Underhang
Also called: load underhang, pallet underhang
Underhang 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.
In depth: Pallet overhang: why loads should not hang past the pallet edge
Underhang is the opposite of load overhang. It is much less harmful to packaging, but it has costs.
Effects
| Effect | Why |
|---|---|
| Wasted space | Trailers and racks are filled by pallet footprint, so uncovered deck is empty space you pay for |
| Pallet damage | Exposed deck edges and lead boards take impacts with nothing to spread them |
| Stability | A load set back from the edges has a smaller base for its height |
| Wrap and strap | Stretch wrap pulls the top of the load inward, and the film between load and deck edge can tear |
Why it matters for pallet design
Large underhang on every shipment is a sign the footprint is wrong. A smaller or custom pallet sized to the case pattern can reduce material and freight cost. Small underhang is often accepted because it protects case walls from rubbing and keeps the load within the pallet's footprint.
On a spec sheet or RFQ
Give the load's outside length and width alongside the pallet size. If you are designing a custom pallet, say whether you want the deck to match the load exactly or leave a margin.
Common confusions
Underhang measures the load against the pallet deck. It does not describe a pallet whose bottom deck is smaller than its top deck (see wing).
Related
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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. 232 words.