ISO/DIS 18995
ISO/TC 51
Secretariat: BSI
Date: 2025-12-02
Flat plastic pallets for general purpose
DIS stage
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Contents
4.4 Stackable vs Rackable Pallets 2
6.2 Vertical dimensions for lifting devices 3
6.3 Horizontal dimensions for lifting devices 3
7 PERFORMANCE REQUIREMENTS AND SELECTION OF TESTS 3
7.3 Performance requirements 4
Annex A (informative) Bottom Support 7
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This document was prepared by Technical Committee ISO/TC 51, ...
This standard is proposed as part of sustainability and need of plastic pallets replacing conventional pallets and giving noticeable improved performance and durability. For the purposes of this document, the terms and definitions given in EN ISO 445:2013 apply. This document is proposed to cover detailed specifications of plastic pallets. The principal pallet dimension and tolerances given in ISO 6780:2003 apply. In addition, the design principles, safety aspects, and aesthetic properties; various types of expected performance and specifications are included such as mechanical performance and tests e.g. stacking, load capacity, forklifting, bending, compression, drop, slip angle, coefficient of friction… etc. Tests are explained in detail along with schematic drawings for their purpose and procedure covering a range of operating temperatures with acceptable performance limits. Test methods for flat pallets given in EN ISO 8611-1:2025,EN ISO 8611-2:2022 and EN ISO 8611-3:2012 apply. Packaging, handling storage and marking instructions are included too. Such information will add value to regulators, manufacturers and end users in efficient designing, manufacturing and utilization of plastic pallets used in the petrochemical industry.
Flat plastic pallets for general purpose
1.0 Scope
This International Standard specifies the specifications and performance for new single-deck and double-deck reversible and non-reversible flat plastic pallets, of all entry types used in all industries. The specifications for features such as openings and clearances that are needed for efficient handling are also included.
2.0 Normative references
The following documents are referred to in the text in such a way that some or all of their content constitutes requirements of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 6780:2003, Flat pallets for intercontinental materials handling — Principal dimensions and tolerances
EN ISO 445:2013, Pallets for materials handling - Vocabulary (ISO 445:2013)
EN ISO 8611-1:2025, Pallets for materials handling - Flat pallets - Part 1: Test methods (ISO 8611-1:2025)
EN ISO 8611-2:2022, Pallets for materials handling - Flat pallets - Part 2: Performance requirements and selection of tests (ISO 8611-2:2021)
EN ISO 8611-3:2012, Pallets for materials handling - Flat pallets - Part 3: Maximum working loads (ISO 8611-3:2011)
3.0 Terms and definitions
For the purposes of this document, the terms and definitions given in cen:proj:38476EN ISO 445:2013apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
- ISO Online browsing platform: available at https://www.iso.org/obp
- IEC Electropedia: available at https://www.electropedia.org
4.0 CLASSIFICATION
4.1 Manufacturing
Plastic pallets can be manufactured using any standard manufacturing technique such as injection molding, blow molding and thermoforming process.
4.1.1 Design Principles
Plastic pallet can be manufactured through injection molding, blow molding and thermoforming process. Injection molded pallets can be divided into two categories. Monoblock pallets that are manufactured in a single piece. The second category comprises pallets manufactured from two or more parts. The parts that make up these pallets can be connected to one another by Snap-on connections, screws, glue or welding after the injection-molding process is finished.
Figure 2 — Two Piece Welded Pallet
4.1.2 Bottom Support
The term bottom support essentially determines the stability and field of application for plastic pallets. A difference is commonly made among pallets that are nestable, stackable or suitable for high-racking systems. More details in Annex A.
4.1.3 Stackable vs Rackable Pallets
Stackable pallets are designed to allow palletized product to be stacked, saving valuable floor space. These pallets are perfect for stack loading, static storage, and conveyance in manufacturing, warehousing, and processing environments. Stackable plastic pallet bases are usually provided with 3, 5 or 6 runners.
Rackable pallets are designed to be used in pallet racks. Whether the pallet rack is a fully-supported open-beam rack, a push-back rack, an edge rack, or a wire mesh rack. Rackable Plastic Pallets have bases with runners, a cruciform or 6 runner pallet is most common.
5.0 GENERAL REQUIREMENTS
5.1 Raw Materials
The pallets shall be manufactured from plastic materials such as high density polyethylene, polypropylene, or any other suitable polymeric material. Recycled and/or recovered polymeric materials can also be used if the final product meets all the requirements. The following additives can be added to the polymeric material during the manufacturing process:
Stabilizers against ultraviolet radiation in order to avoid deterioration of the physical properties of the pallets during continuous exposure.
Reinforcing and non-reinforcing fillers such as glass fibers, calcium carbonate and talc can be used.
Fire retarding agent can be added in order for the pallet to withstand direct fire exposure, if required by the customer.
5.1.1 Pallet Colour
The pallets can be manufactured in any colour according to mutual agreement between the manufacturer and the customer. The colour shall be homogenous and free from any noticeable variation.
5.1.2 Visual Inspection
The pallets shall be free from any noticeable defects such as short shots, excessive flash, warpage, or any other similar defects.
6.0 DIMENSIONS AND TOLERANCES
6.1 Nominal Dimension
The nominal overall dimensions of flat plastic pallets shall be according to ISO 6780:2003. In addition, other regional and industrial specific dimensions can be also considered.
