M200

M A T E R I A L S
I N D U S T R I A L U S E G U I D E
A P A
T h e E n g i n e e r e d W o o d A s s o c i a t i o n
H A N D L I N G
GDE,M200,MtlHdl.0 4/20/00 11:32 AM Page 1
Wood is good. It is the earths natural, energy efficient and renewable
building material.
Engineered wood is a better use of wood. It uses less wood to make
more wood products.
Thats why using APA trademarked I-joists, glued laminated timbers, laminated
veneer lumber, plywood and oriented strand board is theright thing to do.
A few facts about wood.
I
Were not running out of trees. One-third of the United States land base
731million acres iscovered by forests. About two-thirds of that 731 million acres is
suitable for repeated planting and harvesting of timber. But only about half of the land
suitable for growing timber is open to logging. Most of that harvestable acreage also is
open to other uses, such as camping, hiking, hunting, etc.
I
Were growing more wood every day. American landowners plant more than
twobillion trees every year. In addition, millions of trees seed naturally. The forest
products industry, which comprises about 15percent of forestland ownership, is
responsible for 41percent of replanted forest acreage. That works out to more than one
billion trees ayear, or about threemillion trees planted every day. This high rate of
replanting accounts for the fact that each year, 27percent more timber is grown
than is harvested.
I
Manufacturing wood is energy
efficient. Wood products made up
47percent of all industrial raw materials
manufactured in the United States, yet
consumed only 4 percent of the energy
needed to manufacture all industrial raw
materials, according to a1987study.
I
Good news for a healthy planet. For every ton of wood grown, ayoung forest
produces 1.07tons of oxygen and absorbs 1.47tons of carbondioxide.
Wood. Its the right product for the environment.
D O T HE R I G HT T HI N G R I G HT
A P A
Percent of Percent of
Material Production Energy Use
Wood 47 4
Steel 23 48
Aluminum 2 8
NOTI CE:
The recommendations in
this guide apply only to
panels that bear the APA
trademark. Only panels
bearing the APA trademark
are subject to the
Associations quality
auditing program.
RATED SHEATHING
EXPOSURE 1 SIZED FOR SPACING 3
2
/1
6

15/32 INCH
000
PS 1-95 C-D PRP-108
THE ENGINEERED
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C O N T E N T S
INTRODUCTION.................................................................................................... 3
PANEL PROPERTIES............................................................................................... 4
Advantages of Structural Wood Panels
Standards of Manufacture
Grade Designations
Sanded, Unsanded and Touch-Sanded Panels
Exposure Durability
Group Number
Span Ratings
Selecting and Ordering APA Panels
APAS IN DUSTRIAL PAN EL SELECTION GUIDE........................................................... 7
MEZZANINE FLOORS............................................................................................. 8
RackDeck Software System
MATERIALS HANDLING SYSTEMS......................................................................... 11
PALLETS............................................................................................................. 11
Pallet Configurations
Pallet Fabrication
Fasteners for Pallets
Stringers
Pallet Design
Design Examples
Pallet Collars
PALLET BINS...................................................................................................... 22
Pallet Bin Configuration
Pallet Bin Fabrication
Pallet Design
Special Design Considerations
Design Examples
BIG BIN & SLIM BIN.......................................................................................... 32
LIQUID TANKS AND BINS................................................................................. 33
Liquid Bin Fabrication
Design Considerations
CRATING............................................................................................................ 36
Crate Configuration
Crating Fabrication
Crating Design
SHELVING.......................................................................................................... 49
Shelving Fabrication
Shelving Design
Design Examples
ADDITIONAL INFORMATION................................................................................ 54
3
I N T R O D U C T I O N
Industrial and agricultural managers have
found one sure way to increase profits:
decrease materials handling costs. And the
best way to decrease those costs is to tailor an
efficient materials handling system to meet
the needs of each operation.
APA panel products meet the requirements
for an ever-growing number of materials
handling systems and operations. This
brochure from APA The Engineered W ood
Association outlines some of the most
common materials handling applications for
which APA trademarked panels are ideally
suited. If you need more information about
any of the systems described here, simply
contact the nearest APA regional field office
listed on the back cover.
W hatever the industrial application, panel
products bearing the APA trademark do the
job better.
