The horizontal boards forming the lower surface of a double-faced pallet.
Detailed Definition
Bottom deck boards are fastened to the underside of the stringers or blocks. They spread the load onto the floor, conveyor or rack beams, add stiffness, and help keep the pallet square. A single-faced pallet has no bottom deck. On a double-faced pallet the bottom deck may mirror the top, making the pallet reversible, or use fewer boards, making it non-reversible. The outermost bottom boards are lead boards, and on many stringer pallets their inner edges are chamfered so pallet jack wheels can roll over them.
Bottom deck layout and pallet jack access
A pallet jack lifts by lowering load wheels to the floor through openings in the bottom deck. Board count, width and spacing therefore decide whether a jack can enter the pallet and where its wheels land. On a stringer pallet, the gaps between bottom boards at the ends give the wheels room; on a block pallet, a perimeter base can block jack entry from some sides. Forklifts are less affected because their forks pass above the bottom deck, but conveyors, automated storage and pallet dispensers often depend on a specific bottom layout.
What to check on bottom deck boards
- Board thickness, width and count match the specification or cut list
- No cracked, split or missing boards, especially lead boards
- No protruding nails, which damage floors, conveyor rollers and stacked goods
- Board direction suits your conveyors; roller conveyors usually need bottom boards running across the rollers
- Repaired pallets use replacement boards of matching thickness so the pallet sits flat
Bottom decks on single-faced and reversible pallets
Single-faced pallets skip the bottom deck, which saves wood but concentrates the load on the stringers where they touch the floor or rack beams. Reversible pallets carry identical decks on both faces, so either side can take the load. Non-reversible double-faced pallets are the usual compromise: a full top deck for the product and a lighter bottom deck for support and stability.
Related Glossary Terms
Frequently Asked Questions
Are bottom deck boards the same thickness as top deck boards?
Not necessarily. Some designs use the same board size on both faces, especially reversible pallets. Many one-way and GMA-style pallets use fewer bottom boards, and the thickness can differ from the top deck. The only reliable answer is the pallet's specification or cut list, which should state the size and count of every board. When comparing quotes, check that the bottom deck matches, because it affects strength, stiffness and price.
Why do automated systems care so much about the bottom deck?
Conveyors, pallet dispensers, stretch wrappers and automated storage systems carry or sense the pallet by its bottom surface. Missing boards, broken lead boards, wrong board direction or nails sticking out can cause jams, misreads or damage to rollers. Many automated sites publish a pallet specification that defines the bottom deck, and they may reject pallets that do not match it, so share that specification with your pallet supplier.