Two Designs, Different Strengths
Every wooden pallet falls into one of two fundamental construction categories: stringer pallets or block pallets. While they serve the same basic purpose — providing a stable platform for storing and transporting goods — the structural differences between the two designs affect load capacity, forklift accessibility, cost, durability, and suitability for different applications.
Choosing the right type for your operation can improve warehouse efficiency, reduce product damage, and lower your overall logistics costs. Here is a detailed comparison to help you decide.
Stringer Pallet Construction
Stringer pallets — also called two-way or partial four-way pallets — use two or three parallel boards (stringers) running the length of the pallet as the primary structural framework. Deck boards are nailed across the top and bottom of these stringers to create the load-bearing surfaces.
The stringers are typically 2×4 or 3×4 lumber, and they provide the vertical support between the top and bottom decks. The standard GMA 48×40 pallet is a stringer pallet with three stringers — one on each edge and one in the center.
Forklift Access
Standard stringer pallets are two-way entry, meaning forklifts can access them from the two open ends (between the stringers) but not from the sides (where the stringers block entry). However, most stringer pallets used in the U.S. are modified with notched stringers — rectangular cutouts in the stringers that allow partial fork entry from the sides. This makes them partial four-way entry: full access from two sides, partial (notched) access from the other two.
The notches are sized for standard forklift tines but do not accommodate pallet jacks from the notched sides. This can be a limitation in operations that rely heavily on pallet jacks for floor-level handling.
Strengths of Stringer Pallets
- Lower cost. Stringer pallets require less lumber and simpler assembly than block pallets, resulting in a 15-25% cost advantage.
- Lighter weight. Less material means less weight — important when freight charges are calculated by gross weight.
- Easier to repair. Damaged stringers can be reinforced with companion boards. Deck boards are simple to replace. Repair costs are lower than for block pallets.
- Widespread availability. Stringer pallets dominate the North American market (approximately 80% of all pallets in the U.S. are stringer design), making them readily available in both new and recycled options.
Limitations of Stringer Pallets
- Limited to two-way or partial four-way entry (not true four-way)
- Lower load capacity per square inch compared to block pallets of similar dimensions
- Notches create stress points that can lead to stringer failure under heavy loads
- Not ideal for automated handling systems that require four-way access
Block Pallet Construction
Block pallets use a grid of solid wood blocks (typically nine — four corner blocks, four edge blocks, and one center block) as the structural foundation, with stringer boards and deck boards attached to create the complete platform. The blocks provide support at key load points and create openings on all four sides for forklift and pallet jack access.
Forklift Access
Block pallets are true four-way entry. Forklifts and pallet jacks can access the pallet from any of the four sides without restriction. This provides maximum flexibility in warehouse operations, particularly in tight spaces where pallet orientation cannot always be controlled.
Strengths of Block Pallets
- True four-way entry. The most significant operational advantage — any forklift or pallet jack can access the pallet from any direction.
- Higher load capacity. The block design distributes weight more evenly and eliminates the stress concentrations created by stringer notches. Block pallets typically support 15-25% more weight than comparably sized stringer pallets.
- Superior racking performance. The blocks sit directly on rack beams, providing a stable, flush contact surface. This is especially important in push-back and pallet flow racking systems.
- Better for automated systems. Four-way entry and consistent dimensions make block pallets the preferred choice for AS/RS (Automated Storage and Retrieval Systems) and conveyor systems.
- International preference. Block pallets are the standard in Europe (EUR/EPAL pallets) and many international markets.
Limitations of Block Pallets
- Higher cost (15-30% more than comparable stringer pallets) due to more material and more complex assembly
- Heavier weight (5-10 lbs more than a comparable stringer pallet)
- More difficult and expensive to repair — damaged blocks are harder to replace than damaged stringers
- Less readily available in the recycled market (lower circulation volume in North America)
Head-to-Head Comparison
| Feature | Stringer Pallet | Block Pallet |
|---|---|---|
| Entry access | 2-way (or partial 4-way with notches) | True 4-way |
| Dynamic load capacity (48×40) | 2,200 – 2,500 lbs | 2,800 – 3,500 lbs |
| Static load capacity (48×40) | 2,500 – 2,800 lbs | 3,000 – 4,000 lbs |
| Racking load capacity | 2,000 – 2,500 lbs | 2,500 – 3,000 lbs |
| Weight (empty, 48×40) | 35 – 45 lbs | 45 – 55 lbs |
| Cost (new) | $11 – $18 | $15 – $25 |
| Cost (recycled) | $4 – $9 | $7 – $14 |
| Repair cost | $2 – $5 | $4 – $8 |
| Repairability | Easy | Moderate |
| Automated system compatibility | Limited | Excellent |
| Availability (North America) | Very high (~80% of market) | Moderate (~20% of market) |
| International standard | North America primarily | Europe, Asia, global |
Industry Preferences
Different industries tend to gravitate toward one design based on their specific operational requirements:
Industries That Favor Stringer Pallets
- Grocery and retail: The GMA standard is a stringer pallet. Major U.S. retailers are built around this format.
- General manufacturing: Cost sensitivity and high pallet turnover favor the cheaper stringer design.
- Agriculture and produce: Lightweight, economical, and widely available through recycling.
- Construction materials: Heavy loads often ride on heavy-duty stringer pallets with thicker stringers.
Industries That Favor Block Pallets
- Automotive: High-value components on automated systems require the precision and four-way access of block pallets.
- Pharmaceutical: Strict quality requirements and automated warehousing favor block construction.
- International export: EUR/EPAL block pallets are the standard for European trade. ISPM-15 treatment is available for both types.
- Aerospace and defense: Heavy, oversized loads benefit from the superior load distribution of block pallets. See our custom aerospace pallet capabilities.
- Pallet pooling companies: CHEP (blue) and PECO (red) pallets are block pallets, chosen for their durability and universal handling compatibility.
When to Choose Each Type
Choose Stringer Pallets When:
- Cost is a primary concern and your application does not require four-way access
- You operate primarily in the domestic U.S. supply chain
- Your warehouse uses selective racking with standard beam spans
- You need high-volume, readily available pallets with easy repairability
- Your loads are within the standard 2,500 lb dynamic capacity
Choose Block Pallets When:
- Your warehouse uses automated handling systems (AS/RS, conveyors, robotic palletizers)
- You need true four-way access for operational flexibility
- You ship internationally, particularly to European markets
- Your loads exceed stringer pallet capacity ratings
- You use push-back, pallet flow, or other dynamic racking systems
Can You Mix Types in Your Operation?
Absolutely. Many businesses use stringer pallets for general domestic shipping and block pallets for specific applications — export shipments, automated storage areas, or heavy loads. The key is to ensure that your racking, material handling equipment, and receiving partners can accommodate both types.
We stock both stringer and block pallets in standard sizes. Contact our team for current availability and pricing, or visit our size guide to compare dimensions and specifications for both construction types.