Load overhang
Also called: pallet overhang, overhang
Load overhang is any part of a unit load that extends beyond the edges of the pallet's top deck. Unsupported case edges lose compression strength, get damaged in handling, and increase the measured size of the shipment.
In depth: Pallet overhang: why loads should not hang past the pallet edge
Overhang usually happens when the case size does not divide neatly into the pallet footprint and someone chooses more cases per layer over a clean fit.
Why overhang is a problem
| Effect | Why |
|---|---|
| Lower box compression strength | The strongest parts of a corrugated case are its corners and vertical walls. Overhanging walls have nothing under them |
| Damage in handling | Overhanging cases hit rack uprights, trailer walls and other loads |
| Higher freight cost | Carriers measure the outside dimensions, so overhang increases the billed cube and lowers freight density |
| Rejection | Many retailers and carriers do not accept overhang |
Packaging research has measured large compression losses even at small overhangs. The size of the loss depends on the case and the amount of overhang, so treat any single percentage as illustrative.
Why it matters for pallet design
Sometimes the right fix is the pallet, not the pattern. A custom footprint sized to the case pattern can remove overhang and underhang together. The cases per pallet calculator shows the fit on standard footprints.
On a spec sheet or RFQ
State the allowed overhang (often zero) and the case dimensions. If you are sizing a custom pallet to a load, give the load's outside dimensions and let the pallet match or slightly exceed them.
Common confusions
A wing is the pallet's own deck extending past its stringers. That is not load overhang. The overhang guide covers both.
Related
- GuidesPallet overhang: why loads should not hang past the pallet edgePallet overhang is any part of the load that extends past the pallet edge. It leaves the bottom edges of boxes unsupported, cuts their stacking strength, exposes them to damage, and enlarges the billed freight dimensions. Most receivers want zero overhang: keep the load flush with or just inside the pallet edges.
- GlossaryUnderhangUnderhang is when the unit load's footprint is smaller than the pallet's top deck, leaving part of the deck uncovered around the edges. It wastes cube and can leave the load less stable, but it keeps case walls fully supported.
- GlossaryStacking patternA stacking pattern is the arrangement of cases on a pallet: how they are placed within each layer and how each layer relates to the one below. The main choices are column stacking, which maximizes box strength, and interlocking patterns, which improve stability.
- GlossaryFreight densityFreight density is the weight of a shipment divided by the volume it occupies, measured at its outside dimensions with the pallet included. In the US it is given in pounds per cubic foot (pcf) and is the main factor in most LTL freight classes.
- CalculatorsCases per pallet (Ti-Hi)Cases per layer, layers, total cases, load height, gross weight and cube utilization for any case and pallet size, with the layer pattern.
More in Loading and shipping
- GlossaryColumn stackingColumn stacking is a stacking pattern where every case sits directly on top of the case below, with corners and walls aligned through the full height of the load. It keeps the most compression strength but is less stable than interlocking.
- GlossaryCube utilizationCube utilization is the share of the available volume, in a pallet footprint up to its height limit, a trailer or a container, that is actually filled with product. It is usually expressed as a percentage.
- GlossaryFloor loadingFloor loading is shipping cases or bags stacked directly on the floor of a trailer or container, without pallets. It fits more product in the vehicle but must be loaded and unloaded by hand or with special equipment. The term is also used for the load a floor can bear per unit area.
- GlossaryFTL (full truckload)FTL (full truckload) is a shipment that uses a dedicated trailer from origin to destination, with no terminal handling. A 53 ft dry van takes 26 standard 48 × 40 in pallets loaded straight or 30 turned, single stacked, subject to the legal weight limit.
- GlossaryInterlocking stackingInterlocking stacking is a stacking pattern where alternate layers are rotated or shifted so each case bridges the joints between cases in the layer below, like bricks in a wall. It ties the load together but reduces compression strength compared with column stacking.
- GlossaryLoad barA load bar is an adjustable steel or aluminum bar fixed across the inside of a trailer or container, either wedged between the walls or locked into wall track, to keep pallets from sliding during transit. Horizontal decking beams also let a second tier of pallets be carried.
Last reviewed 2026-09-24. 252 words.