HDPE Plastic Pallets: Pros, Cons, Types and Applications

HDPE plastic pallets - high tensile strength, chemical resistance, lightweight and recyclable. Compare HDPE vs PP, classification and industrial applications.

Reviewed and updated by ICD - Week 43/2026

An HDPE plastic pallet is a pallet moulded from high-density polyethylene (density about 0.93 to 0.97 g/cm³): flexible, impact-resistant and cold-tolerant, and it does not rot or absorb moisture. In the ICD Vietnam catalogue, 147 of 172 plastic pallet models list HDPE or HDPE blended with PP as the material, with a median static load of 4,000 kg and a median dynamic load of 1,000 kg.

At ICD Vietnam, questions about HDPE usually arrive with three follow-ups: how HDPE differs from PP, how virgin and recycled plastic compare, and whether a pallet can go on racking or into a cold store. This article answers each in turn, using sourced material data and the specifications of the pallet models currently in the catalogue, so buyers can read a spec sheet before asking for a price.

147/172 models

ICD Vietnam plastic pallets listing HDPE or HDPE blended with PP

4,000 kg

median static load of the HDPE group, up to 8,000 kg

1,000 kg

median dynamic load, up to 3,200 kg on steel-core models

Blue plastic pallets and wooden pallets stacked side by side in a warehouse — A blue plastic pallet beside a wooden pallet in a warehouse: the two materials differ widely in use and lifecycle cost.

What is an HDPE plastic pallet?

An HDPE plastic pallet is a load platform for forklifts and racking, injection-moulded or blow-moulded from HDPE (High-Density Polyethylene) resin, which may be virgin or recycled and is sometimes blended with PP or PPC for extra stiffness. HDPE is a polyethylene with almost no chain branching, so the forces between chains are large and tensile strength is much higher than low-density PE, about 38 MPa versus 21 MPa according to figures compiled on Wikipedia. The foundations of this topic are covered in which pallet material is best.

A few material properties directly explain how an HDPE pallet behaves in the warehouse. HDPE melts at about 130 °C and tolerates only about 120 °C for short periods, so it is not used in steam sterilisation the way PP is. The plastic is inert to many common solvents, acids and alkalis, so the pallet does not rot or rust. Because it is less dense than water, a 1200 x 1000 mm pallet in the ICD Vietnam catalogue weighs only about 6 to 22 kg depending on construction. On the product, HDPE carries resin identification code 2, while PP carries code 5. For more depth, see static and dynamic pallet load.

Blue virgin-plastic cross-deck pallet measuring 1200 x 1000 x 150 mm — A 1200 x 1000 x 150 mm cross-deck pallet made of virgin plastic: a bright, even colour is the easiest sign to spot.

Advantages of HDPE plastic pallets

HDPE is the most widely used of the plastic pallet materials thanks to five points: impact strength, resistance to chemicals and moisture, light weight, easy cleaning and recyclability. HDPE’s flexibility lets the pallet absorb the blow of a fork tine instead of cracking, so it carries heavy loads and lasts for years if not overloaded.

Forklift moving a pallet of goods to the yard to load onto a truck — Loading in the yard: a light pallet that does not soak up water makes each forklift trip faster and steadier.

The plastic is unaffected by most common acids, alkalis and oils, and neither rots nor moulds in damp environments. The pallet is lighter than a wooden pallet of the same size and does not gain weight in the wet, which cuts handling effort and freight cost. The surface is non-absorbent and can be washed with water and cleaning solutions, which suits food warehouses. At the end of its life an HDPE pallet can be ground into recycled resin, which is also why HDPE is one of the most widely recovered plastics.

To understand this plastic family better, you can read PE and HDPE plastic to tell the types of polyethylene apart before choosing a pallet.

Disadvantages of HDPE plastic pallets

HDPE pallets have four main drawbacks: a higher purchase price than wooden pallets, lower heat resistance than PP, softer than PP so they sag on racking without a steel core, and they are very hard to repair once cracked or broken. The higher up-front price is offset by lifespan and the number of trips, so compare total lifecycle cost rather than the price of each unit.