6.1.1 Vertical dimensions for lifting devices
The vertical entry clearance H1 under the top deck for the entry of fork arms of pallet trucks and fork lift trucks is according to ISO 6780:2003
The entries for the forks of fork lift trucks and fingers of pallet trucks shall be according to ISO 6780:2003.
6.1.2 Horizontal dimensions for lifting devices
The horizontal entry clearance for the entry of fork arms of pallet trucks and fork lift trucks is according to ISO 6780:2003.
Horizontal clearances for the entry of pallet trucks into the ends of two-way and partial four-way pallets and into the ends and sides of four-way pallets shall conform to those dimensions specified in ISO 6780:2003 a:
7.0 PERFORMANCE REQUIREMENTS AND SELECTION OF TESTS
7.1 Test Condition
The test conditions for ultimate load, maximum working load and durability tests for plastic pallets shall be according to EN ISO 8611-2:2022 and EN ISO 8611-3:2012.
7.1.1 Number of replicates
For each test, at least three untested pallets shall be used.
7.1.2 Performance requirements
The load capacity of the pallet is determined by considering safety and functionality. It uses a deterministic design procedure using safety factor of 2.0 or higher.
Figure 3 — Load Capacity of the pallet
Table 1 — Procedure for determining the load capacity of pallets
Safety | Functionality |
|---|---|
1. Conduct a strength test. 2. Determine the ultimate load. 3. Divide the ultimate load by the safety factor. 4. Maximum is the safe load value. | 1. Conduct a stiffness test. 2. Measure the deflection of the pallet under the test load at the end of the creep time. 3. Compare the deflection to the performance limit. 4. Adjust the test load to achieve deflection close to the performance limit. 5. Compare the test load to the maximum safe load. 6. The smallest will be your safe load or load capacity. |
EXAMPLE Determining the nominal racking capacity of the pallet
- Conduct an ultimate bending strength test: load the pallet in bending condition until the pallet breaks or deformation exceed the limit (6% of span).
- Load reached in ultimate bending strength test U1 = 2,500 kg.
- Allowable maximum bending load is 50% (Safety factor of 2) of U1 = 1,250 kg.
- Conduct bending stiffness test = load the pallet until the maximum load limit (1,250 kg) or the deformation exceed the limit (2% of span).
- 2% of span (L1) deformation reached at 1,150 kg the maximum racking capacity of the pallet is = 1,150 kg.
7.1.3 Duration of Tests
Test | Test period (Hours) | Relaxation Time (Hours) |
|---|---|---|
Stacking Test | 48 | 2 |
All other tests | 24 | 2 |
7.1.4 Load Capacity Test
The load capacity test shall be conducted in accordance to EN ISO 8611-2:2022.
Bending tests
The bending test shall be done accoring to EN ISO 8611-1:2025.
Forklifting Test
The forklifting test shall be done accoring to EN ISO 8611-1:2025.
Compression tests for blocks or stringers
The compression test shall be done accoring to EN ISO 8611-1:2025.
Stacking tests
The stacking test shall be done accoring to EN ISO 8611-1:2025.
Bottom deck bending tests
The bottom deck bending test shall be done accoring to EN ISO 8611-1:2025.
Wing Pallet Bending tests
The wing pallet bending test shall be done accoring to EN ISO 8611-1:2025.
7.1.5 Durability Test
Table 3 — Durability test cases
Test# | Test Name | Handling Activity | Test load level | Performance Limits |
|---|---|---|---|---|
1 | Corner drop test | Resistance to impacts | Empty pallet | Δy ≤ 4 % h = 0.5 m |
2 | Slip angle test | Slip resistance of loads | Self-weight | Comparative testing |
3 | Static coefficient of friction test | Slip resistance on fork arms | Self-weight | Comparative testing |
7.1.6 Corner Drop Test
The corner drop test shall be done accoring to EN ISO 8611-1:2025.
7.1.7 Slip angle test
The slip angle test shall be done accoring to EN ISO 8611-1:2025.
7.1.8 Static coefficient of friction test
The static coefficient of friction test shall be done accoring to EN ISO 8611-1:2025.
8.0 STORAGE
Pallets shall be stacked ten pieces high and securely strapped together.
9.0 MARKING
Each pallet shall be legibly and indelibly marked according to the national requirements in a visible place with the following information:
Name and/or trademark (if applicable) of the manufacturer (owner).
Designated load capacity in Kg.
Nominal dimensions in millimeters.
Date of manufacture (day, month, year).
Pallets equipped with tapered feet allow the nesting of pallets in a stack, achieving a volume reduction up to 75 % during storage and transportation. Without runners, these pallets cannot generally be used on roller tracks or in high-racks.
Figure A.1 — Pallets with 9 Feet
Pallets with three lengthwise runners are stackable and compatible with automated conveyor and high-racking systems.
Figure A.2 — Pallets with 3 runners
The perimetric bottom decks without a central transverse runner (5 runners) allow for better four-way entry and offer excellent block stackability.
Plastic pallets with a fully perimetric bottom support (6 runners, cruciform perimeter-base) meet the highest demands in terms of block stacking. Their large supporting surface protects and avoids pressure marks on the cargo stored below and also ensures long-term stability for the plastic pallet.
