Euro Pallet Transport: Capacities, Stacking Height, and Load Securing

Euro pallets are among the most important load carriers in logistics. They simplify the transport, storage, and handling of goods and can be moved with almost all common forklifts, pallet jacks, and storage systems.

However, several factors must be considered to ensure that Euro pallet transport is carried out economically and safely. In addition to the number of available pallet spaces, the height and weight of the load units, the stackability of the goods, and proper load securing play a decisive role.

Especially when transporting large quantities, even minor planning errors can lead to the cargo space not being fully utilized, permissible axle loads being exceeded, or additional vehicles being required.

What are the dimensions and weight of a Euro pallet?

A standardized Euro pallet has the following dimensions:

• 1,200 millimeters in length
• 800 millimeters in width
• 144 millimeters in height
• approximately 25 kilograms dead weight

The standardized dimensions allow for relatively precise planning of the required loading area. The Euro pallet can also be accessed from all four sides. This means it can be picked up by a forklift or pallet jack from both the long and short sides.

An intact EPAL Euro pallet is designed for a load capacity of up to 1,500 kilograms. This assumes that the load is evenly distributed and the pallet is in good condition.

Broken boards, damaged blocks, protruding nails, or improper repairs can significantly reduce load-bearing capacity. The condition of the pallets should therefore be checked before every loading.

How many Euro pallets fit into a truck?

The possible number of Euro pallets depends primarily on the size of the vehicle and the usable loading area. In addition, the weight of the goods, the interior height, the door height, and the permissible payload must be taken into account.

Typical planning figures for a single-layer loading of the cargo area are:

• Transporter or Sprinter: approx. 4 to 10 Euro pallets
• 7.5-tonne truck: approx. 14 to 15 Euro pallets
• Rigid truck with approx. 6 meters of loading space: approx. 15 Euro pallets
• Standard semi-trailer with a length of 13.6 meters: 33 Euro pallets
• Mega trailer: 34 Euro pallets
• Jumbo vehicle: up to 38 Euro pallets

These figures refer to a single-layer loading of the cargo area. If loaded pallets can be safely stacked on top of each other or transported in a double-deck system, the actual number may be higher.

When transporting empty Euro pallets, however, the pallets are loaded in high stacks. This allows several hundred Euro pallets to be transported in a single vehicle.

The vehicle's permissible payload must not be exceeded. With heavy goods, it is often the weight rather than the available space that is the limiting factor.

Why do 33 Euro pallets fit into a standard semi-trailer?

A standard semi-trailer usually has a usable interior length of approximately 13.6 meters and an interior width of around 2.4 to 2.45 meters.

If the Euro pallets are aligned so that their 800-millimeter-wide side is perpendicular to the direction of travel, three pallets can be placed side by side:

3 × 800 millimeters = 2,400 millimeters

In the direction of travel, eleven rows are formed with the 1,200-millimeter-long side of the pallets:

11 × 1,200 millimeters = 13,200 millimeters

This results in:

3 pallets per row × 11 rows = 33 Euro pallets

Mathematically, a different orientation can sometimes result in 34 pallet spaces. In this configuration, two pallets are placed side by side with their 1,200-millimeter-long side, while 17 pallets, each 800 millimeters wide, are arranged in the direction of travel.

In practice, however, 33 pallet spaces are usually calculated for a standard semi-trailer. Vehicle bodywork, tolerances, loading gaps, securing equipment, and the actual dimensions of the pallets can prevent 34 pallets from being loaded reliably.

For larger pallet quantities, mega trailers or jumbo vehicles can be used. A mega trailer offers up to 34 pallet spaces. Depending on the vehicle configuration, jumbo vehicles can accommodate up to 38 spaces.

What does a loading meter mean for Euro pallets?

A loading meter refers to one meter of the total usable loading length of a vehicle. The entire width of the loading area is considered occupied.

Mathematically, one Euro pallet requires approximately 0.4 loading meters. The calculation is:

1.20 meters × 0.80 meters ÷ 2.40 meters loading width = 0.4 loading meters

Ten Euro pallets therefore correspond to approximately four loading meters. This calculation is particularly useful for transport planning and calculating partial loads.

The actual space required may be higher if the goods overhang the pallet, cannot be placed tightly next to each other, or if there are special requirements for load securing.

Round, fragile, or irregularly shaped goods may also require a full pallet space, even if the goods themselves only occupy a portion of the area.

How high can Euro pallets be stacked?

There is no universal maximum stacking height for all Euro pallet transports. The permissible height depends on the condition and uniformity of the pallets, the weight and stability of the goods, and the load-bearing capacity of the bottom pallets.