PLR4-1289 welded plastic pallet: the sections are joined by heat welding, the usual joining method for HDPE, which can hardly be glued.

On heat, HDPE melts around 130 °C while commercial PP melts at about 160 to 166 °C, so areas with very hot washing or steam sterilisation suit PP better. On repair, HDPE can hardly be glued, joints must be heat-welded and rarely regain the original strength; a pallet with a broken leg usually has to be replaced.

Why an HDPE pallet sags on racking even when not overloaded

Polyethylene shows creep: under a constant load over a long time the plastic keeps deforming a little more. Isotactic PP is stiffer and resists creep better than PE. That is why the rack load of an HDPE pallet is always the lowest of its three load ratings, and why a pallet left on rack beams for long periods needs a steel-core or bottom-rail model, not one chosen by static load.

In practice all four drawbacks can be managed if you pick the right model from the start: ask about rack load, ambient temperature and whether a UV-resistant additive is needed before you order.

Types of HDPE plastic pallets

HDPE plastic pallets are classified by construction, by plastic source (virgin or recycled), and by deck and leg style. By construction there are four common forms:

A one-piece moulded pallet is cast in a single shot with no joints, so it is strong and distributes load evenly.
A modular pallet is assembled from several pieces, so a damaged section can be replaced on its own.
A double-deck pallet can be used on either side, suited to heavy goods and multi-tier stacking.
A single-deck pallet is lighter, suited to light goods and fast handling.

Underside of a 1000 x 1200 x 150 mm plastic pallet: the layout of ribs, legs and runners sets its weight and load rating.

By plastic source: virgin HDPE and recycled HDPE

Virgin HDPE is made from new resin, so the colour is bright and even (blue, green, red, yellow) and quality is stable from batch to batch. Recycled HDPE is made from recovered plastic, usually black, grey or dark green, costs less, but its consistency depends on the incoming plastic. The difference lies in uniformity, not in every recycled pallet being weak: a recycled green three-leg 1000 x 1200 x 150 mm pallet in the ICD Vietnam catalogue still states a static load of 4,000 kg and a dynamic load of 2,000 kg.

A sensible approach is to divide by requirement: goods that touch the pallet surface directly in food, pharmaceutical and deep cold storage should favour virgin plastic; one-way export, dry warehouses and industrial goods can use recycled plastic to save money. For cold stores, ask for the specifications of each recycled model before putting it into service.

Dark green cross-deck pallet made of recycled plastic measuring 1200 x 1000 x 150 mm — A 1200 x 1000 x 150 mm cross-deck pallet in recycled plastic: a darker colour, suited to dry warehouses and one-way exports.

By deck style and leg style

A mesh deck is light, airy and drains quickly, suited to agricultural and seafood goods; a solid deck stops dust and liquids falling to the tier below, is easy to wipe clean and suits pharmaceuticals and dry foods. On legs, a cup-leg (9-leg) pallet is light and nests inside others when stored empty, while a 3-leg or 6-leg pallet with bottom runners is more stable on racking and under repeated forklift handling.

Blue solid-deck HDPE plastic pallet measuring 1200 x 1200 x 150 mm — A 1200 x 1200 x 150 mm solid-deck pallet: the flat, continuous surface shows any dirt left after washing at a glance.

Dimension drawing of a 9-leg mesh-deck plastic pallet, 1200 x 1200 x 140 mm — Drawing of a 9-leg mesh-deck plastic pallet, 1200 x 1200 x 140 mm: hollow cup legs let the pallets nest when stored.

Where are HDPE plastic pallets used?

HDPE plastic pallets are used most in warehousing and transport, the food, pharmaceutical, seafood and cold-storage industries, the chemical industry and industrial plants, that is, wherever durability, hygiene and moisture resistance are needed. Each environment calls for a different configuration.

Multi-tier racked warehouse with a forklift moving along the aisle — In racked warehouses the pallet must suit both the rack and the forklift: choosing the wrong rack load is the most common mistake.

