Pallet shipping is one of the most common ways to move freight that is too large or heavy for standard parcel carriers.
A properly prepared pallet makes freight easier to handle with forklifts and pallet jacks, helps protect the shipment in transit, and gives the carrier more accurate information for pricing.
Incorrect measurements, unstable stacking, pallet overhang, or an inaccurate weight can result in damaged freight or unexpected adjustments to the shipping bill.
This guide explains how to prepare, measure, weigh, and package palletized freight correctly before it is picked up by an LTL carrier.
What Is a Palletized Freight Shipment?
A palletized shipment consists of one or more items secured to a pallet or skid so the entire shipment can be moved as a single handling unit.
Instead of handling individual boxes separately, the carrier can use a forklift or pallet jack to move the complete load.
Palletized shipping is commonly used for:
- Multiple cartons
- Machinery
- Automotive parts
- Commercial equipment
- Building materials
- Packaged food
- Retail products
- Industrial supplies
- Furniture
- Heavy or oversized items
The pallet becomes part of the shipment and should be included when determining the shipment's total dimensions and weight.
Pallet vs. Skid vs. Crate
These terms are sometimes used interchangeably, but they describe different types of shipping platforms.
Pallet
A pallet normally has a top deck and a bottom deck, allowing it to be moved by a forklift or pallet jack.
Wooden pallets are common, although plastic and metal pallets are also used.
Skid
A skid generally has a top platform but does not have the same bottom deck structure as a traditional pallet.
Skids are often used for heavy machinery and industrial equipment.
Crate
A crate surrounds or encloses the product and provides more protection than an open pallet.
Crates are often used for fragile, valuable, irregularly shaped, or sensitive items.
No matter which method is used, the complete shipping unit should be measured and weighed after packaging is finished.
Choosing the Correct Pallet
The pallet should be large enough to support the entire shipment without allowing the freight to extend beyond its edges.
It should also be strong enough to support the shipment's total weight.
Before using a pallet, inspect it for:
- Broken boards
- Missing boards
- Loose nails
- Cracks
- Weak corners
- Structural damage
- Excessive wear
A damaged pallet can fail during forklift handling or while the shipment is in transit.
Standard Pallet Sizes
One of the most common pallet sizes in the United States is approximately:
48 x 40 inches
However, there is no requirement that every freight shipment use this size.
Other pallet sizes are commonly used depending on the industry, product, and equipment involved.
For freight calculations, always use the actual outside dimensions of the finished shipment rather than assuming a standard pallet size.
How to Stack Boxes on a Pallet
Boxes should be arranged to create a stable load.
Whenever possible:
- Place heavier boxes at the bottom.
- Place lighter boxes toward the top.
- Keep the weight evenly distributed.
- Keep boxes within the edges of the pallet.
- Minimize large gaps between cartons.
- Avoid leaning or unstable stacks.
- Keep the top as level as practical.
A stable load is easier to handle and less likely to shift when the truck accelerates, brakes, or turns.
Column Stacking vs. Interlocking
Boxes are commonly stacked using either a column pattern or an interlocking pattern.
Column stacking
Boxes are placed directly on top of one another.
This can provide good vertical compression strength when the boxes are strong and properly aligned.
Interlocking stacking
Boxes are arranged in alternating directions between layers.
This can help stabilize some loads, although it may reduce the vertical strength of certain corrugated cartons.
The best method depends on the type of cartons and the stability of the shipment.
Why Pallet Overhang Should Be Avoided
Overhang occurs when boxes or other parts of the shipment extend beyond the edge of the pallet.
This creates several problems.
The exposed portions of the shipment can be struck by:
- Forklifts
- Other pallets
- Dock equipment
- Trailer walls
- Other freight
Overhang can also increase the shipment's measured dimensions.
For example, a 48-inch-wide pallet does not necessarily produce a 48-inch-wide shipment if boxes extend beyond the pallet.
If freight extends two inches on each side, the actual shipment width may be approximately 52 inches.
The carrier may use those outside dimensions when evaluating the shipment.
How to Measure a Pallet Correctly
Measure the shipment only after it has been completely packed and secured.
Measure the maximum outside:
Length x Width x Height
Do not measure only the pallet itself.
Include anything that extends beyond the pallet or increases the total dimensions.
This can include:
- Boxes
- Crates
- Packaging
- Stretch wrap
- Protective padding
- Protruding equipment
- Pallet overhang
- Corner protection
Always round according to the requirements of the carrier or shipping system you are using.
How to Measure Shipment Height
Height is frequently measured incorrectly.
Measure from the floor to the highest point of the completed shipment.
The pallet itself counts toward the total height.
For example:
Product and boxes: 42 inches
Pallet: 6 inches
Total shipment height:
48 inches
Entering only 42 inches would understate the actual size of the freight.
Measuring Irregularly Shaped Freight
Not every shipment forms a perfect rectangle.
Machinery, furniture, automotive parts, and industrial equipment can have irregular shapes.
For shipping purposes, measure the greatest outside dimensions.
Imagine placing an invisible rectangular box around the entire shipment.
Measure the:
- Longest length
- Widest width
- Highest point
These dimensions represent the amount of space the shipment may require.
Do not subtract open or unused areas inside the shipment's overall footprint.
How to Calculate Cubic Feet
Once you know the outside dimensions, you can calculate the volume of the shipment.
When dimensions are measured in inches:
Length x Width x Height ÷ 1,728 = Cubic Feet
For example, suppose a pallet measures:
48 x 40 x 48 inches
Multiply:
48 x 40 x 48 = 92,160 cubic inches
Then divide by 1,728:
92,160 x 1,728 = 53.33 cubic feet
The shipment occupies approximately 53.33 cubic feet.
