Pallet stacking pattern viewer
What each case-stacking pattern is, when to use it, its strength trade-off and the usual mistakes.
Get this tool with its role plan
This is a premium tool. It comes with its role's plan: sign in, then add the role in Billing.
Comes with the warehouse and forklift crew plan: every tool for the role, from $10.20 a month at the launch price.
- Your own numbers, worked out as often as you like
- The full build sheet you can print or save to My work
- 3 cited sources, linked, with the checks to make
- Every other tool for the same role, in the same plan
- A plain-words read of your result (a fuller AI read with the Bifrost AI add-on)
Included in these role plans
Example result · fictional numbers
What you get: build sheet
Worked out by this tool from its default inputs. Its role plan lets you run your own numbers, print the sheet and save it.
Column stack on a 48 x 40 in (GMA) pallet: 9 cases a layer, 5 layers, 45 cases (1,125 lb)
- What it is
- Cases stacked directly on top of each other, corners aligned, every layer the same.
- Use it when
- Cases carry the load (beverages, canned goods); stacks will be double-stacked or racked.
- Key numbers
- Keeps close to 100% of carton compression strength.
- Watch out for
- Columns can lean and split apart; use corner boards, tie sheets every few layers and full stretch-wrap.
Pallet build sheet
- Pattern
- Column stack
- Pallet
- 48 x 40 in (GMA)
- Case
- 16.0 x 12.0 x 10.0 in, 25.0 lb
- Cases per layer
- 9 (every layer the same, corners aligned)
- Layers
- 5 (50.0 in of the 54.0 in limit)
- Cases per pallet
- 45
and 2 more lines
Also on the sheet
- Top-load check on the bottom case · 4 lines, starting with “Weight on the bottom case”
The plain-words read of this example
A column stack of 16.0 x 12.0 x 10.0 in cases on a 48 x 40 in (GMA) pallet fits 9 a layer and 5 layers, 45 cases and 1,125 lb. Bottom-case check: OK: 6.0 times the load, above your 3.0 times. Stored loads must stay stable and secure against sliding or collapse, and any overhang lowers box strength further.
3 cited sources
- 29 CFR 1910.176, Handling materials: general (OSHA)
- Effect of Pallet Overhang on Box Compression Strength, final report (Horvath and Molina) (Virginia Tech Center for Packaging and Unit Load Design, for the Fibre Box Association)
- Predicting the Effect of Pallet Overhang on the Box Compression Strength (Kim et al., 2023) (Virginia Tech (VTechWorks))
Plus 5 step-by-step checks, a print layout and a link that reopens it with your numbers.
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