Seafood stores and cold stores need pallets that tolerate cold and frequent washing, so choose virgin HDPE with a mesh or solid deck. Food and pharmaceuticals need a clean surface that resists soiling and is easy to inspect, so choose a solid deck and virgin plastic. Chemical stores need chemical-resistant material that holds leaked liquid, so use a solid-deck or spill-containment pallet. Racking warehouses carrying heavy goods need a pallet that does not sag on the beams, so choose 3-leg or 6-leg with a steel core. One-way export goods need a light, low-cost pallet with no quarantine treatment, so use cup-leg models, which may be recycled plastic.

Export with no ISPM 15 treatment

The ISPM 15 standard of the International Plant Protection Convention applies only to wood packaging material, so HDPE pallets need no heat treatment, fumigation or quarantine stamp when shipped with export goods.

HDPE plastic pallets compared with PP plastic pallets

HDPE is tougher and handles impact and cold better; PP is stiffer, slightly lighter and more heat-resistant but turns brittle below 0 °C, so cold stores almost always use HDPE. The table below summarises the differences using material data. Another angle is in plastic pallets versus wooden pallets.

Property	HDPE plastic pallet	PP plastic pallet
Toughness, impact resistance	Tough, absorbs impact well, hard to crack	Stiffer, more brittle under impact at low temperatures
Melting temperature	About 130 °C, tolerates 120 °C for short periods	About 160 - 166 °C, withstands steam sterilisation
Low temperature	Stays flexible at freezer-store temperatures	Brittle below 0 °C
Stiffness, creep resistance	Softer, sags on racking without a steel core	Stiffer, better creep resistance
Chemical resistance	Chemically durable, resists many acids, alkalis and solvents	Good resistance at normal temperature, weaker than PE against strong oxidisers
Density	0.93 - 0.97 g/cm³	0.895 - 0.93 g/cm³, the lowest of the common plastics
Best suited to	Cold stores, food, seafood, general warehouses	Hot environments, hot-wash areas, dry warehouses

Many pallet models are not pure HDPE but are blended with PP or PPC (PP copolymerised with ethylene), to get the stiffness of PP while keeping some of PE’s toughness at low temperatures. In the ICD Vietnam catalogue only 15 models list pure PP, 26 list HDPE with PPC, and the rest are mostly HDPE. So when reading a spec sheet, read the material line together with the rack load and the working temperature.

For more on the material, the article what HDPE plastic is, its properties and uses goes into the structure and characteristics of this plastic, while the plastic pallet articles in this topic cluster answer questions on sizes, load ratings and how to choose.

Blue HDPE plastic pallet measuring 1400 x 1100 x 160 mm — A 1400 x 1100 x 160 mm HDPE plastic pallet: a standard outer size for bulky goods and machinery.

HDPE plastic pallet specifications

A standard-size HDPE pallet is usually 120 to 160 mm high and carries a static load of several thousand kg, but its dynamic load is only about one third to one half of the static load, and its rack load is the lowest. The three most common sizes in Vietnam are 1200 x 1000 mm, 1100 x 1100 mm and 1200 x 800 mm.

When reading specifications, separate the three load ratings because they differ many times over: static load is when the pallet sits still on the floor or is stacked, dynamic load is when a forklift lifts and moves it, and rack load is when the pallet is supported only at its two edges on beams. Choosing the wrong rating is the usual reason pallets sag or break on racking. The figures also vary with plastic weight, one-piece or modular construction, and whether steel reinforcement is used. The table below summarises the models that list HDPE as the material in the ICD Vietnam catalogue.

Size (mm)	HDPE models	Common height	Static load (kg)	Dynamic load (kg)
1200 x 1000	41	150 mm	1,500 - 6,500	500 - 3,200
1100 x 1100	20	150 mm	1,500 - 6,000	500 - 2,000
1200 x 1200	16	160 mm	3,500 - 6,000	1,000 - 2,000
1200 x 800	12	150 mm	2,000 - 6,000	800 - 1,500

Compiled from the specifications of plastic pallet models listing HDPE as the material on the ICD Vietnam website, checked 11 October 2026; static load counts only models rated 1,000 kg or more.