The interior and door height of the vehicle, the center of gravity, the securing equipment used, the loading and unloading technology, as well as the ground surface and vehicle body also play an important role.

When planning, a fundamental distinction must therefore be made between empty and loaded Euro pallets.

Stacking height for transporting empty Euro pallets

A Euro pallet is 144 millimeters high. The theoretical height of a uniform pallet stack can therefore be calculated based on the number of pallets stacked on top of each other.

For a standard semi-trailer with 33 pallet spaces, the following quantities are considered standard:

• 15 pallets per stack: 495 Euro pallets
• 16 pallets per stack: 528 Euro pallets
• 17 pallets per stack: 561 Euro pallets

A full truckload of 495 empty Euro pallets is therefore based on 33 stacks of 15 pallets each.

If the pallets are stacked 16 high, 528 Euro pallets can be transported with the same vehicle. With 17 pallets per stack, the capacity increases to 561 Euro pallets.

In addition to standard semi-trailers, Palettenpool Deutschland also uses mega trailers and jumbo vehicles.

A mega trailer has up to 34 pallet spaces. With a stacking height of up to 20 Euro pallets, this allows for a theoretical capacity of up to 680 empty Euro pallets.

Jumbo vehicles offer up to 38 pallet spaces. With 20 pallets per stack, this results in a theoretical total capacity of up to 760 empty Euro pallets.

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However, the theoretical number is not automatically the practically permissible number. A stack of 17 Euro pallets already reaches a theoretical height of 2,448 millimeters. A stack of 20 Euro pallets even reaches a height of 2,880 millimeters.

Whether such stack heights can actually be utilized depends in particular on the vehicle being used. Mega trailers and jumbo vehicles offer different conditions for this than classic standard semi-trailers.

Loading with a forklift also becomes more difficult when the pallet stack fills almost the entire interior height. Deviating pallet heights, slightly warped boards, and uneven stacks can take up additional space.

In practice, therefore, one should not rely solely on the theoretical interior height of the vehicle. The decisive factors are the actual usable door height, the type of loading, and the safe handling of the stacks.

What should you keep in mind when stacking empty Euro pallets?

Empty Euro pallets should be stacked straight and as flush as possible. Misaligned or differently sized pallets can create an unstable center of gravity.

For safe transport, the following principles apply, among others:

• Only stack identical pallets together.
• Sort out damaged or severely warped pallets.
• Place heavier and more stable pallets at the bottom.
• Align the individual pallets as flush as possible.
• Do not build stacks higher than they can be safely handled.
• Allow for sufficient clearance from the roof, doors, and vehicle body.
• Secure pallet stacks against sliding, tipping, and falling apart.

Loosely stacked pallets can shift against each other during heavy braking. Particularly high stacks also have a higher center of gravity and are therefore more prone to tipping.

Strapping or suitable bundling can stabilize an individual stack. However, this does not automatically replace the need to secure the entire stack on the vehicle.

Stack height for loaded Euro pallets

For loaded Euro pallets, the total height is calculated based on the pallet and the goods placed on it:

Pallet height + goods height = total height of the load unit

If the goods are, for example, 1,000 millimeters high, the total load unit height including the Euro pallet is 1,144 millimeters.

Whether two loaded pallets can be stacked on top of each other depends on more than just the interior height of the truck. The goods at the bottom must be able to support the weight of the upper load unit without being damaged or deformed.

Double stacking is only advisable if:

• the goods are explicitly stackable,
• the packaging is sufficiently pressure-resistant,
• the load is distributed evenly,
• the bottom pallet is not overloaded,
• both load units are securely connected to each other,
• the vehicle has sufficient clearance,
• the cargo can still be loaded and unloaded safely.

Cardboard boxes, sacks, canisters, or sensitive machinery can have very different stacking requirements. The "do not stack" instruction should always be followed.

Even with stackable goods, intermediate layers, anti-slip materials, pallet collars, or special stacking aids may be required.

Calculating weight and payload correctly

In addition to the number of pallet spaces, the total weight of the cargo must be taken into account. The weight of a load unit consists of the weight of the goods, the pallet, and, if applicable, the packaging.

An example:

• Weight of goods: 800 kilograms
• Weight of the Euro pallet: approximately 25 kilograms
• Weight of the packaging: 10 kilograms
• Total weight of the loading unit: 835 kilograms

With 33 loading units, the total weight would be 27,555 kilograms. This would already exceed the payload capacity of many standard semi-trailers.

In this case, while 33 pallets may fit on the loading area, they cannot be transported together in a single vehicle.

