The "Cube Rule"
Carriers charge for the "Imaginary Box" that encloses your shipment. LTL carriers do not care that your pallet is 40x48. If your boxes stick out, they measure the boxes.
Real World Data: Overhang is the #1 cause of LTL "Billing Adjustments". If you quote for 40x48 but ship 42x50 (due to overhang), the carrier's laser scanner will catch it, re-class it, and charge you the difference + a processing fee.
The Math of Overhang
Let's look at the numbers.
Scenario: 1 Pallet, 60" High
Perfect Load
Dims: 48" x 40" x 60"
Volume: 66.6 Cu Ft
Billable: ~666 lbs
1" Overhang
Dims: 50" x 42" x 60"
Volume: 72.9 Cu Ft
Billable: ~729 lbs
Result: +63 lbs Billable Weight (+9.4% Cost Increase)
Calculate Your Overhang Cost
Avoid Re-bills
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The "Flush" Strategy
The goal is Flush Loading. Your boxes should align perfectly with the edge of the pallet.
- Underhang (Recessed): While this saves shipping costs, it weakens the stack. The corners of the boxes are unsupported, leading to crushing during transit.
- Overhang: Increases cost and damage risk (boxes get hit by forklifts).
- Flush: The Goldilocks zone. Max strength, min cost.
Visualize Pallet Patterns
See exactly how your boxes fit (or don't fit) on a standard 40x48.
Launch 3D PalletizerGlossary
DimensionerA laser scanning device at freight terminals that automatically measures L x W x H.
GMA PalletGrocery Manufacturers Association standard pallet (48" x 40").
Column StackStacking boxes directly on top of each other (aligned corners). Strongest for compression, weak for stability.
Interlock StackRotating layers (brick pattern) to tie the load together. Good for stability, but can reduce compression strength.
Frequently Asked Questions
Yes. Carriers measure the 'extreme dimensions' of the palletized unit. If your boxes hang 1 inch off the side of a standard 48x40 pallet, the billable dimensions become 50x42. This increases the billable volume by ~9.3% and could push you into a higher Over-Dimension surcharge bracket.
For a 48-inch tall pallet, adding 1 inch to length and width increases Billable Weight by roughly 25-30 lbs (depending on the divisor). At an average LTL rate of $0.50/lb, that 1 inch of overhang costs you $12-$15 per pallet.
For billing, YES. Keeping boxes strictly inside the 48x40 footprint ensures you only pay for the pallet size. However, severe underhang (boxes recessed >1 inch from the edge) can cause stack instability. Aim for 'flush' alignment.
They measure the 'Bounding Box' of the entire unit. If the pallet is bigger, they measure the pallet. If the boxes hang over, they measure the boxes. They always take the largest dimension on each axis.
Ideally no, but practically yes. Automated dimensioners (lasers) are very sensitive. Loose, flapping shrink wrap can trigger a wider measurement. Always ensure wrap is tight and heat-sealed or taped down.