The load range above is wide because the catalogue includes both light cup-leg pallets for exports and steel-core pallets for heavy racking. Weight differs accordingly: a 1200 x 1000 mm cup-leg pallet weighs only about 6 kg, a 1100 x 1100 x 150 mm pallet about 11.5 to 18.5 kg, and a 1200 x 1000 x 150 mm warehouse pallet or steel-core pallet about 13.5 to 22 kg. A heavier pallet usually has thicker plastic or steel inside, so it carries higher dynamic and rack loads.

Dimension drawing of a flat-deck four-way-entry HDPE plastic pallet, 1500 x 1200 x 180 mm — Drawing of a 1500 x 1200 x 180 mm flat-deck HDPE pallet with four-way entry: fork-opening height and leg positions decide which forklifts can use it.

To choose the right model for your actual load and rack type, see the full plastic pallet catalogue with specifications for each model. Plastic pallets distributed by ICD Vietnam carry a 2-year warranty.

HDPE pallets in cold storage and outdoors

HDPE pallets work well in cold stores and freezer stores because they stay flexible at sub-zero temperatures, but for long-term outdoor use they must be a grade with a UV-resistant additive. The working range published by manufacturers varies by resin grade and design: the cold end from about -18 to -40 °C, the hot end from 60 to 70 °C. Ordinary food freezer stores at -18 to -25 °C fall within this range, but you should ask for the range of the exact pallet model you plan to buy.

Cold-store doorway with plastic strip curtains and a forklift working inside — At a cold-store door, pallets pass constantly through a temperature gradient and condensing moisture, where non-absorbent HDPE has a clear advantage.

In seafood and frozen-food cold stores, the advantage of HDPE shows clearly against PP, which turns brittle below 0 °C, and against wooden pallets, which absorb moisture, freeze and mould easily. Condensation formed as pallets move in and out of the store does not soak into the plastic, so the pallet does not gain weight or rot. For example, the 1100 x 1100 x 150 mm cold-store pallet in the ICD Vietnam catalogue is made of HDPE and PPC and states a static load of 4,000 kg and a dynamic load of 1,000 kg.

Conversely, ultraviolet light is polyethylene’s weak point. HDPE without UV stabiliser, exposed to the sun regularly, fades, chalks on the surface and gradually becomes brittle, at a rate that depends on sunlight intensity and storage. If pallets are kept in an open yard, choose a grade with a UV-resistant additive from production, and state the conditions of use (cold store, indoor or outdoor) when ordering so you get the right resin formulation.

Several stacks of blue plastic pallets in a yard in front of a warehouse — Plastic pallets stacked in a yard take sun and rain every day: this is the case to ask about a UV-resistant additive.

Besides standard flat pallets, ICD Vietnam also supplies container-type plastic pallets made from HDPE for bulk storage with four closed sides.

Yellow HDPE plastic pallet box measuring 1200 x 1000 x 740 mm — A 1200 x 1000 x 740 mm HDPE plastic pallet box: four closed walls and a base with feet for forklifts.

How can you check that a pallet really is HDPE?

The surest way is to match the marking moulded into the pallet body against the supplier’s specification sheet and documents, because colour or a water test cannot tell HDPE from PP. Both are lighter than water and both float; a bright colour only suggests the pallet may be made of virgin plastic, not whether it is HDPE or PP. On delivery, check the following points:

Look for the HDPE marking or resin code 2 moulded into the body or legs of the pallet.
Match the material line on the spec sheet against the contract, noting whether it is pure HDPE or HDPE blended with PP or PPC.
Ask whether the plastic is virgin or recycled and write that into the contract if goods will touch food directly.
Request migration test results under QCVN 12-1:2011/BYT for the exact pallet model if goods will sit directly on the plastic surface.
Check the pallet for cracks, sharp burrs or crooked legs before it goes onto racking.

A green PLR4-1275 solid-deck pallet: the material has to be read from the spec sheet, not inferred from the colour.

Frequently asked questions

How many kg can an HDPE plastic pallet carry?

It depends on size and construction. For the HDPE models in the ICD Vietnam catalogue, the median static load is 4,000 kg (up to 8,000 kg) and the median dynamic load is 1,000 kg (up to 3,200 kg on steel-core models). Rack load is always lower than static and dynamic load, so choose the pallet for how it will actually be used to avoid sagging or breaking.

