A pallet block placed at each of the four corners of a block pallet.
Detailed Definition
Corner blocks sit at the four outside corners of a block pallet. In the common nine-block layout they connect the perimeter stringer boards above with the bottom deck boards below, and they carry the load at the pallet's corners. Because they are at the edges, corner blocks take more forklift, pallet jack and conveyor impacts than any other block, and they are the most frequent source of block damage. They are usually the same height as the center and edge blocks so the pallet sits level, and they may be solid wood, laminated or composite.
Why corner blocks take the most abuse
Forks entering at a slight angle strike corner blocks first. Pallets dragged or pushed along floors catch on their corners, and conveyors, stretch wrappers and dock plates contact them as well. Each hit can split the block, loosen nails or tear the bottom deck boards away. Composite blocks resist splitting but can chip or crumble, especially after getting wet. Since the corners also support the edges of the load, a failed corner block can let the load lean and stack poorly.
Inspecting and repairing corner blocks
- Look for splits running through the nail zone and for missing or protruding nails
- Check that the block is still square and tightly fastened top and bottom
- Watch for composite blocks that are swollen, chipped or delaminating
- Use replacement blocks of matching height and material during repair
- Remove pallets with split or loose corner blocks from racked or automated use until repaired
Corner blocks and pallet grading
Recycled block pallets are often graded partly on block condition, and a damaged corner block is a common reason a pallet is downgraded or sent for repair. When agreeing on a grade with a supplier, describe acceptable block condition in writing, such as no split blocks and no missing nails, so both sides judge deliveries the same way.
Related Glossary Terms
Frequently Asked Questions
Are corner blocks different from the other blocks on a pallet?
Often they are the same size and material as the edge and center blocks, which keeps manufacturing simple and the pallet level. Some designs use different block lengths or add protection such as chamfered or rounded corners. The difference is mainly their position: corner blocks carry the edges of the load and take most handling impacts. Check the pallet specification if you need to know the exact block dimensions.
Can a pallet with a split corner block still be used?
It is risky. A split corner block can let the bottom deck separate, the corner sag or nails protrude, which can cause load lean, damaged goods or a pallet failure in rack. Minor surface damage may be acceptable for floor use with light loads, but most sorting rules send pallets with split or loose corner blocks to repair. For racked storage, conveyors and automated equipment, repair first.