Definition
A layer of deck boards positioned between the top and bottom decks of a pallet, typically found in heavy-duty or specialty pallet designs. Intermediate decks add structural rigidity, distribute point loads more evenly, and increase the overall load-bearing capacity. They are used in applications where exceptionally heavy or concentrated loads would otherwise cause deflection or failure in a standard two-deck pallet design.
Related Terms
Deck Board
The flat boards that form the top and bottom surfaces of a pallet. Top deck boards provide the platform on which goods are placed, while bottom deck boards (also called bottom boards) provide stability and allow the pallet to be stored on flat surfaces. Deck board thickness, width, and spacing directly affect a pallet's load capacity and suitability for different applications.
Double Deck
A pallet configuration that features deck boards on both the top and bottom surfaces. Double-deck pallets (also called double-faced pallets) have bottom boards that provide a more stable base for stacking and improve weight distribution on racking and conveyors. The bottom deck also protects goods on the pallet below when loads are stacked. Most commercial pallets are double-deck designs.
Stiffener
A structural member added to a pallet to increase its rigidity and reduce deflection under load, particularly in racking applications. Stiffeners are typically boards or engineered wood elements placed between or beneath the deck boards, running perpendicular to the primary deck board direction. They distribute loads more evenly across the pallet span and are common in custom-designed pallets for heavy or concentrated loads.
Point Load
A concentrated force applied to a small area of a pallet deck, as opposed to a uniformly distributed load spread across the entire surface. Point loads are caused by heavy items with small footprints, such as machinery legs, steel drums, or stacked pails. Pallets subjected to point loads require thicker deck boards, closer board spacing, or solid deck panels to prevent localized failure. Point load capacity is an important but often overlooked pallet specification.
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