Pallet height, weight, and stability limits: what controls the load?

Calculate the height ceiling correctly

Subtract pallet base, cap, slip sheets, and required clearance from the maximum total height before dividing by carton height. Round down to full layers. If a customer requires a fixed layer count or label orientation, that operating rule may control before the geometric limit.

A 165 cm total-height limit, 15 cm pallet base, and 25 cm cartons allow six full layers before other constraints. The finished height is 165 cm, leaving no unrecorded clearance.

Apply every weight rating

Compare gross carton total with the pallet's rated capacity, rack or floor limits, forklift capacity at the relevant load centre, vehicle payload, and any customer limit. A 1,000 kg planning cap with 12 kg cartons limits the load to 83 cartons even if geometry fits more.

Use gross packed carton weight and include stabilisation materials when the margin is small.

• Do not use pallet capacity as a carton-compression rating.
• Check dynamic and racking conditions separately.
• Record the limiting constraint on the load sheet.

Approve stability with a physical standard

Column stacking, interlocking, stretch wrap, straps, corner boards, coefficient of friction, load-centre position, and route vibration affect stability. A calculator can expose the proposed pattern and totals, but a competent trial and documented acceptance criteria must approve the load.