What Is a Block Pallet? Beginner-Friendly Explanation and Components

A block pallet is a type of pallet in which the top deck (the part you load goods onto) is supported by separate blocks—usually arranged under the corners and sometimes in the center—rather than continuous stringers running along the side. This block construction gives the pallet greater strength, allows forklifts and pallet jacks to enter from all four sides, and provides reliable load-bearing characteristics for warehousing, transport, and racking systems.

Basic construction and materials

• Deck boards — The top and often the bottom decks are made from wood (softwood or hardwood), plastic, or composite materials and form the flat surfaces where products are placed.
• Blocks — Typically square or rectangular blocks are fixed between the top and bottom deck boards at strategic positions (corners and midpoints). Blocks can be made from wood, engineered wood, plastic, or molded composite materials.
• Fasteners and joinery — Nails, screws, adhesive, or molded joints hold the deck and blocks together. Heavy-duty pallets use stronger fastenings for load resilience.

Key characteristics

• Four-way entry — Unlike some stringer pallets that allow forklift entry only from two sides, block pallets typically allow access from all four sides, improving handling flexibility.
• High load capacity — Block pallets distribute loads through multiple supporting points, giving them higher static and dynamic load capacities compared to basic two-stringer pallets of similar size.
• Racking compatibility — Block pallets are commonly used on pallet racking systems because their shape and support points suit beam shelving and selective racks.

Types and variations

• Full block pallets — Standard pallets with blocks at all corners and often in the center for extra support.
• Nine-block pallets — A common style with nine support blocks: one at each corner, one at the middle of each side, and one in the center.
• Molded plastic block pallets — Made as one piece or with molded blocks, these resist moisture and contamination and suit hygienic environments like food and pharmaceuticals.
• Engineered and composite — Use combinations of wood, recycled plastics, or metal reinforcements for heavier loads or specialized applications.

Standards and treatment

Block pallets intended for export should comply with international phytosanitary standards (ISPM 15), which require wood pallets to be heat-treated (HT) or fumigated to prevent pest spread.

• Common sizes follow regional standards—e.g., 48x40 inches in North America or EUR pallets in Europe—but many manufacturers produce custom sizes to fit racks or containers.

Advantages

• Durability and strength — Better suited for heavy or dense loads and repeated handling.
• Versatility — Four-way access increases handling options and reduces maneuvering time.
• Racking and stacking — Stable for stacking and compatible with common racking systems.

Disadvantages and trade-offs

• Weight — Block pallets (especially wood and solid composites) can be heavier than lightweight stringer pallets, affecting freight costs.
• Cost — Initial purchase price can be higher, though lifetime cost-per-use can be lower for durable applications.
• Repair complexity — Block pallets with molded or glued components may be less repairable than simple nailed stringer pallets.

Everyday examples

• Warehouse operators place full skids of boxed electronics on block pallets for secure storage and easy movement to shipping lanes.
• Food processors use plastic block pallets in cold rooms where moisture would damage wooden pallets.
• Exporters of industrial machinery pack heavy components onto nine-block pallets, which provide center support and meet ISPM 15 requirements when heat-treated.

For beginners, it helps to think of block pallets as the sturdy, versatile option in the pallet family: they are built to carry heavier loads, make handling easier from any side, and perform well in racking and shipping. When choosing between pallet types, consider load, handling equipment, environmental exposure, and regulatory requirements to decide if a block pallet is the right fit.