RULES CURRENTNMFC density scale · Jul 19, 2025USPS DIM 139 · Jul 12, 2026Last checked Sep 24, 2026
All 13 calculators
T-04 · WAREHOUSE

Pallet Calculator

Work out how many cases fit on a pallet, how many layers you get, and whether the weight limit stops you before the height does.

UNITS

Max total height includes the pallet deck, so a 5.5 in deck comes off before the cases are stacked.

HOW WE GOT THERE1. 60 − 5.5 in deck = 54.5 in of stacking height2. 54.5 ÷ 10 = 5 layers3. 3 × 3 = 9 per layer4. 9 × 5 = 45 cases
RESULTSINGLE ORIENTATION
CASES PER PALLET
45
PER LAYER9
LAYERS5
PATTERN3 × 3
TOTAL WEIGHT1,350 lb
Space used: 83% of the usable cube.
PALLET · STACKED45 cases

Worked example

A 16 × 12 × 10 inch case on a standard 48 × 40 GMA pallet, with a 60 inch height limit and a 2,500 pound weight cap.

  1. The pallet deck is 5.5 inches, so you have 54.5 inches of stacking height.
  2. 54.5 ÷ 10 = 5 layers. The leftover 4.5 inches is wasted, not a sixth layer.
  3. Per layer: three cases fit along the 48 inch side and three across the 40 inch side, so 9 per layer. Turned 90 degrees you would get only 8.
  4. 9 × 5 = 45 cases, weighing 1,350 pounds, comfortably under the cap.

The formula

Usable height = max height − pallet deck
Layers        = ⌊usable height ÷ case height⌋
Per layer     = the better of
                ⌊pallet L ÷ case L⌋ × ⌊pallet W ÷ case W⌋
                ⌊pallet L ÷ case W⌋ × ⌊pallet W ÷ case L⌋
Total         = per layer × layers, capped by max weight

This is the single-orientation answer: every case sits the same way up and the same way round. Real pallet patterns sometimes beat it by mixing orientations in a pinwheel, but a single orientation is what most pick lists and load plans actually specify, and it never overstates what fits.

Height and weight limits that matter

Sixty inches total is a common LTL ceiling, and many carriers price above it as an oversize handling unit. Warehouses often cap lower for rack clearance, and air freight caps lower again.

On weight, 2,500 pounds per pallet is a practical LTL ceiling. Past that you need to confirm the forklift capacity, the dock plate rating and the floor loading at both ends. A pallet nobody can lift is not a shipment.

Beyond a single orientation

This calculator uses one orientation for the whole pallet, which is what most pick lists and load plans specify and what a warehouse can build reliably. Real pallet patterns sometimes beat it.

A pinwheel pattern rotates cases around the pallet edge so the corners interlock, which can fit an extra case per layer on some footprints and ties the layer together without relying on wrap alone. Column stacking, where every case sits squarely on the one below, carries the most weight because the load travels down the case corners — but it relies entirely on wrap for lateral stability. Interlocked stacking, which rotates alternate layers, is far more stable in transit and costs you roughly a third of the stacking strength.

The trade is stability against capacity. For LTL, where a pallet is handled several times and rides with strangers’ freight, stability usually wins. For a dedicated container load that is handled twice, capacity often does.

Common mistakes

  • Forgetting the deck. A 60 inch limit is not 60 inches of cases. The 5.5 inch deck is the difference between five layers and six.
  • Overhanging the edge. Cases hanging past the pallet lose their corner support, get crushed, and change the dimensions the carrier measures for class.
  • Ignoring the turned layout. Rotating the cases 90 degrees sometimes adds a whole column. This calculator checks both and reports the better one.
  • Stacking to the weight limit. Just because 2,500 pounds fits does not mean the bottom layer can carry it. Check the case crush rating.
  • Assuming every pallet is 48 × 40. European EUR pallets are 120 × 80 cm, and plenty of industries use their own footprint.

FAQ

How many boxes fit on a pallet?

Work out how many fit in one layer, then how many layers clear your height limit, then multiply. A 16 by 12 by 10 inch case on a 48 by 40 pallet gives 9 per layer and 5 layers under a 60 inch limit, so 45 cases.

What is a standard pallet size?

In North America the GMA pallet is 48 by 40 inches with a deck about 5.5 inches high. In Europe the EUR pallet is 120 by 80 cm. Both appear as defaults here.

Does the pallet height count toward my limit?

Yes. A 60 inch maximum includes the pallet, so a 5.5 inch deck leaves you 54.5 inches of stackable space.

What is a safe maximum pallet weight?

Most LTL carriers are comfortable to about 2,500 lb per pallet, and many warehouses cap lower. Above that you need to check equipment limits at both ends before it ships.

Should I turn the cases 90 degrees?

Sometimes it fits more. This calculator tries both the square-on layout and the turned one and reports whichever gives more cases per layer.

Rules last checked: Sep 24, 2026

Estimate only. Confirm with your carrier before booking.