Pallet calculator: how many boxes fit on a pallet, stacking pattern and pallet cubic feet
Pick a pallet, enter the box size and the load height limit — the calculator works out how many boxes fit per layer and per pallet, compares four stacking patterns, checks the weight and the crush strength of the bottom row, and shows the pallet cubic feet and where the tier sheets go.
Sizes in inches, weight in pounds; switch to feet with the unit buttons. Everything is calculated in your browser — no data is sent anywhere.
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Get a shipping quotethis button is for saleHow to use the pallet calculator
Choose the pallet: the 48×40 GMA pallet, 48×48 for drums and bulk bags, 42×42 for telecom and paint, or a euro pallet — or enter your own size, deck height and weight. Then enter the outer size and gross weight of the box, the maximum load height including the pallet, and the weight limit. The height presets “53′ dry van · 110″”, “40′ container · 94″” and “40′ HC · 106″” take the inside height of the trailer or container; if you double or triple stack, set it in “Pallets stacked” and the height is split between the tiers.
The calculator shows how many boxes fit in one layer (the tie), how many layers fit in the height (the high) and how many boxes go on the whole pallet, then checks the gross weight and the strength of the bottom row. Tick “Can lie on its side” only for product without a “This side up” arrow. Overhang adds footprint, but cases hanging past the deck edge lose a big part of their compression strength and get damaged by forklifts.
Pallet patterns: column, interlock, block and pinwheel
First the boxes are laid out in one layer across the deck: a straight grid, mixed rows, blocks in two orientations and a pinwheel. Then the calculator counts how many layers fit in the height with the pallet and tier sheets, and checks the weight and the bottom-case strength. The last layer may be partial if the weight limit is reached first.
Column stacking puts cases exactly on top of each other: the corners carry the load, so the pallet takes the most weight, but the load can shift without tier sheets and stretch wrap. Interlocking (brick pattern) alternates two different layers: the pallet is more stable, but the corners no longer line up and stacking strength drops — the calculator assumes a 40% loss. Block uses two orientations inside identical layers. Pinwheel sets four blocks around the center and mirrors every other layer.
The BCT check compares the weight of everything above the bottom case (including pallets stacked on top) with the case compression strength divided by the safety factor. If the case is not strong enough, the calculator removes layers and shows the BCT you would need for one more.
Pallet cubic feet: table for a 48×40 pallet
Pallet cubic feet = length × width × total height in inches ÷ 1,728. A 48×40 pallet covers 13.33 sq ft, so every foot of height adds 13.33 cu ft. The table answers “how many cubic feet is a pallet” for three common load heights; the floor area assumes pallets placed without gaps.
| Pallets | up to 48 in, cu ft | up to 60 in, cu ft | up to 72 in, cu ft | Floor area, sq ft |
|---|---|---|---|---|
| 1 | 53.3 | 66.7 | 80.0 | 13.3 |
| 2 | 106.7 | 133.3 | 160.0 | 26.7 |
| 4 | 213.3 | 266.7 | 320.0 | 53.3 |
| 6 | 320.0 | 400.0 | 480.0 | 80.0 |
| 8 | 426.7 | 533.3 | 640.0 | 106.7 |
| 10 | 533.3 | 666.7 | 800.0 | 133.3 |
| 12 | 640.0 | 800.0 | 960.0 | 160.0 |
| 15 | 800.0 | 1,000.0 | 1,200.0 | 200.0 |
| 20 | 1,066.7 | 1,333.3 | 1,600.0 | 266.7 |
| 26 | 1,386.7 | 1,733.3 | 2,080.0 | 346.7 |
| 30 | 1,600.0 | 2,000.0 | 2,400.0 | 400.0 |
For a 48×48 pallet multiply the values by 1.2, for 42×42 by 0.92. The exact cubic feet of your pallet are shown in the calculator result.
