Pallet Design 101: Stringer vs. Block, 2‑Way vs. 4‑Way, and Deckboard Choices

If you’re responsible for shipping or warehousing, you already know the pallet under your product can make or break your operation. A poorly designed pallet leads to product damage, forklift issues, and higher costs. A well-designed pallet supports your load safely, works smoothly with your equipment, and saves you money over the long run.

This guide walks you through the basics of pallet design—stringer vs. block, 2‑way vs. 4‑way entry, and key deckboard choices—and explains how modern pallet design software helps optimize strength and forklift access.

At the end, we’ll show you how to request a CAD or PDF spec for a pallet design tailored to your exact load requirements.

What Really Matters in Pallet Design?

Before you choose a pallet style, you need to understand how the pallet will be used:

• Load weight (light, medium, or heavy)
• Load type (evenly distributed boxes vs. point loads like drums or machinery)
• Handling equipment (forklifts, pallet jacks, conveyors, automated systems)
• Storage conditions (floor storage, racking, stacking)
• Trip life (single-use vs. multiple-use / returnable)

A “standard” pallet is not always the right pallet. The right design balances:

• Strength and safety
• Ease of handling
• Material cost
• Repair and reuse potential

Now let’s break down the main design choices.

Stringer vs. Block Pallets

What Is a Stringer Pallet?

A stringer pallet uses long boards called stringers running between the top and bottom deckboards. These stringers act like beams that carry the load.

Typical features:

• 2 or 3 stringers running lengthwise
• Top deckboards fastened across the stringers
• Often 2‑way entry (forks enter from front and back)

Advantages of stringer pallets:

• Cost‑effective for many applications
• Easy to repair (replace individual deckboards)
• Widely used and familiar to most operators

Best uses:

• General warehouse and shipping loads
• Products that are evenly distributed on the pallet
• Situations where you don’t need full 4‑way entry

What Is a Block Pallet?

A block pallet uses solid blocks instead of stringers. Blocks are placed at the corners, along the sides, and often in the center. Deckboards run across the top (and usually bottom) and attach to these blocks.

Typical features:

• 9 or more blocks (corners, sides, and center)
• True 4‑way entry (forks from all four sides)
• Often stronger in both directions

Advantages of block pallets:

• Excellent forklift and pallet jack access
• Better suited for automation and high-throughput operations
• Can offer higher strength and stiffness when properly designed

Best uses:

• Heavier loads and high-value products
• Facilities with tight aisles or complex traffic patterns
• Export pallets and standardized systems

Quick Comparison

The “best” choice depends on your load, your equipment, and your workflow. That’s where design software becomes critical.

2‑Way vs. 4‑Way Entry: Why It Matters

Entry describes how many sides a forklift or pallet jack can use to pick up the pallet.

2‑Way Entry

A 2‑way pallet allows forks to enter from two opposite sides only (front and back). On stringer pallets, the stringers usually block side entry.

Pros:

• Often less expensive
• Adequate for simple, straight‑line operations
• Common for one‑way or disposable loads

Cons:

• Less flexible in tight aisles
• Harder to reposition in crowded warehouses
• Limits how pallets can be loaded into trailers or racks

4‑Way Entry

A 4‑way pallet allows forks to enter from all four sides.

Pros:

• Far easier to handle in tight or busy areas
• Better for high‑throughput warehouses
• Gives you more options for trailer loading and storage

Cons:

• Typically higher initial cost
• Requires more careful design to balance strength and access

In many operations, the extra handling efficiency of 4‑way entry easily pays for itself, especially when forklifts and pallet jacks are constantly moving product.

Deckboard Choices That Really Count

Deckboards are the boards you see on the top and bottom of the pallet. Their design has a huge impact on both load support and forklift performance.

1. Deckboard Thickness and Wood Species

• Thicker deckboards handle heavier loads and repeated use.
• Hardwood is generally stronger and more durable.
• Softwood can be cost‑effective for lighter or one‑way loads.

Choosing the wrong thickness can lead to:

• Board cracking or breaking
• Excess deflection (sagging) under load
• Damage to your product during transport

2. Deckboard Width and Spacing

• Narrow spacing supports small cartons and prevents sagging.
• Wider spacing may be fine for large, rigid loads and reduces material cost.
• Incorrect spacing can let cartons crush or slip through, especially under vibration.

3. Top vs. Bottom Deck Design

• Full bottom deck (boards across the bottom) improves stability, especially in racking and stacking.
• Partial bottom deck saves material and is fine for floor‑stored or lighter loads.
• Double‑wide lead boards (wider boards at the edges) help resist damage from forklifts entering the pallet.

4. Special Features

• Chamfered edges help pallet jacks roll onto the pallet smoothly.
• Flush vs. overhang affects how the load fits and how pallets stack.
• Solid deck (no gaps) can be used for very small items or specific hygiene needs.

Getting these details right ensures your pallet works with your product and your equipment, not against them.

How Pallet Design Software Optimizes Your Pallet

Experience matters—but with today’s loads, racking systems, and automation, experience alone isn’t enough. That’s why we use pallet design software to engineer pallets for your exact needs.

Here’s what the software helps us do:

1. Analyze Your Load

We input details such as:

• Load weight and footprint
• How evenly weight is distributed
• Whether the load is stored on the floor, in racks, or stacked

The software calculates how the pallet will behave under:

• Static load (sitting still)
• Dynamic load (being moved by forklift or pallet jack)
• Racking load (supported only on the edges or center)

2. Model Forklift and Pallet Jack Interaction

Design software allows us to check:

• Fork entry points (2‑way or 4‑way)
• Stresses around notches, stringers, and blocks
• Risk of breaking or excessive deflection when lifted

This helps reduce:

• Broken boards during handling
• Damage to forklift tines and pallet jacks
• Load shifts when pallets are being moved

3. Optimize Strength vs. Cost

By adjusting:

• Deckboard thickness, width, and spacing
• Stringer or block dimensions and layout
• Overall pallet size

…we can engineer a pallet that:

• Meets your safety and performance requirements
• Uses no more material than necessary
• Reduces your total cost per trip

4. Provide Clear CAD/PDF Specifications

Once we finalize a design, we can generate:

• CAD drawings for engineering and approvals
• PDF spec sheets showing dimensions, materials, and ratings

These documents make it easy to:

• Standardize pallets across your operation
• Communicate requirements to purchasing and logistics teams
• Share specs with your customers or suppliers

Common Pallet Design Mistakes to Avoid

When companies don’t use engineered designs, we often see:

• Overbuilt pallets that waste lumber and money
• Underbuilt pallets that fail in racking or during handling
• Pallets that don’t match equipment (e.g., no 4‑way access in a tight warehouse)
• Deckboard spacing that damages cartons or allows products to fall through
• Ignoring future changes in load weight or handling methods

A short conversation and a proper design review can prevent these headaches.

Get a CAD/PDF Spec for Your Load

If you’re not sure whether you need stringer or block, 2‑way or 4‑way, or which deckboard setup is right for you, we can help.

Here’s the next step:

1. Gather basic details about your load:
   • Product type and packaging
   • Load weight and pallet footprint
   • How you handle and store the pallets
2. Contact Pasadena Skid & Pallet with this information.
3. Ask us to run your load through our pallet design software.

We’ll recommend a pallet design and provide a CAD drawing or PDF spec so you and your team know exactly what you’re getting.

Ready to improve your pallet performance and protect your products? Reach out and ask for a CAD/PDF of a recommended pallet spec for your load—our team will help you choose a design that fits your operation, your budget, and your equipment.