In addition to the total weight, individual axle loads must be observed. Heavy loading units should therefore not be placed exclusively at the front or rear of the trailer.

The cargo must be arranged according to the vehicle's load distribution plan. Incorrect weight distribution can negatively affect steering and braking performance, even if the permissible total weight has not yet been exceeded.

Why proper load securing is essential

Euro pallets and the goods on them must be secured so that they do not slide, tip over, fall off, or cause avoidable noise under normal traffic conditions.

This must also account for heavy braking, evasive maneuvers, cornering, and uneven road surfaces. Simply placing a pallet on the loading area is therefore not sufficient.

Load securing is generally divided into positive and friction-locking methods.

Positive locking

With positive locking, the cargo is placed against the front wall, side walls, or other loading units with as little space between them as possible.

Any resulting gaps can be closed using aids such as:

• Locking bars
• Dunnage bags
• Partition walls
• Additional pallets
• Square timber
• Suitable filler materials

Whether the front wall, side walls, and vehicle body can withstand the required securing forces depends on their design and load-bearing capacity.

A tarpaulin alone is generally not a sufficient substitute for a load-bearing side wall.

Friction-based securing

Friction-based load securing works by increasing the friction between the cargo and the loading surface. This is commonly achieved using lashing straps and anti-slip materials.

Anti-slip mats can significantly reduce the risk of shifting. However, they only work reliably if the loading surface and contact areas are clean and the materials used are suitable for the specific application.

Lashing straps must be routed correctly, tensioned sufficiently, and attached to suitable lashing points. Factors such as pre-tensioning force, strap load capacity, and lashing angles must be taken into account.

Edge protectors protect both the goods and the strap. They prevent the strap from being damaged by sharp edges and stop it from crushing delicate packaging.

Stretch wrap primarily stabilizes goods on a pallet. It does not necessarily replace the need to secure the entire pallet to the vehicle.

Common mistakes when transporting Euro pallets

Many transport damages are not caused by extraordinary situations, but by avoidable errors during preparation and loading.

Typical problems include:

• Damaged pallets continue to be used.
• Goods overhang the sides of the pallet.
• Cartons are not sufficiently secured to one another.
• Tall load units have an unstable center of gravity.
• Gaps in the cargo space remain unsecured.
• Anti-slip mats are only partially placed underneath.
• Lashing straps are routed over unstable packaging.
• The permissible payload is not fully calculated.
• Heavy pallets are distributed poorly.
• The cargo is not re-secured after a partial unloading.

Especially with multiple unloading points, it must be taken into account that the load distribution and available space change during the journey.

Therefore, cargo securing should be checked and adjusted after every partial unloading.

How to plan transport efficiently

Good transport planning begins before the vehicle is even provided. Companies should record not only the number of pallets but also dimensions, weight, stackability, and the unloading sequence.

The following information is helpful:

• Number of Euro pallets
• Weight per loading unit
• Height of the loaded pallet
• stackable or non-stackable
• overhanging goods
• Type and condition of the pallets
• Loading and unloading address
• available loading equipment
• Number of unloading points
• special requirements for the goods

Based on this data, it can be determined whether a full truckload, partial load, or less-than-truckload transport makes the most sense.

This also makes it easier to select the right vehicle type. Depending on the number of pallets and the required stacking height, a standard semi-trailer, a mega trailer, or a jumbo vehicle may be the most economical solution.

For recurring pallet volumes, it is also worth planning procurement, returns, and pallet exchanges together. This helps reduce empty runs and compensate for missing load carriers more quickly.

Palettenpool Deutschland supports companies in providing new and used Euro pallets, including for large or short-notice quantities. Through coordinated procurement and delivery, the required pallets can be provided to match specific transport needs.

Bottom line: Capacity alone is not enough for planning

A standard semi-trailer can generally accommodate 33 loaded Euro pallets on a single level. For the transport of empty pallets, 495, 528, and 561 units are considered standard quantities.

These figures are based on 33 pallet spaces, with 15, 16, or 17 Euro pallets stacked on each.

For larger quantities, mega trailers with up to 34 pallet spaces or jumbo vehicles with up to 38 spaces can be used. With a stacking height of up to 20 Euro pallets, this results in a theoretical capacity of up to 680 or 760 empty Euro pallets, respectively.

However, available loading space is only one part of transport planning. Equally important are the actual interior and door height, payload, axle load distribution, the height and stability of the load units, and appropriate load securing.

Taking these factors into account early on allows you to make better use of available cargo space, avoid additional trips, and reduce the risk of damage or delays.