Packaging & Logistics worked example

Pallet Height with pallet deck height of 3 in: a worked example

This worked example runs the pallet height numbers for a tougher week than the baseline: pallet deck height of 3 in instead of the typical 6 in. Add pallet deck, load stack, top cap, and allowance to get total pallet height for racking and trailer clearance.

The inputs for this scenario

  • Pallet deck height: 3 in (the input this scenario stresses; the baseline uses 6)
  • Stacked load height: 48 in (held at the documented default)
  • Top cap or slip sheet: 1 in (held at the documented default)
  • Wrap and overhang allowance: 1 in (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total pallet height = pallet deck height + stacked load height + top cap + wrap and overhang allowance.
  • Total pallet height works out to 53 in at these inputs, and this is the headline figure for the scenario.
  • Pallet deck height works out to 3 in at these inputs.
  • Stacked load height works out to 48 in at these inputs.
  • Top cap plus allowance works out to 2 in at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where pallet deck height sits at 6 in and the headline result is 56 in, this scenario comes in 5.36% below the baseline at 53 in.
  • Use it before releasing a pallet pattern to confirm door, rack, and double-stack clearances. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total pallet height: 53 in (headline result)
  • Pallet deck height: 3 in
  • Stacked load height: 48 in
  • Top cap plus allowance: 2 in

Run it with your numbers

  • To rerun this with your own numbers, open the live Pallet Height calculator, set pallet deck height to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.