Mục lục
- Three pallet load ratings: do not confuse them
- Why plastic pallets break on racking
- When steel-reinforced pallets are mandatory
- ICD plastic pallet racking load table
- Rack accessories that rescue weak pallets: support bars and wire mesh
- How the rack type drives the pallet requirement
- Deflection rule based on beam spacing
- Rules for choosing a racking pallet safely
- Related articles
- Frequently asked questions about pallets on racking
- Contact and plastic pallet quote from ICD
Many warehouses buy a plastic pallet rated 3,000-4,000 kg static load, place it on racking, and watch it sag and crack at mid-span. The reason: the load a pallet carries when supported on two beam edges (racking load) is completely different from the load it carries flat on the floor (static load). This guide explains the three pallet load ratings, why pallets break on racking, when steel reinforcement is required, and the measured ICD racking load table so you choose correctly.
Three pallet load ratings: do not confuse them
Every pallet has three distinct load ratings. Choosing a racking pallet by static load alone is the single most common mistake.
| Load type | Definition | When it applies |
|---|---|---|
| Static load | Weight a pallet bears when sitting fixed on a flat floor | Floor stacking, no movement |
| Dynamic load | Weight a pallet bears while being moved by a forklift with goods on it | Loading, transport by forklift |
| Racking load | Weight a pallet bears when supported only on two beam edges, with the centre unsupported | Placed on selective pallet racking |
Racking load is always the LOWEST of the three, typically only 20-30% of static load. A pallet rated 4,000 kg static may carry only 1,000 kg on racking, because once supported on two edges the centre has no floor beneath it.
Why plastic pallets break on racking
Loss of support at the centre
On the floor, the entire underside of the pallet is supported evenly. On racking, the pallet rests on two beam edges only and the middle hangs free. The weight of the goods concentrates at the centre, making the pallet sag like a loaded bridge. Unreinforced plastic deflects progressively, then cracks along its length.
Creep: deflection that grows over time
Plastic exhibits creep, deforming slowly under a sustained static load. A pallet left on racking for a few weeks with heavy goods will sag more than it did on day one, even though the load has not changed. This is why a pallet that looks fine when first loaded can collapse later.
Warehouse temperature makes it worse
A hot warehouse accelerates creep; a cold one makes the plastic brittle. For the same pallet, a racking load that is safe in a cool warehouse drops as the warehouse temperature rises. Allow a load margin when the warehouse is not climate-controlled.
When steel-reinforced pallets are mandatory
Steel reinforcement is a steel bar threaded through the body of the plastic pallet, carrying the bending force at the centre when the pallet is supported on the beams. Use steel bars when:
Racked goods exceed 700-1,000 kg
Plastic pallets typically carry 700-1,000 kg on racking. Heavier goods require steel bars to raise the racking load to 5,000-6,000 kg without sagging.
Wide-span racking with widely spaced beams
The further apart the beams, the longer the unsupported centre span and the greater the bending moment. Wide spans always need steel bars, even when the load is not especially heavy.
Long-term storage with low turnover
Goods stored on racking for long periods accumulate creep. Steel bars keep the pallet from deforming over time, making them the safe choice for long-term storage.
ICD plastic pallet racking load table
Measured figures, used to choose the right pallet by racking load instead of guessing from static load.
| ICD pallet line | Size (mm) | Static load | Racking load |
|---|---|---|---|
| HDPE warehouse stacking | 1200 x 1000 x 145 | 4,000 kg | 1,000 kg |
| HDPE closed deck | 1100 x 1100 / 1200 x 1000 | 4,000 kg | 1,000 kg |
| HDPE open deck | 1100 x 1100 / 1200 x 1000 | 3,000 kg | 800 kg |
| HDPE cup-foot | 1100 x 1100 x 140 | 3,000 kg | 700 kg |
| ICD steel-reinforced pallet | Size (mm) | Static load | Unit price |
|---|---|---|---|
| PP with steel bars | 1200 x 800 x 150 | 5,000 kg | 1,800,000 VND |
| PP with steel bars | 1200 x 1000 x 150 | 6,000 kg | 2,800,000 VND |
Pallets without steel bars should only go on racking for light goods below the racking load in the table. Above that threshold, switch to a steel-reinforced line.
Rack accessories that rescue weak pallets: support bars and wire mesh
When your existing pallets have a low racking load but you do not want to replace them with steel-reinforced ones, you can reinforce the rack with accessories placed on the beams.
