Plastic pallet sizes: standard dimensions and weights
Plastic pallets come in the same footprints as wood: 48 × 40 in dominates in North America, plus 48 × 45, 48 × 48, 42 × 42 and 45 × 45 in, and 1200 × 800, 1200 × 1000 and 1100 × 1100 mm elsewhere. Most are 5 to 6.5 in tall and weigh about 14 to 70 lb.
Plastic pallets are made in the same standard footprints as wood pallets, because they have to fit the same trucks, racks and conveyors. What differs is that a molded plastic pallet exists only in the sizes a maker has tooled. You choose from catalog models at standard sizes, and you usually can't ask for an odd size the way you can with wood.
Standard plastic pallet sizes
| Size (in) | Size (mm) | Where and why |
|---|---|---|
| 48 × 40 | 1219 × 1016 | North America: grocery, general freight, the iGPS plastic pool |
| 48 × 45 | 1219 × 1143 | Automotive returnable programs |
| 48 × 48 | 1219 × 1219 | Drums, IBCs, chemicals |
| 42 × 42 | 1067 × 1067 | Paint, chemicals |
| 45 × 45 | 1143 × 1143 | Light nestable export pallets |
| 40 × 40 | 1016 × 1016 | Dairy and other square loads |
| 47.2 × 31.5 | 1200 × 800 | Europe: food, pharma, hygienic loops |
| 47.2 × 39.4 | 1200 × 1000 | UK, Europe and Asia |
| 43.3 × 43.3 | 1100 × 1100 | Japan and Korea pools, Asia exports |
| 44.9 × 44.9 | 1140 × 1140 | CP3 and CP9 in plastic, chemicals |
| 48 × 20 | 1219 × 508 | North American half display pallet |
| 24 × 20 | 610 × 508 | North American quarter display pallet |
| 31.5 × 23.6 | 800 × 600 | European half display pallet |
| 23.6 × 15.7 | 600 × 400 | European quarter display pallet and dollies |
Availability varies by maker. The common North American catalog footprints are 48 × 40, 48 × 48, 48 × 45, 42 × 42 and 45 × 45, plus 1200 × 800, 1200 × 1000, 800 × 600 and the display sizes.
Heights and weights
| Style | Typical height | Typical weight (48 × 40 class) |
|---|---|---|
| Nestable, export | about 5 to 5.5 in | about 14 to 30 lb |
| Stackable (not rackable) | about 5.5 to 6 in | between nestable and rackable |
| Rackable | about 6 to 6.5 in | about 35 to 55 lb, up to about 70 lb reinforced |
| Hygienic (closed deck) | about 6 to 6.5 in (150 to 165 mm) | varies |
Heights are typical values and weights are typical catalog ranges; the model's data sheet is authoritative. Heavy rackable pallets often have steel or fiberglass reinforcement, which adds weight. Metric pallets are often listed in mm: for example, CHEP lists plastic 1200 × 1000 pallets at 150 to 160 mm and 22 kg, and its 600 × 400 display pallet at 2.2 kg.
Plastic vs wood at the same size
| Plastic (48 × 40 class) | Wood GMA-style 48 × 40 | |
|---|---|---|
| Height | about 5 to 6.5 in | 4-3/4 in with 5/8 in decks |
| Weight | about 14 to 70 lb | about 39 to 59 lb (estimate) |
| Custom size | Only if tooled, or plastic lumber | Any size, cut to order |
| ISPM 15 | Exempt | Required for export |
| Repair | Usually not repairable | Repairable |
Plastic pallets are usually taller than a GMA pallet, so check stack heights and trailer clearance when you switch. See plastic vs wood.
Why plastic sizes are fixed
Most plastic pallets are injection-molded or structural-foam molded. Each size and style needs its own steel mold, which is a large investment, so makers build only the sizes with big markets. If you need a non-standard size in plastic, the options are:
- Plastic lumber pallets: extruded HDPE boards assembled like a wood pallet, available in almost any size with no tooling. See the plastic lumber template.
- Rotational molding and thermoforming: lower tooling cost than injection molding, used for special sizes and low volumes.
- A nearby catalog size: often the cheapest route.
Load ratings differ by maker
Plastic pallets are rated for static (floor), dynamic (moving) and racking (edge-racked across beams) loads, and the racking figure is always the smallest, often in the range of about 1,500 to 4,400 lb for rackable 48 × 40 models. Makers test differently, so compare the conditions behind each number, not just the number. See pallet load capacity and the plastic pallet buying guide.
ISPM 15 and plastic
Plastic pallets are exempt from ISPM 15, which is why light nestable 45 × 45 and 48 × 40 plastic pallets are popular for one-way exports. See the 45 × 45 export template and export pallet.
Specifying a plastic pallet
- Footprint and maximum height.
- Style: nestable, stackable, rackable or hygienic.
- Deck: open or closed; lip; anti-slip.
- Ratings needed: static, dynamic and racking, with beam span and direction.
- Material and resin (HDPE or PP; virgin or recycled), color, fire rating, RFID if needed.
- A reference model "or equal", if you have one.
The templates for rackable, nestable and hygienic plastic pallets hold these fields. See plastic vs wood for the trade-offs.
Frequently asked questions
What is the standard size of a plastic pallet?
48 × 40 in (1219 × 1016 mm) in North America, 1200 × 800 mm or 1200 × 1000 mm in Europe, and 1100 × 1100 mm or 1200 × 1000 mm in Asia: the same footprints as wood pallets.
How much does a plastic pallet weigh?
