To prepare pallets for freight, use a sound standard pallet and stack cartons squarely with the heaviest at the bottom. Then wrap, strap and label the load, and record its real weight and dimensions. This guide covers each step for road freight in Australia, with a checklist to use before pick-up.
Choose a sound, standard pallet
The standard Australian pallet is 1165 × 1165 mm, as CHEP’s Australian pallet specifications show. CHEP and Loscam both hire wooden pallets in this size, 150 mm high, so it suits most domestic road freight.
Imported goods can arrive on other pallet sizes, so measure them rather than assume. The guide to importing goods into Australia explains what happens before they reach you.
Before loading, check the pallet has:
- No broken, cracked or missing boards.
- No protruding nails or splinters.
- No rot or wet timber.
- Clear fork entry for a forklift or pallet jack.
A damaged pallet can collapse when it is lifted. If in doubt, swap it out.
Hire pallets from CHEP or Loscam
Pooled pallets are hired, not bought. CHEP says its Australian pallets are shared and reused for a hire fee and are not for sale. Loscam charges each account as its pallets pass through.
Hire charges stay on your account until a transfer is recorded. Both pools expect the sender to record pallets leaving its account. When you book, tell the carrier which pool the pallets belong to and how many there are. Also say whether the receiver accepts transfers. Send the transfer docket copies with the freight for the receiver to sign.
Large retail distribution centres often set their own pallet rules, so check before dispatch. For plain timber pallets, tell the carrier whether they are one-way or need to come back.
Stack cartons squarely, heaviest at the bottom
Follow these steps so the pallet arrives in one piece:
- Put the heaviest, strongest cartons on the bottom layer.
- Stack in neat columns or an interlocking brick pattern, with each layer flat and level.
- Keep every carton inside the pallet edges. Overhang crushes carton walls and catches on other freight.
- Fill gaps with void fill or cardboard so nothing can shift.
- Finish with a flat top that is easy to wrap.
- Keep the load as low and compact as the goods allow.
If the load cannot take weight on top, mark it “Do not stack” and tell the carrier when you book.
Height affects cost as well as stability. Many carriers charge a light, bulky pallet on its size rather than its weight. The guide to how cubic weight is calculated shows why a compact pallet often costs less.
Secure the load so it moves as one unit
A finished pallet should behave like one solid block. Heavy or tall loads usually need more than one of these methods.
| Method | What it does | How to use it |
|---|---|---|
| Stretch or shrink-wrap | Holds cartons together and helps keep out dust and moisture | Start at the base and wrap around the pallet deck to tie the load to the pallet. Overlap each layer and add extra turns at the top. |
| Strapping | Holds heavy or dense loads down onto the pallet | Run straps under the top deck and over the load. Tension them firmly without crushing cartons. |
| Corner or edge boards | Protect carton edges and spread strap pressure | Fit them on all four vertical corners before wrapping or strapping. |
| Top sheet or cap board | Spreads pressure across the top layer | Use one under straps or over light cartons. |
Once the pallet is wrapped, give the top a firm push. If it sways or cartons slide, add more wrap or a strap.
Label the pallet and complete the paperwork
Put a label on at least two sides of each pallet showing:
- Receiver name and full delivery address.
- Delivery contact name and phone number.
- Sender name and phone number.
- Consignment or reference number.
- Pallet count, such as “1 of 3”.
The consignment details you give the carrier should match the labels. Include the pallet count, each pallet’s weight and dimensions, and any delivery time window or receiving booking.
Declare dangerous goods
Tell the carrier before booking if any goods are dangerous goods. Everyday products such as aerosols, paint and lithium batteries can fall into this group. Under NSW EPA rules on dangerous goods transport documents, the consignor must make sure the driver or prime contractor has one. Not every carrier accepts every class, so check first.
Confirm loading access at both ends
When you book, say whether the pick-up and delivery sites have:
- A forklift or pallet jack, and someone to operate it.
- A loading dock, or ground-level access only.
- Room for a truck to park, turn and unload.
- Set receiving hours, booking times or site inductions.
If there is no forklift or dock at delivery, the carrier needs to know in advance. Finding out on the day can mean a failed delivery or a second trip.
Get weights and dimensions right
Weigh and measure every pallet after wrapping, including the pallet itself. An empty CHEP wooden pallet averages about 38 kg and a Loscam wooden pallet about 34 kg. Measure the full height from the floor to the top of the load.
Accurate figures are also a legal matter. The Heavy Vehicle National Law applies in NSW to vehicles over 4.5 tonnes gross vehicle mass. Its Chain of Responsibility covers businesses that send, pack or load goods for these vehicles. Each must keep its transport activities safe, so far as reasonably practicable. NHVR guidance on the primary duty expects accurate information about the mass of loads.
In practice, weigh pallets instead of guessing, and never understate weight to save on cost. Wrong figures can lead to overloaded vehicles, unsafe handling and a re-quoted job.
Worked example
A business sends 40 cartons on one CHEP pallet. Each carton weighs 12 kg, so the goods weigh 480 kg. Add about 38 kg for the pallet and the gross weight is around 518 kg.
The cartons stand 1,250 mm tall on the 150 mm pallet, so it measures 1165 × 1165 × 1400 mm. That is about 1.9 cubic metres. The booking should read: 1 pallet, 518 kg, 1165 × 1165 × 1400 mm.
Pre-pick-up checklist to prepare pallets for freight
- The pallet is sound, dry and the right size.
- Heaviest cartons are at the bottom, with no overhang.
- The load is wrapped to the pallet deck and strapped if heavy.
- Labels on two sides show the delivery contact’s name and phone number.
- Each pallet is weighed and measured, and the booking matches.
- Dangerous goods are declared, with transport documents ready.
- CHEP or Loscam pallets are declared, with transfer dockets ready.
- Loading equipment and access are confirmed at both ends.
How PBR Express Logistics can help
We collect palletised freight around Newcastle through our road freight service, for one-off jobs or regular runs. Every job is quoted first, and the price is confirmed before pick-up. Our Warehousing & Fulfilment service can also store pallets and cartons and handle pick, pack and dispatch for you. Send your route, pallet count, weights and dimensions through our freight quote form and we’ll confirm.
FAQs
What size is a standard Australian pallet?
The standard Australian pallet is 1165 × 1165 mm. CHEP and Loscam wooden pallets in this size are 150 mm high. Imported goods can arrive on other sizes, so measure before you book.
How high can I stack a pallet for road freight?
It depends on the carrier, the vehicle and the goods, so check before you build. Keep the load stable, with a flat top and no overhang. A tall pallet may be charged on its size rather than its weight.
Do I need to tell the carrier I am using CHEP or Loscam pallets?
Yes. Hire pallets stay on your account, and keep attracting hire charges, until a transfer is recorded. Tell the carrier which pool, how many pallets and whether the receiver accepts transfers.
Should the pallet’s weight be included in the freight weight?
Yes. Declare the gross weight: goods, packaging, wrap and the pallet itself. Leaving out a CHEP pallet understates each load by about 38 kg.
