Rackable plastic pallet: runners, reinforcement and racking ratings
A 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.
- Type
- Plastic (molded)
- Footprint
- 48.00 × 40.00 in
- Height
- 6.00 in
Every dimension is editable. Get the drawing free, or request a quote.
Racking is the hardest job for a plastic pallet. On the floor the whole base carries the load. In a rack, the pallet must bridge the gap between two beams for weeks at a time, and plastic slowly sags under load. Rackable models are built specifically for this.
What is a rackable plastic pallet?
A rackable plastic pallet is one the manufacturer rates for open-beam pallet racking, with a published racking load. It has a continuous base, either runners or a frame, so it bears on the beams along its edges rather than on legs. See the plastic pallets hub for the other types.
How is a rackable plastic pallet built?
The pallet.design rackable template:
| Feature | Template value | Metric |
|---|---|---|
| Footprint | 48 × 40 in | 1219 × 1016 mm |
| Height | 6 in | 152 mm |
| Deck | Closed | |
| Base | 3 runners | |
| Reinforcement | Steel if needed | |
| Racking requirement | 2,000 lb, across the width, 42 in beam span | 907 kg, 1067 mm |
Common base layouts:
| Base | Notes |
|---|---|
| 3 runners | 2-way for pallet jacks, 4-way for forklifts; rides conveyors along the runners |
| 5 or 6 runners | Stiffer; common on structural foam pallets |
| Perimeter (picture frame) | 4-way, rides conveyors both ways |
| Cruciform | Perimeter plus a centre cross; stiff |
Reinforcement is molded-in steel tubes or rods, or fiberglass. Steel is roughly 30 times stiffer than PP or HDPE. Polypropylene copolymer is often chosen over HDPE for rackable models because it is stiffer at room temperature.
Racking ratings: edge vs across the width
The rating depends on which way the pallet spans the beams:
- Racked across length (edge racking): the pallet's length spans the beams, supported along its two shorter edges.
- Racked across width: the width spans the beams.
A rating applies only at the tested support condition and beam span; wider spans reduce capacity. Test standards differ too: ASTM D1185 and ISO 8611 use different loading methods, creep durations and deflection limits, so ratings from different vendors are not directly comparable unless you know the basis. See racking and deflection.
Published examples
| Model | Static | Dynamic | Racking | Weight |
|---|---|---|---|---|
| 48 × 40 in, injection molded | 30,000 lb | 5,000 lb | 2,800 lb (edge) | 68.3 lb (31 kg) |
| 48 × 40 in, structural foam, 6 runners, FR | 30,000 lb | 5,000 lb | 2,200 lb (edge) | 49 lb (22 kg) |
| 1200 × 1000 mm, no reinforcement | 7,500 kg | 1,500 kg | 1,250 kg | model dependent |
| Same, with 5 steel rods | 7,500 kg | 1,500 kg | 2,000 kg | model dependent |
These are catalog figures for specific models. Rackable 48 × 40 in pallets typically weigh about 35–55 lb (16–25 kg), with heavy models near 70 lb (32 kg).
Where are rackable plastic pallets used?
- Selective, push-back and flow racks in closed-loop distribution
- Food, beverage and pharma warehouses that need washable pallets
- Automated storage and conveyors, where consistent dimensions matter
- Cold stores (with a resin rated for freezer temperatures)
- Pooled plastic pallets: one pooled 48 × 40 plastic pallet is described as fully edge rackable at 2,800 lb
Pros and limits
| Pros | Limits |
|---|---|
| Rated for racking, unlike nestable models | Heaviest and most expensive plastic type |
| Consistent size for automation | Rating valid only at the tested span and orientation |
| Long life, washable | Creep: deflection increases with time and heat |
| ISPM 15 exempt | Does not nest: empties take full space |
| Can carry fire listings (UL 2335, FM 4996) | Reinforced models are harder to recycle |
ISPM 15
Plastic pallets are exempt from ISPM 15.
What drives the cost?
As an indicative 2026 US range, new rackable 48 × 40 in plastic pallets cost about $80–160, and heavy-duty models $100–200. Drivers:
- Resin weight, type (PP copolymer vs HDPE) and virgin vs recycled
- Steel or fiberglass reinforcement
- Fire-retardant compound for UL 2335 or FM 4996 listing
- Branding, colour, RFID
- Quantity and freight (rackables do not nest)
Specifying a rackable plastic pallet for a quote
- Footprint, maximum height, entry
- Deck: open or closed; lip; anti-slip
- Base: runners (how many) or perimeter or cruciform
- Maximum load and distribution
- Rack type (selective, drive-in, push-back, flow), orientation (edge or across width) and clear beam span
- Minimum racking rating and the test standard behind it
- Temperature range and dwell time in the rack
- Resin preference, reinforcement allowed, fire listing, food contact
- Conveyor or AS/RS requirements
- Reference model ("or equal"), quantity, delivery location
Related: nestable vs rackable, stackable plastic pallet, creep. The rackable template records these fields; open it in the designer.