About 14 lb (6.5 kg) for a light nestable export pallet up to about 70 lb for a heavy rackable one. Nestable pallets are typically 20 to 30 lb and rackable pallets 35 to 55 lb in the 48 × 40 class.
Can I get a plastic pallet in a custom size?
Injection-molded pallets come only in the sizes a maker has tooled, because molds are very expensive. Custom sizes are practical in plastic lumber (built like a wood pallet), rotational molding or thermoforming.
Are plastic pallets the same height as wood pallets?
Similar. Most are about 5 to 6.5 in (127 to 165 mm) tall, compared with about 4.75 to 6 in for a wood 48 × 40. Nestable pallets are designed to stack inside each other when empty.
Sources and references
Related
- TypesPlastic pallets: types, materials, load ratings and how to buy themA plastic pallet is a molded or fabricated pallet made from HDPE or polypropylene. Types range from light nestable pallets (about 14–30 lb) to reinforced rackable pallets (about 35–70 lb). They are washable, ISPM 15 exempt and long-lived, cost several times more than wood, and carry three separate load ratings.
- GuidesPlastic pallet buying guide: styles, resins, ratings and costChoose a plastic pallet by how it is handled and stored: nestable for cheap one-way use, stackable for floor stacking, rackable for open-beam racking. Compare static, dynamic and racking ratings only when the test standard and support match. New US prices run about $40–200 (2026 estimates).
- TypesRackable plastic pallet: runners, reinforcement and racking ratingsA rackable plastic pallet is designed to sit in open-beam racking with nothing underneath. It has runners (3, 5 or 6) or a perimeter or cruciform base, often with steel reinforcement. Racking ratings for 48 × 40 in models are typically about 1,500–4,400 lb, valid only at the tested span and orientation.
- TypesNestable plastic pallet: light, cheap and not for racksA nestable plastic pallet has legs or feet, usually nine, that fit into the pallet below when empty, so stacked empties take little space. It is the lightest and cheapest plastic pallet, about 14–30 lb (6–14 kg) in 48 × 40 in, with 4-way entry. It is not rackable.
- TypesRackable plastic pallet: runners, reinforcement and racking ratingsA rackable plastic pallet is designed to sit in open-beam racking with nothing underneath. It has runners (3, 5 or 6) or a perimeter or cruciform base, often with steel reinforcement. Racking ratings for 48 × 40 in models are typically about 1,500–4,400 lb, valid only at the tested span and orientation.
- TypesExport pallets: ISPM 15, container sizes and material choicesAn export pallet must meet ISPM 15 (heat-treated and marked wood, or an exempt material such as plastic, presswood, paper or metal), fit the container and the consignee's equipment, and usually be cheap enough to lose. Common choices are HT wood, 45 × 45 in or 1200 × 1000 mm footprints, and nestable plastic.
- ComparisonsPlastic vs wood pallets: cost, strength and when to use eachChoose wood when you need the lowest price, a custom size, easy repair or one-way shipping. Choose plastic when pallets run in a closed loop for many trips, when hygiene and washability matter, when you need consistent dimensions for automation, or to avoid ISPM 15 treatment on exports.
More in By region and topic
- SizesUS pallet sizes: the standard North American dimensionsThe standard US pallet is 48 × 40 in (1219 × 1016 mm), the GMA pallet, used for grocery, retail and most general freight. Other common North American sizes are 42 × 42, 48 × 48, 48 × 42, 40 × 40, 48 × 45, 44 × 44, 36 × 36 and 48 × 36 in, each tied to particular industries.
- SizesEuropean pallet sizes: Euro, industrial, half, quarter and CP palletsThe standard European pallet is the 1200 × 800 mm Euro pallet (EPAL 1), 144 mm tall. The 1200 × 1000 mm industrial pallet (EPAL 2 and EPAL 3) is the second standard. Retail uses the 800 × 600 half and 600 × 400 quarter pallets, and the chemical industry uses the CP1 to CP9 pallets.
- SizesUK pallet sizes: the 1200 × 1000 standard and the Euro palletThe standard UK pallet is 1200 × 1000 mm (47.2 × 39.4 in). CHEP's UK wooden pallet at this size is 162 mm tall and 28 kg, rated 1,500 kg safe working load. The 1200 × 800 mm Euro pallet is also widely used in the UK, along with 800 × 600 half and 600 × 400 quarter pallets for retail.
- SizesAustralian pallet sizes: the 1165 × 1165 standard and export sizesThe standard Australian pallet is 1165 × 1165 mm (45.9 × 45.9 in), defined by AS 4068 and pooled by CHEP and Loscam. It is about 150 mm tall and was sized for Australian rail containers. For container exports, Australian shippers often use 1100 × 1100 or 1200 × 1000 mm pallets instead.
- SizesAsian pallet sizes: T11 (1100 × 1100) and 1200 × 1000The two standard Asian pallet sizes are 1100 × 1100 mm (43.3 × 43.3 in), known as T11, and 1200 × 1000 mm (47.2 × 39.4 in). T11 is the standard pool pallet in Japan (JIS Z 0601, 144 mm tall) and Korea. China's national standard specifies both sizes. Both are ISO 6780 footprints.
- SizesISO pallet sizes: the six ISO 6780 footprintsISO 6780 lists six standard pallet footprints: 1200 × 800 mm (Europe), 1200 × 1000 mm (Europe, Asia), 1219 × 1016 mm or 48 × 40 in (North America), 1165 × 1165 mm (Australia), 1067 × 1067 mm or 42 × 42 in (North America, Europe, Asia) and 1100 × 1100 mm (Asia). There is no single world pallet size.
Last reviewed 2026-09-24. 883 words.