Why Pallet Shipping Changes the Economics of Heavy Freight
A 500-lb shipment sent as multiple boxes via UPS Ground could cost $600–$900 in total. The same goods palletized and sent via LTL freight: $150–$250. Pallet shipping via LTL (Less-than-Truckload) freight is the standard method for businesses moving heavy goods, and understanding it is essential for any company shipping over 150 lbs regularly.
This guide covers the complete pallet shipping process — from building the pallet correctly to getting quotes, avoiding hidden charges, and choosing the right carrier for your lane.
Standard Pallet Sizes
In North America, the standard pallet is the GMA pallet: 48" × 40" (also called a "48×40 pallet"). This is what LTL carriers expect and what fits most warehouse racking systems.
Other common sizes:
- 42" × 42": Common in the paint and chemical industry
- 48" × 48": Used for drums and some industrial goods
- Euro pallet (1200mm × 800mm / ~47" × 31.5"): Standard in Europe, less common in US
For most B2B shipments, use 48×40 pallets. They're universally accepted, cheapest to acquire ($10–$15 for a used pallet), and optimized for standard truck loading.
How to Build a Proper Shipping Pallet
- Inspect the pallet: No broken boards, no protruding nails, no rot. A damaged pallet is a liability.
- Stack heaviest items on the bottom: Low center of gravity prevents tipping. Never stack heavy items on top of lighter ones.
- Keep weight within the pallet footprint: Overhang of more than 1 inch can result in surcharges or refusal. Keep boxes within the 48×40 edge.
- Stack in a column or brick pattern: Columns (each box directly above another) provide better vertical compression strength. Brick pattern (alternating) provides better lateral stability.
- Apply corner protectors: Cardboard corner protectors on all four vertical edges prevent strapping damage and improve stacking stability.
- Shrink wrap: Apply at least 3–4 passes of stretch wrap around the pallet, including over the top layer and down to the pallet base. Stretch wrap to 250–300% elongation for maximum hold.
- Label clearly: Attach the BOL (Bill of Lading) and carrier label to the top of the pallet, visible to forklift operators. Use a clear plastic sleeve or tape over the label to protect from moisture.
Maximum pallet height for LTL: typically 90" floor-to-ceiling (pallet + cargo). Weight limit: typically 2,000–3,000 lbs per pallet, but check with your carrier.
Understanding Freight Classes
LTL pricing is based on freight class — an NMFC (National Motor Freight Classification) system that assigns a class number from 50 to 500 based on four factors:
- Density: Weight per cubic foot (PCF). Higher density = lower class = cheaper. Calculate: weight (lbs) ÷ cubic feet of the shipment.
- Stowability: Can it be stacked? Does it have protrusions? Non-stackable or oddly shaped goods = higher class.
- Handling: Is it fragile, hazardous, or requires special handling? Extra handling = higher class.
- Liability: High-value per pound or theft-prone items = higher class.
| Freight Class | Density (PCF) | Common Items |
|---|---|---|
| Class 50 | 50+ PCF | Steel bolts, heavy machinery parts |
| Class 70 | 15–22.5 PCF | Auto parts, food items, appliances |
| Class 100 | 9–10.5 PCF | Wine, boots, furniture |
| Class 150 | 6–7 PCF | Auto sheet metal, motorcycles |
| Class 250 | 1–2 PCF | Bamboo furniture, boxes of pillows |
| Class 500 | <1 PCF | Ping pong balls, gold dust |
Density is the most controllable variable. Denser packing = lower class = lower rate. Before calling for a quote, calculate: (length × width × height in inches) ÷ 1,728 = cubic feet. Then weight ÷ cubic feet = PCF.
Getting LTL Quotes: What You Need
To get an LTL freight quote, you'll need:
- Origin and destination zip codes
- Freight class (use density method above)
- Weight (total shipment weight)
- Dimensions (L × W × H of the palletized shipment)
- Number of pallets
- Accessorial services needed: liftgate pickup, liftgate delivery, residential, inside delivery, appointment, etc.
Get quotes from at least 3 sources: FreightQuote, GoShip, or uShip, plus direct from major carriers (Old Dominion, XPO, Estes, ABF). Rates vary 30–50% for the same lane, even between comparable carriers.
Accessorial Charges: The Hidden Costs
Accessorial charges are the most common source of billing surprises in LTL freight. Budget for these upfront:
| Accessorial | Typical Cost | When It Applies |
|---|---|---|
| Liftgate pickup | $50–$80 | No loading dock at origin |
| Liftgate delivery | $75–$100 | No loading dock at destination |
| Residential delivery | $75–$125 | Delivering to a home address |
| Limited access | $75–$150 | Schools, churches, construction sites, storage units |
| Inside delivery | $75–$200 | Moving freight beyond the threshold |
| Delivery appointment | $35–$75 | Scheduled delivery window required |
| Reweigh/reclass | $15–$25 + rate adjustment | Carrier disputes your declared weight or class |
A residential delivery with liftgate can add $150–$225 to a shipment. Factor these into your comparison before selecting a carrier.
Top LTL Carriers by Strength
- Old Dominion (ODFL): Consistently lowest damage claims rate, excellent service across the US. Premium pricing but worth it for high-value freight.
- XPO Logistics: Strong national coverage, competitive rates. Technology-forward with real-time tracking.
- Estes Express: Strong Southeast and Mid-Atlantic, competitive for those regions.
- Saia: Strong in the South and Midwest. Good rates for regional lanes.
- ABF/ArcBest: Good for time-sensitive LTL; offers guaranteed delivery windows.
Bottom Line
Pallet shipping via LTL is the most cost-effective way to move heavy freight domestically. The key to minimizing cost: accurate freight classification, maximizing pallet density, being upfront about accessorial needs, and comparing multiple carriers before booking. Use our freight cost calculator to estimate LTL rates for your pallet dimensions, or compare freight carriers on your specific lane.