How to Weigh a Palletized Shipment
The shipment weight should represent the complete handling unit presented to the carrier.
Include the weight of:
- Merchandise
- Boxes
- Pallet
- Crate
- Stretch wrap
- Strapping
- Padding
- Protective materials
Do not use only the manufacturer's product weight unless packaging and pallet weight have already been included.
Gross Weight vs. Net Weight
These two terms are useful when preparing freight.
Net weight
The weight of the product itself.
Gross weight
The total weight of the product plus all packaging and shipping materials.
For LTL shipping, the gross weight is generally the number that matters.
For example:
Product weight: 720 lb
Pallet and packaging: 55 lb
Gross shipment weight:
775 lb
What If You Do Not Have a Freight Scale?
For smaller shipments, the weights of individual cartons can sometimes be added together along with the known weight of the pallet and packaging.
For heavier or commercial shipments, a freight scale provides a more reliable result.
Estimated weights should be used cautiously because carriers may reweigh shipments.
If the carrier determines that the actual weight differs from the declared weight, the freight charges may be adjusted.
How Density Relates to Pallet Measurements
The combination of weight and dimensions determines freight density.
Using the previous example:
Dimensions:
48 x 40 x 48 inches
Volume:
53.33 cubic feet
Weight:
775 lb
Density:
775 ÷ 53.33 = approximately 14.53 pounds per cubic foot
This is why both accurate dimensions and accurate weight are important.
A small change in shipment height can significantly change the calculated density.
Secure the Freight to the Pallet
The product should not move independently from the pallet during normal handling.
Common methods include:
- Stretch wrap
- Plastic strapping
- Steel strapping
- Banding
- Shrink wrap
- Blocking and bracing
- Bolting equipment to a skid
The appropriate method depends on the weight and type of freight.
How to Use Stretch Wrap Properly
Stretch wrap should secure the load to the pallet, not simply hold the boxes together.
Begin near the bottom of the shipment and wrap around the pallet and freight several times.
Continue upward while overlapping the previous layers.
For taller loads, additional horizontal wraps around the middle and upper portions can improve stability.
The finished load should remain stable when moved with a pallet jack or forklift.
When to Use Strapping
Strapping can provide additional security for heavy or dense freight.
It is particularly useful for:
- Machinery
- Heavy cartons
- Metal products
- Building materials
- Industrial equipment
Corner protectors can be placed under the straps to prevent them from crushing or cutting into boxes.
Protect the Corners and Edges
Corners are especially vulnerable during freight handling.
Corner boards and edge protectors can help:
- Stabilize stacked cartons
- Protect boxes from straps
- Reduce crushing
- Reinforce the shipment
- Provide additional protection from impact
They are particularly useful for tall palletized loads.
Should the Freight Be Stackable?
A stackable pallet can allow the carrier to use the trailer space above the shipment.
However, not every shipment can safely support freight on top of it.
A shipment may need to be treated as non-stackable if it contains:
- Fragile products
- Machinery with exposed components
- Uneven surfaces
- Crushable cartons
- Equipment extending above the pallet
- Products that could be damaged by vertical pressure
Do not indicate that freight is stackable unless it can safely support another shipment.
When a Crate Is a Better Choice
A pallet alone may not provide enough protection for certain products.
Consider crating when shipping:
- Glass
- Artwork
- Precision machinery
- Electronics
- Sensitive instruments
- High-value equipment
- Fragile furniture
- Items with exposed components
A crate can protect the product from impact and reduce the chance of direct contact with other freight.
Remember that crating usually increases both the weight and dimensions of the shipment.
Label Every Handling Unit
Each pallet should be clearly labeled.
A freight label generally includes:
- Shipper information
- Recipient information
- Destination address
- Reference number
- Purchase order number when applicable
Place labels where they are easily visible.
If there are several pallets in one shipment, consider identifying them individually, such as:
1 of 3
2 of 3
3 of 3
This can help the carrier and receiver identify whether the complete shipment has arrived.
Multiple Pallets
If a shipment contains several pallets, each handling unit should be measured and weighed accurately.
Do not automatically assume all pallets have identical dimensions or weights.
For example:
Pallet 1: 48 x 40 x 42 inches - 620 lb
Pallet 2: 48 x 40 x 56 inches - 810 lb
Pallet 3: 60 x 48 x 45 inches - 940 lb
Recording each pallet separately provides more accurate information than describing all three as identical.
Common Pallet Shipping Mistakes
Some of the most common mistakes include:
- Measuring only the product instead of the finished pallet
- Forgetting to include pallet height
- Ignoring overhang
- Estimating weight
- Using a damaged pallet
- Failing to secure the load to the pallet
- Leaving tall freight unstable
- Using insufficient packaging
- Providing incorrect dimensions
- Assuming every pallet measures 48 x 40 inches
These mistakes can lead to freight damage, carrier adjustments, delays, or additional charges.
Final Pallet Shipping Checklist
Before the carrier arrives, verify that:
- The pallet is in good condition.
- The shipment fits properly on the pallet.
- There is no unnecessary overhang.
- Boxes are stacked securely.
- Heavy items are positioned safely.
- Freight is attached firmly to the pallet.
- Fragile areas are protected.
- The shipment has been measured after packaging.
- Pallet height is included.
- The total gross weight is accurate.
- Each handling unit is labeled.
- Special handling requirements have been communicated.
Measure the Shipment Before Calculating Freight Class
The accuracy of any freight calculation depends on the information entered.
Measure and weigh the shipment only after the pallet has been completely prepared for transportation.
Once you have the final length, width, height, and total weight, you can use the Freight Class Calculator to calculate shipment density and estimate the freight class associated with your shipment.