Pallet sizes and weight capacity
| Pallet | Size, in | Deck height | Pallet weight | Load used |
|---|---|---|---|---|
| GMA (grocery) | 48 × 40 | 5.5″ | 37 lb | 2,500 lb |
| 48×48 — drums, bulk bags | 48 × 48 | 5.5″ | 44 lb | 2,500 lb |
| 42×42 — telecom, paint | 42 × 42 | 5.5″ | 35 lb | 2,500 lb |
| Euro pallet EUR 1200×800 | 47.2 × 31.5 | 5.7″ | 55 lb | 3,300 lb |
| EUR 2 1200×1000 | 47.2 × 39.4 | 5.7″ | 73 lb | 2,750 lb |
Deck height, pallet weight and capacity are typical figures — they depend on the wood, the design and the condition of the pallet. Enter your own pallet with “+ Custom size”.
Tier sheets, slip sheets and stretch wrap
A corrugated or chipboard sheet on the deck protects case bottoms from gaps between the boards and from nails. In a column stack the layers are not tied together, so a tier sheet every 2–3 layers keeps the load square; a top sheet spreads the pressure of stretch wrap and banding. The calculator adds the thickness and weight of the sheets to the pallet height and weight and counts how many you need.
Other calculators
Cubic feet calculator — the volume of a shipment in cu ft. Dimensional weight — dim weight for air and parcel. Box in a box — how many cartons fit in a master case. Freight class — LTL class by density.
Frequently asked questions
How many boxes fit on a 48×40 pallet?
It depends on the box size and the load height. At up to 72 in including the pallet: a 12×12×12 in box — 60 boxes (12 per layer × 5 layers), 16×12×12 — 50 (10 × 5), 24×16×16 — 20 (5 × 4), 12×10×10 — 96 (16 × 6). Enter your own box — the pallet calculator compares four stacking patterns and picks the one that holds the most.
How many cases of copy paper fit on a pallet?
A case of letter-size copy paper (10 reams) is about 17.5 × 11.25 × 10.5 in and 50 lb. Without overhang a 48×40 pallet takes 9 cases per layer: 36 cases at a 48 in load height, and at 72 in the 2,500 lb weight limit stops the pallet at 49 cases. Mills often ship 40 cases per pallet (10 × 4) using slightly smaller cases or a small overhang — enter your case size to check.
How do I calculate pallet cubic feet?
Multiply length × width × total height in inches, including the pallet, and divide by 1,728. A 48×40 pallet loaded to 72 in: 48 × 40 × 72 ÷ 1,728 = 80 cu ft; to 60 in — 66.7 cu ft; to 48 in — 53.3 cu ft. If cases overhang, measure the overhang. The calculator shows the loaded pallet cubic feet in the result.
How tall can a pallet be?
Many LTL carriers and warehouses ask for 72 in or less including the pallet, and some charge extra or refuse anything taller — check your carrier. A 53-ft dry van has roughly 108–110 in of inside height, so for double stacking each pallet should stay under about 54 in. Use the height presets or type your own limit.
Which pallet stacking pattern is best?
Column stacking — case exactly on case — gives the most compression strength because the corners line up, but it needs tier sheets and good stretch wrap. Interlocking (brick) is more stable in transit, but stacking strength drops by about 40%. Block and pinwheel patterns help when the case divides the pallet awkwardly. The calculator works out all four and marks the best one.
How many layers can a case carry? BCT and ECT
BCT (box compression test) is the load a case takes before it crushes; it is on the box spec or can be estimated with the McKee formula from the board ECT. The calculator takes ECT in kN/m — multiply lb/in by 0.175, so 32 ECT board is about 5.6 kN/m. The weight above the bottom case times the safety factor (×3 short trip, ×4–5 warehouse, ×6 cold storage) must stay below the BCT, otherwise the calculator removes layers.
How much weight can a pallet hold?
A standard 48×40 GMA hardwood pallet is typically rated at about 2,500 lb of moving (dynamic) load spread evenly over the deck — that is the default limit in the calculator. Sitting still on a flat floor the same pallet carries much more, often quoted up to about 4,600 lb. Lighter or used pallets carry less, so check the rating from your supplier.
How many pallets fit in a 53-foot trailer?
A 53-ft dry van takes 26 standard 48×40 pallets loaded straight in two rows, or up to 30 when the pallets are turned, in a single tier; double stacking doubles that if the load and the weight allow. The total shipment volume in cubic feet is worked out by the cubic feet calculator, and the LTL class by the freight class calculator.