42 x 42 pallets
A 42 x 42 pallet is a compact square, 1,067 by 1,067 millimetres, ranked second in North American production by PHS, with telecommunications and paint as its listed users. Its 12.3 square feet of deck suit loads built to a square footprint.
Why a square
A square footprint is the same in both directions, so a pallet can enter a rack or a trailer from either side without a choice of orientation. Match the footprint to the line or the rack that will use it: a palletizer or a rack bay is set to a single size, and a 48 x 40 is not a substitute for a 42 x 42 even though it is bigger.
Build and grade
A square pallet is usually built as a block pallet, since four-way entry suits a footprint that is the same in both directions. Grade A is the usual ask for a clean line; grade B is acceptable where the load is wrapped to the pallet. See grades for how to read a repair.
Notes for a request
- State whether four-way entry is required.
- Give the stacking height.
- Say whether it is for drums or cases.
- Ask whether stock exists or a build is needed.
09 48 x 45 pallets
A 48 x 45 pallet, 1,219 by 1,143 millimetres, is the size listed for the automotive industry and ranks seventh in North American pallet production. It turns up alongside 48 x 40 at auto plants and their suppliers.
Why a size sits between two others
Parts bins and stamped components come in boxes that pack more efficiently on a five-inch-longer width than on a 40 inch deck. A 48 x 45 gives 15.0 square feet of deck, 1.7 more than a 48 x 40. It is a niche in the sense that fewer pallets are made and stocked than the standard, but the people who need it need it exactly.
Sourcing
Used 48 x 45 supply is scarce because few shippers handle it. Machine shops and parts suppliers around McKees Rocks, in the metal-fabrication corridor, and in Leetsdale and the Allegheny valley are the sort of place where mixed sizes include a few. If your plant needs a run of them, a new build to a spec sheet is usually the more reliable route.
Builds
Heavy parts favour reinforced and block builds. A reinforced wood pallet weighs 55 to 66 lb empty against a standard 33 to 49 lb, and the extra weight is lumber in the right places. State the load on the request.
On the request
- Say 48 x 45 explicitly; do not write 'automotive size'.
- State which dimension is the fork-entry direction.
- State the weight of a loaded pallet.
- State whether the pallet is new or used.
10 48 x 42 pallets
A 48 x 42 pallet, 1,219 by 1,067 millimetres, is a chemical and beverage size ranked fifth in North American production. It sits between the 48 x 40 standard and the 48 x 48 square.
Where it fits
The two extra inches over a 48 x 40 matter on drum and keg loads where the product's footprint sits just past 40 inches. Chemical packaging in bagged and boxed form also uses it. Fifth in production means the supply of new pallets is deep, while used stock depends on who in the area runs it.
Used or new
Because it is a mid-ranked size, a sorted used stack is possible but not routine. Ask for it by name and say which grade you will take. For a recurring order, a standing spec on the truckload page keeps the size consistent.
Where 48 x 42 sits among its neighbours
Of the six ISO 6780 footprints only 1,067 x 1,067 mm, at 11.5% wasted floor, and 1,016 x 1,219 mm, at 3.7%, are close in size. In inches, 48 x 42 is two inches longer on one side than 48 x 40 and six inches longer than 42 x 42.
11 Common mistakes
- Substituting 48 x 40 on a line or palletizer set up for 42 x 42 or 48 x 42, and finding it jams.
- Racking 48 x 42 in 40 inch bays.
- Ordering by name without stating the build.
- Specifying a spaced deck for bagged goods.
- Forgetting that a pallet for a clean line needs to be dry and free of odour.
Q Questions
What is the standard pallet size?
In North America it is 48 x 40 inches, 1,219 x 1,016 mm. Other sizes are common in specific industries.
Can I get a size not listed?
Ask. Odd sizes are built to order.
Can I mix 42 x 42 with other sizes on one truck?
Yes, but each size racks and stacks separately. Say so on the request and list the sizes and counts.
Is 42 x 42 a GMA size?
No. The GMA pallet is 48 x 40. 42 x 42 is a separate footprint; PHS lists telecommunications and paint as its main users.
Is 48 x 45 only for cars?
It is listed as the automotive size, but any shipper whose product packs to that footprint can use it.
Is 48 x 42 the same as 42 x 48?
Yes, in different order. Length is conventionally the first number, which matters for fork entry on a stringer pallet.
Does it carry more?
It has more deck, not a higher rating.
Src Sources
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