Long pallets for long loads

On a long pallet the stringers do most of the work. They carry the load end to end and have to stay straight when the pallet is lifted from the middle. Long stringers are usually thicker, and some builds join two stringers end to end with a splice; tell us if your loads are lifted at the ends, at the middle or from the side, because that decides where the stringers need their strength.

Long pallets are usually lifted from the long side, across the stringers, which is the opposite of a 48 x 40. That means notches in the stringers, or a block build, so the forks can pass under the deck. Plan the notches around where the load’s weight sits and where your forks are spaced. Two-way and four-way entry shows how the notches work.

Long loads need fewer, wider deck boards than cartons do, but they need them where the bundle rests and where bands go round. Leave gaps for banding or straps, and put full boards under the bundle’s dunnage or blocking. If the load can roll, as pipe can, chocks or a cradle can be nailed to the deck as part of the build.

Long pallets follow the product, so there is no list to choose from. 96 x 48, an eight-foot footprint, has its own page with a drawing. Send the product’s length and the overhang you will accept at each end.

Some long goods are allowed to overhang the pallet ends by a few inches; others must not overhang at all. Decide how much is acceptable before the pallet is drawn, because each inch of pallet you save is an inch of load in the air. Bands that hold a bundle to the pallet need room to pass under the deck between stringers, so tell us how many bands you use and where they go, and the gaps are left in the right places.

Pipe and round bar want to roll. Chocks, wedges or a shaped cradle nailed across the deck hold them in place; tell us the diameter and how many pieces sit side by side in a layer, and those parts are drawn into the build.

Extrusions and trim scratch easily, so some buyers want the deck boards planed smooth or covered; say if the finish of your product matters. Painted or anodized profiles may need protective strips between product and wood.

Long pallets flex between supports, so lifting one with forks set close together lets both ends droop. Spread the forks as wide as the truck allows, or use fork extensions on very long builds. Storing them flat on level dunnage stops a permanent bow forming before they’re loaded. Mark the center on each side so drivers find it quickly.