Walk into any warehouse in America and you will find pallets. But not all pallets are built the same way. The two fundamental construction types — stringer pallets and block pallets — differ in design, strength, accessibility, cost, and suitability for different applications. Choosing the wrong type can lead to handling inefficiencies, compatibility problems with racking and automated systems, and unnecessary spending.
Understanding the key differences between stringer and block pallets allows you to match the right pallet type to your specific application, optimize your warehouse operations, and make more informed purchasing decisions. Here is a comprehensive comparison of the two designs.
Construction: How Each Type Is Built
A stringer pallet uses two or three long boards — called stringers — that run the full length of the pallet between the top and bottom deck boards. These stringers are the primary structural members. They support the load and provide the opening for forklift fork entry. The standard 48x40 GMA pallet uses three stringers: one on each edge and one in the center. The top deck boards are nailed across the stringers to create the load-bearing surface.
A block pallet uses a different structural approach. Instead of continuous stringers, it uses short, square blocks — typically nine blocks arranged in three rows of three — positioned at the corners, sides, and center of the pallet. These blocks are connected by both top and bottom deck boards and, in some designs, by stringerboard runners between the blocks. The result is a more complex but more versatile structure.
Construction Comparison
Fork Entry: 2-Way vs True 4-Way Access
The most significant operational difference between stringer and block pallets is fork entry direction. A standard stringer pallet allows full fork entry from only two sides — the open ends between the stringers. The sides of the pallet are blocked by the stringers themselves, preventing fork entry. Some stringer pallets are manufactured with notches cut into the stringers on the blocked sides to allow partial fork entry, creating what is called a "partial 4-way" or "notched stringer" pallet. However, notched entry is typically narrower than full entry and may not accommodate all forklift fork widths.
Block pallets provide true 4-way entry. Because the blocks are discrete structural points rather than continuous boards, forks can enter from all four sides with equal clearance. This makes block pallets significantly more versatile in tight warehouse environments, double-deep racking systems, and applications where pallets must be accessed from multiple directions.
For businesses with narrow aisles, automated storage and retrieval systems, or frequent need to rotate pallets during loading, the true 4-way entry of block pallets can meaningfully improve operational efficiency. For straightforward shipping and storage applications where pallets are always accessed from the same direction, the 2-way entry of stringer pallets is perfectly adequate and the lower cost makes them the more economical choice.
Strength and Durability: Performance Under Load
Block pallets are generally stronger than stringer pallets of equivalent size and wood species. The block construction distributes weight across nine support points and uses both top and bottom deck boards as structural members, creating a rigid, box-like structure that resists bending, twisting, and racking forces more effectively than the linear stringer design.
The superior racking performance of block pallets is particularly important for warehouses using selective, drive-in, or push-back racking systems. The continuous bottom deck boards of a block pallet span the full width of the racking beams, distributing the load evenly and reducing the risk of board deflection. Stringer pallets, especially those with minimal or no bottom deck boards, rely on the stringers alone to bridge the racking beams — a configuration that is more susceptible to failure under heavy loads.
However, for applications that do not involve racking — floor stacking, direct shipping, and short-term storage — stringer pallets provide more than adequate strength at a lower cost. Their simpler construction also makes them lighter, which can reduce shipping costs in weight-sensitive freight scenarios.
Cost Analysis: Price vs Performance
Stringer pallets are less expensive to manufacture than block pallets. They use fewer components — typically 11 to 13 pieces compared to 18 to 22 for a block pallet — and require simpler assembly processes. A new stringer pallet typically costs $10 to $16, while a comparable block pallet costs $14 to $22. The cost gap narrows in the recycled pallet market, where a recycled stringer pallet might cost $4 to $7 and a recycled block pallet $6 to $10.
The total cost of ownership calculation should consider more than just the purchase price. Block pallets typically last longer due to their more robust construction, so the cost per use cycle may actually favor block pallets in heavy-duty applications where stringer pallets would need more frequent replacement. Block pallets also have higher resale value on the secondary market, so your recovery value when selling used pallets is better.
For most small and medium businesses in Phoenix, the practical recommendation is straightforward: use stringer pallets for general shipping, warehouse storage, and applications where cost is the primary consideration. Use block pallets for heavy loads, racking storage, automated handling systems, and international shipping to European markets where block pallets are the standard format.
Industry Preferences: Who Uses What and Why
In the United States, stringer pallets dominate the market, accounting for approximately 80% of all wood pallets in circulation. The 48x40 GMA stringer pallet is the de facto standard in grocery, retail, beverage, and general merchandise distribution. Its ubiquity means that virtually every warehouse, truck, and racking system in America is designed to handle stringer pallets efficiently.
Block pallets are the preferred format in Europe, where the EUR/EPAL pallet (800x1200mm) is a block design. Companies involved in international trade with European markets often use block pallets to maintain compatibility with their overseas customers' handling equipment. The pharmaceutical, chemical, and automotive industries also tend to favor block pallets for their superior strength and 4-way handling characteristics.
At Phoenix Pallet Recycling, we maintain inventory of both stringer and block pallets in multiple sizes and grades. Whether you need standard GMA stringer pallets for everyday shipping or heavy-duty block pallets for specialized applications, we can supply them from recycled stock at competitive prices. Our team can also help you determine which type is the best fit for your specific operations if you are unsure.