Selecting the right pallet for your operation is a crucial decision. Both block and stringer pallets have distinct advantages, and picking the best fit depends on factors such as manual and mechanical handling requirements, durability, and overall cost. Understanding the structural differences between these two types of pallets is the first step toward optimizing your material handling system.

Block Pallets vs. Stringer Pallets: Structural Differences

Let’s start with the obvious differences. According to the National Wooden Pallet and Container Association (NWPCA) Uniform Standard for Wood Pallets, your basic choices come down to block and stringer, the two classes of wood pallets.

The defining characteristic of a block pallet is its use of solid blocks, often arranged in a three-by-three grid, connecting the top and bottom decks. The top deck boards are fastened directly to the blocks, often with the addition of stringer boards sandwiched between them. These stringer boards help distribute weight and add structural stability. On non-reversible block pallets, the bottom deck boards are attached to the underside of the blocks to form the base. Depending on handling requirements and load distribution needs, the bottom deck can take different forms, including parallel base, perimeter frame, or cruciform designs.

Common varieties of block pallets include the standard EPAL specification and the nine varieties of specialized chemical pallets.

A critical factor in block pallet construction is fastener selection. Unlike stringer pallets, which often use uniform nail sizes throughout, block pallets frequently require multiple nail lengths to accommodate different attachment points. For instance, nails that secure the top deck boards to the blocks must be longer than those that connect the deck boards to the stringer boards.

By contrast, stringer pallets are generally less complex. They rely on wood stringers running parallel to each other, usually three in total, to provide structural support. These stringers provide beam strength, distributing weight across their length. Some stringer pallets are notched to allow partial four-way forklift entry, while others are solid and only accessible from the two ends.

The top deck boards are fastened directly onto the stringers, which provide primary support. In most cases, stringer pallets have a unidirectional bottom deck, meaning all bottom boards run in the same direction. A standard GMA pallet, for example, typically has five bottom deck boards aligned lengthwise, providing sufficient stability for stacking and transport.

Regarding fasteners, while block pallets require varied nail lengths, stringer pallets typically use single-length annularly or helically threaded nails to provide strong holding power. In cases where extra durability is needed, the design may call for bolts or screws in place of nails to reinforce critical stress points.

Benefits of Block Pallets

Block pallets are associated with more efficient forklift handling, better cube utilization, safer stacking, and improved conveyability—factors that can help supply chains work smarter and safer. Cumulative savings in time, freight, damage reduction, material handling efficiency, and equipment can translate into significant long-term savings. Let’s take a look at some of the key benefits of block pallets:

• Compatibility with walkie rider pallet jacks: While notched stringer pallets require a forklift to enter from the side, block pallets allow the walkie rider to enter from all four sides. This can help eliminate the need for forklifts to supplement walkie riders on the loading dock. One 2016 study found that by switching to block pallets, a grocery distribution center saved almost $40,000 annually by reducing its need for forklifts on the dock.

• Fuller trailers: The same study found that using block pallets allowed the distribution center to increase the number of palletized loads on each trailer from 24-28 pallets to 30, delivering significant freight savings—greater than $440,000 annually.

• Faster, safer operations: With partial four-way stringer pallets, walkie rider operators often have to circle a pallet to access the end opening, or forklift operators must stack a loaded stringer pallet on top of a block pallet. These activities increase material handling time and contribute to dock congestion.

• Better stacking and conveyability: High-quality block pallets fitted with a perimeter frame or cruciform base provide extra bottom coverage, evenly distributing weight for safer load stacking. This reduces the risk of crush damage to products in lower loads. Regardless of travel direction, block pallets with a perimeter or cruciform base also tend to perform more flexibly on roller conveyors than stringer pallets with a unidirectional base.

Benefits of Stringer Pallets

While block pallets offer operational efficiencies, stringer pallets remain a strong choice for many operations due to their cost-effectiveness, repairability, and widespread availability. Let’s take a closer look at why they remain a practical option:

• Lower Cost: Stringer pallets tend to be less expensive. They require less wood and simpler construction, leading to lower manufacturing costs and a more affordable price point. This cost savings can be substantial for industries that move high volumes of pallets—especially in one-way shipping or limited-use applications.

• Easier to Repair: One of the biggest advantages of stringer pallets is their ease of repair. The process is well-established among pallet recyclers, and repairs are readily available from service providers across North America. In contrast, block pallets can be more complex and costly to repair, especially when multiple blocks need replacing.

• Higher Strength-to-Weight Ratio: While block pallets are often assumed to be stronger, well-built stringer pallets can also offer impressive load capacity. High-density hardwood or reinforced stringers allow them to balance durability with lightweight efficiency.

• Greater Availability in North America: Stringer pallets have long been the industry standard in North America, making them widely available and easy to source. Most pallet manufacturers and recyclers maintain ample supplies of new and reconditioned stringer pallets, ensuring a steady inventory for businesses requiring consistent pallet flow.

Choosing the Right Pallet for Your Supply Chain

Ultimately, the right pallet depends on your supply chain’s unique needs. Block pallets excel in high-volume, automation-heavy environments where four-way entry, stacking stability, and conveyor compatibility lead to significant efficiency gains and cost savings over time. If those factors align with your operations, block pallets may be the best fit.

However, stringer pallets offer undeniable advantages in terms of cost, repairability, and widespread availability. For businesses prioritizing affordability and practicality, stringer pallets remain a solid choice.

The key to optimizing your supply chain isn’t about choosing the “best” pallet overall—it’s about selecting the one that best supports your operational efficiency, costs, and long-term logistics strategy. Contact our national sales team today—we’ll help you find the perfect pallet solution for your business.