Block Pallet

Block pallet

A block pallet is a type of pallet whose deckboards are supported by a series of discrete blocks rather than by continuous stringers. These blocks—made from wood, plastic, metal, or composite materials—are positioned under the top deck to create a sturdy platform that allows forklifts and pallet jacks to enter from all four sides (four-way entry). Block pallets are widely used where higher load capacity, frequent handling, and compatibility with automated systems are required.

Construction and materials

Block pallets differ from stringer pallets primarily in the form of vertical support. Instead of elongated side members (stringers), block pallets use individual blocks placed under the top deck and often under the bottom deck as well. Blocks can be solid rectangular pieces, molded blocks (in plastics), or shaped wooden blocks.

Common materials:

• Wood — the traditional and most economical choice; easily repaired and widely used for domestic and export shipments (often heat-treated to meet export regulations).
• Plastic — resistant to moisture and chemicals, easier to clean, and preferred in hygienic environments such as food and pharmaceuticals.
• Metal — used for very heavy loads or specialized applications where fire resistance or extreme durability is needed.
• Composite — blends of wood and plastic or other materials to combine strength and durability with lighter weight or increased hygiene.

Design variants and features

Block pallets come in multiple configurations: full-deck or partial-deck, with top-only deck or with bottom deck for extra stability. They are commonly manufactured to be 4-way entry, but some designs include notches to allow 4-way entry on otherwise stringer-like designs. Some block pallets are specifically engineered for racking and have reinforced blocks or stringers designed for pallet racking (racking-rated pallets).

Typical dimensions and load considerations

Block pallets are produced in standard industry sizes (for example ISO and regional standards such as 1200 x 1000 mm, 1200 x 800 mm, or 48 x 40 inches) and in custom sizes to suit specific product or system requirements. Load capacities depend on material, block geometry, deckboard thickness, and construction quality. Pallet load characteristics are usually described as:

• Dynamic load — capacity while being moved by forklifts or pallet trucks.

• Static load — capacity when the pallet is stationary on the floor.

• Racking load — capacity when stored on pallet racking, which is often the most limiting specification and requires specific testing or certification.

As a general guideline, block pallets tend to carry higher loads and present better stiffness and load distribution than comparable stringer pallets, but exact figures should be taken from manufacturer specifications.

When and why block pallets are used

Block pallets are chosen when the operational needs favor durability, higher load capacity, and multi-directional entry. Typical use cases include:

• Warehousing and racking — block pallets that are racking-rated are preferred in high-density racking systems because of their stiffness and even load distribution.
• Heavy or uneven loads — industries such as automotive, building materials, and heavy machinery use block pallets for robustness.
• Automated handling — four-way entry and consistent geometry make block pallets suitable for conveyors, automated guided vehicles (AGVs), and automated storage/retrieval systems (AS/RS).
• Export — wooden block pallets can be treated to meet ISPM 15 requirements, making them suitable for international shipping when properly stamped.
• Hygienic environments — plastic block pallets are common in food, beverage, and pharmaceutical industries where washability and contamination control are important.

Advantages

• Four-way entry increases forklift and handler flexibility and improves warehouse throughput.

• Superior load distribution and stiffness, making them suitable for heavier loads and racking.

• Modular block supports can reduce point-loading damage and allow easier repair of damaged deckboards.

• Available in a wide range of materials to meet specific hygiene, durability, or weight requirements.

Disadvantages and trade-offs

• Typically more expensive than simple stringer pallets, especially in plastic or metal variants.

• Heavier designs (e.g., solid wood or metal) can add weight, increasing transport cost.

• Not all block pallets are racking-rated — assuming they are without verification is a common error.

Best practices for selection and use

Select a block pallet by matching material, dimension, and load ratings to your operational needs. Key considerations include:

• Specify dynamic, static, and racking load requirements and verify manufacturer test data.

• Choose material based on hygiene, durability, and environmental exposure (e.g., plastic for washdown, treated wood for export).

• Confirm compatibility with forklifts, pallet jacks, conveyors, and automation in your facility.

• For export, ensure wooden block pallets are ISPM 15 compliant (heat-treated or fumigated and stamped).

• Implement inspection and maintenance routines: repair cracked blocks or broken deckboards promptly to avoid product damage or accidents.

Common mistakes

• Assuming all block pallets are suitable for racking without verifying racking load ratings.

• Ignoring ISPM 15 or other regulatory requirements for cross-border shipments of wooden pallets.

• Using the wrong material in hygienic or corrosive environments (e.g., wooden pallets where washdown is required).

• Overloading pallets or unevenly loading the deck, which can cause failure even if rated capacity appears sufficient.

Real-world examples

An automotive manufacturer uses heavy-duty wooden block pallets to move stamped body panels and engine components between production cells and into racking; the block construction distributes weight and withstands repeated forklift handling. A food distribution center relies on plastic block pallets because they can be washed and sanitized, reducing contamination risk while providing robust four-way handling for fast pallet turnover. A third-party logistics operator serving retail chains uses standardized 1200 x 1000 mm block pallets to optimize pallet racking density and ensure compatibility with automated pallet handling equipment.

Summary

Block pallets are a versatile, durable pallet type characterized by block-style supports that provide four-way forklift access, superior load distribution, and compatibility with modern warehousing systems. Selecting the right block pallet requires attention to material, dimension, and rated loads, along with compliance for export and hygiene considerations. When chosen and maintained correctly, block pallets improve handling efficiency, protect product integrity, and support higher-density storage strategies.