Best Pallet Sizes for Warehousing
The 48 x 40 size works best for the majority of US warehouses, though a few exceptions exist for the best pallet sizes for warehousing. The exceptions include the racks used, the extensions of the cargo being moved, distinct export pathways, and dock door restrictions. Riverview Industrial Wood Products manufactures large quantities of pallets for its customers in Ohio.
What Are the Standard Pallet Sizes in the US?
The standard pallet sizes used is the 48 x 40 GMA pallet, accounting for about 30% of new wood pallets made in the US. Most other industrial pallet dimensions, with a few notable exceptions throughout the history of standard pallet sizes and their uses. The 42 x 42 size, which is the main standard size for the paint and telecommunications industry, was initially designed for military purposes.
Size (inches) | Common use | Safe max load* |
48 x 40 | Grocery, general warehousing | 4,592 lbs |
42 x 42 | Paint, telecom | 4,445 lbs |
48 x 48 | Drums, chemicals | 4,673 lbs |
40 x 48 | General freight | 3,696 lbs |
36 x 36 | Beverage | 3,544 lbs |
*Loads from the Kamps Pallets size chart (updated 2025) and specific to those builds. The automotive industry runs its own 48 x 45 standard.
Which Pallet Sizes Fit Warehouse Racking Systems Best?
The design of most selective racking is based on the 48” deep pallet combined with 42” deep rack frames. In this configuration, the 40” edge of the pallet is located on the outside, thus resulting in the 48” length being aligned from the front to the back of the rack. The protruding deck part, over 3” of length, is made purposely. The standard height of 96” beams allows placing two pallets of 48”x40” size in each rack bay.
Double-check your numbers before ordering anything, since the pallet sizes for racking systems tend to be less forgiving than those used in floor storage. If the pallet is too light for its frames, it will fall down, and if the pallet is too deep, it will block the space in between the frames designed to meet the fire regulations. In case there is a disagreement between the pallet and the dimensions of the rack, the warehouse pallet dimensions will prevail and thus the pallet will have to be redesigned.
Does a Bigger Pallet Carry More Weight?
No, and this is the most common sizing mistake we hear. Pallet weight capacity by size is a myth: capacity comes from the build, meaning stringer count, stringer size, deck thickness, and wood species. On the published Kamps chart, a little 42 x 31 pallet rates 6,585 lbs, while the much larger 48 x 48 rates 4,673 lbs. The small one has more structure packed under a smaller deck.
So never order a bigger footprint, hoping for more capacity. Have the pallet engineered for the load instead. Riverview models builds in Pallet Design System (PDS) software through our pallet design service, which calculates safe load capacity before production.
When Do the Best Pallet Sizes for Warehousing Turn Out to Be Custom?
When your product, racking, or dock doors don’t match the chart above. Choosing the right pallet size starts with the standard sizes because they are cheaper and available everywhere, and it moves to custom the moment a standard footprint makes your product overhang the deck or leaves your racks half empty.
Custom pallet sizes for warehouses are common in Ohio manufacturing for exactly those reasons, like a stamped part that needs a 52-inch deck or a conveyor line with a hard width limit. We build custom pallets and wooden skids to those numbers rather than forcing the load onto a 48 x 40.
Sizing Help, Delivery, and End-of-Life, All From One Ohio Plant
Riverview delivers sized orders on our own fleet through Riverview Transport, from the Smithville plant to docks in Cleveland, Akron, and Columbus.
Worn-out pallets have somewhere to go, too. Our recycling services pull the reusable material back out, and our grinding services turn the rest into mulch and biomass fuel.
Final Thoughts
Start at the 48 x 40 and let the evidence push you off it. If your racking and your freight both fit the standard, you’ll never beat its price. If any one of them doesn’t, the cheapest pallet on the quote sheet stops being the cheapest pallet in the building.
Not sure which size your operation needs? Call Riverview Pallets at (330) 669-8509 or request a free quote, and we’ll size the pallet to your load and your racks.
Frequently Asked Questions About Industrial Pallet Delivery Services
What Is the Most Common Pallet Size in the US?
The 48 x 40 inch GMA pallet, which accounts for about 30% of new wood pallets produced in the US. It was standardized by the Grocery Manufacturers Association and now runs through grocery and general warehousing. Most US handling equipment and racking assume this footprint.
What Size Pallet Fits Standard Warehouse Racking?
A pallet that is 48 inches deep is the cause of the turmoil that the 48 x 40 pallet creates in the world of racking. For example, when utilized correctly, the standard selective racking setup with its 42-inch deep frames and 96-inch beams can safely store two 48 x 40 pallets, as there would be only three inches of overhang. The question of depth arises, as certain pallets are deeper and lighter than normal and the rack specifications must be verified first.
What's the Difference Between a 48x40 and a 48x48 Pallet?
It is interesting to note the difference in the width measuring eight inches and the industries in which it is used. The same 48 x 40 pallet is used in almost every grocery and warehousing operations, whereas the square 48 x 48 pallet is always utilized for types of loads in barrels as well as chemical cargo. Strength characteristics vary only in typical models, and depending on the style of loading, it is better to choose the one that fits your support and rack.
Can Pallet Sizes Be Customized for Specific Products?
Yes. Footprint, deck spacing, stringer size, and species can all be set from your product’s dimensions and weight. Riverview engineers custom pallet sizes for warehouses in PDS design software, so the custom footprint is stress-tested digitally before it is built.
What Pallet Size Is Best for Export Shipping?
The widely recognized heat-treated 48 x 40 pallet is suitable for the majority of exporting container vessels around the world, as all the necessary devices are available. If your shipment is to be stored on shelves in European countries, the correct Euro pallet measuring 1200 x 800 mm will be required to fit the storage requirements. However, it is important to keep in mind the necessity of having an ISPM-15 label on each exported wooden pallet.
Partner with Riverview Industrial Today
Ready to optimize your shipping solutions with premium wooden pallets, wooden shipping crates, and tailored designs? Contact Riverview Industrial for high-quality materials that comply with global standards and deliver unmatched durability.
Riverview Industrial Contact Information:
Phone: 330-669-8509
Email: sales@riverviewpallet.com
Location: Smithville, Ohio
As one of Ohio’s largest pallet producers, Riverview Industrial takes pride in helping businesses thrive in global shipping.
Make the move to smarter, safer, and more efficient shipping solutions today with Riverview Industrial’s custom wood packaging expertise.