Support bars
A support bar is a steel bar laid across the two beams, beneath the pallet, to share the load and reduce the mid-span deflection. A low-racking-load pallet sitting on support bars can be used more safely.
Galvanised wire mesh decking
Welded wire mesh with roughly 50 x 50 mm cells and 5-6 mm wire is laid across the full beam surface to support the entire underside of the pallet, eliminating the loss of central support. It is a cheaper solution than upgrading every pallet and suits warehouses that already hold standard pallets.
How the rack type drives the pallet requirement
The fewer the support points, the stiffer the pallet or steel reinforcement you need.
| Rack type | How it supports the pallet | Pallet requirement |
|---|---|---|
| Selective | Beams support two edges, the most common type | A pallet at the correct racking load is enough |
| Drive-in | Rests on two side rails along its length | Stiff or steel-reinforced pallet required |
| Double-deep, push-back | Deep reach, edges easily knocked | Durable pallet with strong edges |
Deflection rule based on beam spacing
Permissible deflection is usually taken as about 1/100 to 1/150 of the span length. For a 1,000 mm beam span, the maximum deflection should stay under 7-10 mm. The further apart the beams, the longer the unsupported centre and the greater the deflection, so wide spans need steel-reinforced pallets. For storage beyond 6 months, add a load margin for accumulated creep.
Rules for choosing a racking pallet safely
Use racking load, not static load
When briefing a supplier, state the weight of goods per pallet and that the pallet will sit on racking. Compare against the racking load column, not the static load. Add a 20-30% margin if the warehouse is hot or storage is long.
Measure beam spacing before buying
Measure the distance between the two rack beams. The pallet must rest firmly on both edges without dropping through the gap. Widely spaced beams need a stiffer pallet or steel bars.
Do not use old pallets on racking
Old pallets have aged and their racking load drops sharply compared with new ones. Load-bearing racking should always use new pallets at the correct rating.
Related articles
| ICD industrial plastic pallets | Plastic pallet sizes: specification reference | ISO standards for export plastic pallets |
Frequently asked questions about pallets on racking
1. What is racking load and how does it differ from static load?
Racking load is the weight a pallet bears when supported only on two beam edges, with the centre hanging free. Static load is when the pallet sits on a flat floor and is supported evenly. Racking load is always much lower, typically only 20-30% of static load.
2. Can a pallet rated 4 tonnes static go on racking?
Only with goods below its racking load, around 1,000 kg. A 4,000 kg static rating does not mean it carries 4,000 kg on racking. Heavier goods need a steel-reinforced pallet.
3. When do I need a steel-reinforced pallet?
When racked goods exceed 700-1,000 kg, the rack has wide beam spacing, or for long-term storage. Steel bars raise the racking load to 5,000-6,000 kg and resist deflection over time.
4. Why does a pallet on racking sag more over time?
Because of plastic creep, slow deformation under a sustained load. The pallet looks fine when loaded but deflection grows over a few weeks. Steel bars or choosing the correct racking load avoid this.
5. Which is better on racking, open deck or closed deck?
Closed deck usually has a higher racking load (1,000 kg versus 800 kg for an open deck of the same size) thanks to its solid structure. Both still need their real racking load checked and steel bars when the load exceeds the threshold.
6. Can I use racking without buying steel-reinforced pallets?
Yes, by reinforcing the rack: lay support bars or galvanised welded wire mesh across the beams to support the entire underside of the pallet. This is cheaper than replacing every pallet and suits warehouses that already hold standard low-racking-load pallets.
7. Which plastic pallet suits drive-in racking?
Drive-in racking supports the pallet on two side rails, so stress is high and a stiff or steel-reinforced pallet is mandatory. Standard pallets with low racking load deflect and break easily on drive-in racking.
Contact and plastic pallet quote from ICD
ICD Viet Nam Industrial Production Company Limited
North: Floor 3, Thang Long A1 Building, Bau Hamlet, Thien Loc Commune, Hanoi - 0983 797 186 / 090 345 9186 / 090 5859 186
South: 551/212 Le Van Khuong, Tan Thoi Hiep, District 12, Ho Chi Minh City - 098 6784 186
Email: sales@icdvietnam.com.vn · Zalo: Chat on Zalo now
Send the weight of goods per pallet and your rack specifications, and ICD will recommend the right pallet line by racking load and quote right away.
Author: ICD Viet Nam technical team. Load figures measured on ICD pallets; reference prices updated June 2026 and subject to change by timing and quantity. Products carry a 2-year genuine warranty.