Can HDPE plastic pallets be used in cold storage?

Yes. HDPE stays flexible at sub-zero temperatures and does not absorb moisture, so it is preferred for seafood and frozen-food cold stores. Manufacturers publish different working ranges by resin grade, with the cold end from about -18 to -40 °C and the hot end from 60 to 70 °C, so ask for the range of the exact pallet model. PP is unsuitable because it turns brittle below 0 °C.

Which is more durable, an HDPE pallet or a PP pallet?

HDPE handles impact and cold better, suiting cold stores and general warehouses; PP is stiffer, resists sagging better and tolerates more heat, suiting hot environments or hot-wash areas. For most warehouses and logistics operations in Vietnam, HDPE or HDPE blended with PP is a balance of durability and cost.

White-walled food cold store with stainless steel racks and staff in protective clothing — A food cold store: damp, cold conditions are where virgin HDPE is preferred over PP.

Are HDPE plastic pallets food-safe?

Yes, when they are virgin HDPE. HDPE and PP belong to the polyolefin group permitted for food-contact materials, in the US under FDA 21 CFR 177.1520, and in Vietnam PE plastic packaging and utensils in direct food contact must meet QCVN 12-1:2011/BYT. Recycled pallets of unknown plastic origin should not be used where goods touch the pallet surface directly.

Virgin or recycled when carrying food?

Goods already packed in cartons or sealed wrap can sit on a recycled pallet that meets the load rating. Goods that touch the pallet surface directly, such as vegetables and fruit or seafood, should use virgin HDPE.

What is the HS code for HDPE plastic pallets?

Under Vietnam’s Export and Import Commodity List issued with Circular 31/2022/TT-BTC, HDPE or PP plastic pallets are declared under code 3923.90.90; code 3923.10 is for plastic boxes, cases and crates, and wooden pallets fall under 4415.20.00. US Customs also classifies HDPE and PP plastic pallets of 1200 x 1000 x 150 mm under subheading 3923.90 in ruling NY J80577.

Inspector checking goods stacked on wrapped pallets inside a container — Goods on pallets in an export container: the HS code of the pallet must be declared correctly when the pallet travels with the shipment.

How much does an HDPE plastic pallet weigh?

In the ICD Vietnam catalogue, a 1200 x 1000 mm cup-leg pallet weighs about 6 kg, a 1100 x 1100 x 150 mm pallet about 11.5 to 18.5 kg, and a 1200 x 1000 x 150 mm warehouse pallet about 13.5 to 22 kg. A heavier pallet usually has thicker plastic or a steel core.

Orange HDPE plastic pallet measuring 1100 x 1100 x 100 mm used under jumbo bags — A 1100 x 1100 x 100 mm HDPE pallet under jumbo bags: the rib layout and plastic thickness decide the weight of each unit.

Can HDPE plastic pallets be recycled?

Yes. HDPE carries resin identification code 2 and is one of the most commonly recovered and recycled plastics. A damaged HDPE pallet can be ground into recycled resin to mould new pallets or other industrial plastic products.

Contact ICD Vietnam

ICD Vietnam supplies virgin and recycled HDPE plastic pallets, solid-deck, mesh-deck and steel-core models for racking, with a specification sheet for each model to check before ordering.

North: 0983 797 186 / 090 345 9186 / 090 5859 186.
South: 098 6784 186.
Email: sales@icdvietnam.com.vn.
Zalo: Chat with ICD Vietnam on Zalo.

References

HDPE properties, density and melting point (see also the Polypropylene entry for PP): Wikipedia, High-density polyethylene.
HDPE plastic material: British Plastics Federation (BPF).
Food-contact polyolefins: FDA, 21 CFR 177.1520.
Plastic packaging and utensils in food contact: QCVN 12-1:2011/BYT, Ministry of Health.
Plastic pallet classification: US Customs and Border Protection (CBP), ruling NY J80577; Circular 31/2022/TT-BTC, Ministry of Finance.
Wood packaging material: IPPC, ISPM 15.
Pallet counts, sizes, load ratings, weights: ICD Vietnam plastic pallet catalogue, checked 11 October 2026.