How do you calculate total pallet height?

Add the pallet deck height, the stacked product height, any top cap or slip sheet, and a wrap/overhang allowance. A 6 in deck, 48 in of product, a 1 in top cap, and 1 in allowance give a 56 in total pallet height.

What is the standard pallet deck height?

A GMA 48x40 pallet is typically 5.5-6 in tall at the deck. This calculator uses 6 in; block pallets and some export pallets can be slightly taller.

How tall can a pallet be for a dry van?

Most 53 ft dry vans have about 108-110 in of interior height. To double-stack, each pallet must stay near 50-54 in; the 56 in example fits single-stacked with clearance but is too tall to double-stack in a standard van.

Why add a wrap and overhang allowance?

Stretch film, a bulging top layer, and any product that overhangs the deck all add measurable height and width. The 1 in allowance here keeps your paperwork honest so the load actually fits the opening.

Does the top cap count toward pallet height?

Yes. A top cap, freeze frame, or slip sheet sits above the product and adds to the stack — 1 in in the example — so it must be included when checking clearance.

What is a good pallet height for double-stacking?

Aim for a finished height at or below half the trailer's interior clearance, roughly 50-54 in, so two pallets plus a gap fit under about 108 in. At 56 in this load exceeds that and should ship single-stacked or be built shorter.

Packaging & Logistics calculator

Pallet Height Calculator

Total pallet height is the finished height of a built unit load measured from the floor to the top of the wrap — deck, product stack, top cap, and film allowance combined. Warehouse planners and load engineers use it to confirm loads clear trailer door openings, fit rack bay openings, and allow double-stacking without crushing the bottom pallet. It matters because a load that measures an inch too tall can jam a trailer roll-up door or force a costly single-stack configuration that strands trailer cube.

What this calculator does

Add pallet deck, load stack, top cap, and allowance to get total pallet height for racking and trailer clearance.
Use it to fit pallets into rack openings and trailers, plan double stacking, and avoid clearance problems at the dock.
It adds pallet deck height, stacked load height, top cap, and wrap/overhang allowance into one total palletized height.

Formula used

Total pallet height = pallet deck height + stacked load height + top cap + wrap and overhang allowance
Average component = total ÷ component count

Inputs explained

Pallet deck height:
Stacked load height:
Top cap or slip sheet:
Wrap and overhang allowance:

How to use the result

Use it before releasing a pallet pattern to confirm door, rack, and double-stack clearances.
It assumes a stable, square stack; leaning columns, bulging cases, or settling can add height beyond the calculated value.

Current U.S. benchmarks

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Common questions

How do you calculate total pallet height? Add the pallet deck height, the stacked product height, any top cap or slip sheet, and a wrap/overhang allowance. A 6 in deck, 48 in of product, a 1 in top cap, and 1 in allowance give a 56 in total pallet height.
What is the standard pallet deck height? A GMA 48x40 pallet is typically 5.5-6 in tall at the deck. This calculator uses 6 in; block pallets and some export pallets can be slightly taller.
How tall can a pallet be for a dry van? Most 53 ft dry vans have about 108-110 in of interior height. To double-stack, each pallet must stay near 50-54 in; the 56 in example fits single-stacked with clearance but is too tall to double-stack in a standard van.
Why add a wrap and overhang allowance? Stretch film, a bulging top layer, and any product that overhangs the deck all add measurable height and width. The 1 in allowance here keeps your paperwork honest so the load actually fits the opening.
Does the top cap count toward pallet height? Yes. A top cap, freeze frame, or slip sheet sits above the product and adds to the stack — 1 in in the example — so it must be included when checking clearance.

Last reviewed 2026-05-12.