New stringer pallets

A plain stringer pallet takes forks from the two ends, between the stringers. Cut notches into the stringers and forklift forks can come in from the sides as well, which is called partial four-way entry. A pallet jack still can’t, because its wheels need the open space a block pallet has. If your trucks and jacks only ever lift from the ends, the notches cost strength you don’t need. Two-way and four-way entry explains the difference with drawings.

Notches are cut to a standard shape and depth so forks of common sizes pass through; if your forks are unusually wide or thick, measure them and include the numbers.

Three stringers is the standard US build, one under each edge and one down the middle. A fourth or fifth shortens the span of every deck board and spreads a heavy load across more wood; it is how a stringer pallet becomes a heavy-duty pallet. Stringer length sets the first number in the size, so a 48 x 40 has 48-inch stringers.

Deck boards run across the stringers. The outside board on each edge, top and bottom, is the lead board, and because it takes the first hit from a fork it is often specified wider or thicker. A top deck of seven boards is typical on a 48 x 40; small cartons and bags need closer spacing so nothing drops through. Deck boards and lead boards covers coverage and spacing.

The common stringer sizes are 48 x 40, 48 x 42, 48 x 44, 48 x 45, 48 x 48, 42 x 48, 36 x 36, 32 x 30 and 30 x 30. Published figures for a standard 48 x 40 put its capacity at 2,000 to 2,800 lb moving and 2,500 to 4,600 lb at rest, and its empty weight at 33 to 49 lb. Those are the trade’s numbers for a typical build, not a rating for yours: a quoted pallet is worked out from your load. See the sizes for each footprint.

Four answers settle most stringer builds: the size, stringer length first; the heaviest load a pallet will carry; whether forklifts, pallet jacks or both handle it, and from which sides; and whether it is floor-stacked, stacked loaded or racked across beams. With those, the stringer count, notches, deck boards and lumber follow. Quantity and the delivery ZIP complete the quote. If you already use a stringer pallet that works, measure it and send the numbers: we can write the same build down, or suggest where it carries more wood than the load needs.

Look along each stringer for splits running from nail holes, and at the notches for cracks at the corners, where a notched stringer is weakest. Lay a straightedge across the top deck. A pallet that rocks on the floor or racks out of square feeds badly into conveyors and stretch wrappers.