Stacking pattern
Also called: pallet pattern, palletizing pattern, load pattern
A 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.
In depth: Pallet stacking patterns: column, interlock, pinwheel and brick
The pattern decides how many cases fit, how stable the load is, and how much compression strength the bottom cases keep.
Main pattern types
| Pattern | Layers | Strength | Stability |
|---|---|---|---|
| Column | Each case sits directly on the one below | Highest | Lowest |
| Interlocking (brick) | Alternate layers rotated or offset | Lower | Higher |
| Pinwheel | Cases rotate around the center, alternate layers mirrored | Lower | Higher |
| Hybrid | Column at the bottom, interlock on top layers | Middle | Middle |
Why it matters for pallet design
The pattern sets the load's footprint and weight distribution on the deck. Column stacks put case corners in fixed places, so they concentrate load on specific deckboards and gaps. A pattern that lines up case edges with deck gaps can crush the bottom layer. PDS lets the designer choose column or interlock stacking and enter custom case positions.
On a spec sheet or RFQ
Give the case dimensions, cases per layer, layers (ti-hi), the pattern type, and a pattern drawing if you have one. The cases per pallet calculator helps you try options on standard footprints.
Common confusions
Pallet-pattern software (for example TOPS Pro or Cape Pack) arranges cases. It does not design the pallet structure. Those are separate problems that meet at the deck.
Related
- GuidesPallet stacking patterns: column, interlock, pinwheel and brickColumn stacking puts each box directly on the box below and keeps the most compression strength. Interlocking patterns (brick, pinwheel) rotate alternate layers so boxes overlap, which adds stability but can cut stacking strength sharply. Many loads use columns with tie sheets, or interlock only the top layers.
- 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.
- 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.
- GlossaryPinwheelingPinwheeling has two meanings. In palletizing it is a pattern where cases are arranged in rotated groups around the center of each layer, often leaving a small void. In trailer loading it means turning some pallets 90 degrees so more fit on the floor.
- GlossaryWhat is ti-hi?Ti-hi describes how cases are stacked on a pallet: the ti is the number of cases in each layer and the hi is the number of layers. Ti times hi gives the cases per pallet; for example, a 10 × 5 ti-hi is 50 cases.
- 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
- 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.
- 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.
- 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.
- 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.
- GlossaryLoad overhangLoad 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.
Last reviewed 2026-09-24. 231 words.