Drawing and parts listEdit in the design app
Rackable plastic 48×40 template, generated from the model. Every dimension is editable.
Pallet
- Type
- Plastic (molded)
- Footprint
- 48.00 × 40.00 in
- Overall height
- 6.00 in
- Classification
- 48.00 x 40.00 x 6.00, Plastic, Rackable, Closed Deck, 3 Runners, 4-Way, Reusable
Construction
- Style
- Rackable
- Deck / base
- Closed deck, Runners3
- Max height
- 6.00 in (6)
- Resin
- Any, either
- Reinforcement
- If Required
- Anti-slip
- None
- Color / RFID
- Black
- Reference model
- Supplier to propose
- Ratings needed
- racking ≥ 2000 lb
Requirements
- Load
- 2,000 lb, uniform
- Handling
- forklift, pallet jack
- Racking
- Across Width, 42 in beam span
- Floor stack
- 1 high
- Use
- Reusable / multi-trip
- Environment
- Standard
- ISPM-15
- Domestic only
- Certified rating
- Not required
- Food contact / fire
- No / no listing
Order
- Quantity
- Not specified
- Ship to
- —
- Needed by
- —
Frequently asked questions
What makes a plastic pallet rackable?
A bottom structure that bridges the rack beams (runners or a perimeter or cruciform frame) and enough stiffness, often from steel tubes or rods, to keep deflection within limits under a sustained load.
What is edge racking?
Racking with the pallet supported only at two opposite edges on the beams. For a 48 × 40 in pallet, edge racking usually means the 48 in length spans the beams. Ratings for edge racking and racking across the width differ.
How much can a rackable plastic pallet hold in a rack?
Published 48 × 40 in examples include 2,200 lb and 2,800 lb edge-racking ratings. A 1200 × 1000 mm model rises from 1,250 kg to 2,000 kg racking with five steel rods. Always use the rating for your beam span and orientation.
Why does plastic sag in racks over time?
Plastic creeps: it slowly deflects under a sustained load, faster at higher temperatures. Racking ratings are set by deflection limits over a test period, which is why steel reinforcement matters.
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.
- ComparisonsNestable vs rackable plastic pallets: differences and when to use eachChoose a nestable plastic pallet for floor stacking, one-way export and closed loops where cheap return freight matters, since empties nest into each other. Choose a rackable plastic pallet, with runners or a perimeter base and often steel reinforcement, when loaded pallets sit on open rack beams.
- GuidesPallet racking and deflection: rack spans, direction and sag limitsIn a rack a pallet spans between two beams with nothing underneath, so it bends. Racked across the length (stringers span about 40 to 44 in on a 48 in pallet) is usually stiffer than across the width (deckboards span about 36 in). Common deflection limits are about 2% of span, or 0.5 in or less for automated storage.
- GlossaryRacking loadRacking load is the weight a pallet can safely carry while it spans the gap between rack beams with no support underneath. It is usually the lowest of a pallet's ratings and depends on the span, the direction racked and the number of beams.
- GlossaryRacked across lengthRacked across length is a support condition where the rack beams support the pallet's two ends and the pallet's length spans the open gap. On a stringer pallet the stringers carry the load across the span.
- GlossaryRacked across widthRacked across width is a support condition where the rack beams support the pallet's two long sides and the pallet's width spans the open gap. On a stringer pallet the deckboards, not the stringers, carry the load across the span.
- TypesStackable plastic pallet: built for floor stackingA stackable plastic pallet has a continuous bottom (runners or a perimeter frame) that spreads load onto the floor or the goods below, so loaded pallets can be block-stacked. It sits between nestable pallets (lighter, cheaper) and rackable pallets (reinforced for beams). Many are not rated for racking.
- GlossaryCreepCreep is the gradual increase in a pallet's deflection while a load stays on it over time. Wood creeps, and plastic creeps much more, especially when warm, so racked pallets sag more after days or weeks than when first loaded.
More in Plastic pallets
- 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.
- TypesHygienic plastic pallet: closed decks for food and pharmaA hygienic plastic pallet has a closed, smooth top deck and a closed bottom, with no hollow cavities where dirt, water or bacteria can collect. It is made from virgin HDPE or PP, designed to be washed, and used in food processing, meat, dairy, bakery and pharmaceutical plants.
- TypesPlastic lumber pallet: built like wood from HDPE boardsA plastic lumber pallet is assembled from extruded plastic boards, usually HDPE, in the same stringer or block layouts as a wooden pallet and fastened with screws or nails. It needs no mold, so any size is possible in small quantities. It is ISPM 15 exempt, rot-proof and heavier than wood.
Last reviewed 2026-09-24. 849 words.