1995 APA - The Engineered Wood Association
Dimensions and weight of load, mode of
transportation, type of handling equip-
ment and frequency of use all affect
specifications for materials handling
products. Because these factors are so
important and variable, each materials
handling application should be considered
independently. Your choice of structural
wood panel, whether plywood, composite
panels, or oriented strand board, will
depend on the specific requirements of
your operation. Some industrial
applications discussed in this brochure
require conventional plywood.
For most applications, any of the APA
structural wood panels described in this
publication may be used. For most
cratesand bins, Exposure 1 panels are
suitable. For long outdoor exposure,
especially export use, Exterior panels
may be necessary.
Note: Load tables presented in this brochure
are based on dry conditions of use, unless
otherwise noted.
Advantages of Structural
WoodPanels
Strength. Structural wood panels possess
inherent strength and durability. They
resist bending or deflection; racking or
shape distortion; and impact damage.
Because of their split resistance,
structural wood panels possess excellent
fastener-holding properties and can be
nailed very near panel edges. For
maximum strength, install panels with
the strength axis perpendicular to
supports. Structural wood panels, relative
to their strength, are lightweight and easy
to handle, work, and install.
Note: The strength axis is the original long panel
dimension unless otherwise indicated on the panel.
Stiffness. Excellent stiffness measured
as resistance to deflection under uniform
and concentrated loads and to forces that
would tend to distort the panel from its
rectangular shape (rack resistance) is
another major advantage of structural
wood panels. This stiffness often permits
structural wood panels to be used with
less framing or bracing than required by
other materials.
Effect of Temperature. The strength of
structural wood panels is less when
heated than at normal temperatures. In
the range of 0 degrees F to 200 degrees
F, the strength of the panel at 12 percent
moisture content or more will increase or
decrease approximately 1/2 percent for
each one degree increase or decrease in
temperature from 70 degrees F.
However, such panels exposed to
temperatures up to 200 degrees F for a
year or more will not experience any
significant or permanent loss in strength.
If drying occurs, the increase in strength
due to drying can offset the loss in
strength due to elevated temperature.
Thermal, Acoustical and Fire-Resistant
Properties. Structural wood panels are
real wood, a natural insulator, and there-
fore provide good protection against heat
loss and condensation. Large panel size
also minimizes the number of joints that
can leak heat, airborne noise or flames.
Impact Resistance. Structural wood
panels improve on woods well-known
ability to absorb shock. Even when sup-
ported on only two edges, the construc-
tion and large panel size distribute
impact loads. The advantages are even
greater when the panel is supported on
all four edges. Published working stresses
for normal load may be doubled when
considering impact.
Workability. Ordinary tools and basic
carpentry skills are all that are required to
work with structural wood panels. Wood
panels can be cut, drilled, routed, jointed,
glued, and fastened. In addition, panels
can be bent to form curved surfaces
without loss of strength. Fabric or plastic
materials can be stitched to panels up to
3/8-inch thick with industrial sewing
machines. Ultimate test values in excess
of 100 pounds per linear inch have been
achieved with fabrics stitched to 1/4-inch-
thick panels.
Standards of Manufacture
Panels for construction and industrial
applications can be manufactured in a
variety of ways as plywood (cross-
laminated wood veneer), as composites
(veneer faces bonded to wood strand
cores), or as oriented strand board (OSB).
This growing family of APA panels
evolved from the new performance
standard approach to structural panel
manufacture and classification. APA-rated
structural panels are designed, manufac-
tured, and identified according to
standards which establish performance
criteria for specific applications. These
criteria include panel strength, stiffness,
durability, and stability.
4
P A N E L P R O P E R T I E S
5
T A B L E 1
Veneer Grades
S m o o th , p a i n ta b le . N o t m o re th a n 1 8 n e a tly m a d e re p a i rs, b o a t, sle d , o r
ro u te r typ e , a n d p a ra lle l to g ra i n , p e rm i tte d . M a y b e u se d fo r n a tu ra l
fi n i sh i n le ss d e m a n d i n g a p p li ca ti o n s. S yn th e ti c re p a i rs p e rm i tte d .
S o lid su rfa ce . S h im s, circu la r re p a ir p lu g s a n d tig h t kn o ts to 1 in ch a cro ss
g ra in p e rm itte d . S o m e m in o r sp lits p e rm itte d . S yn th e tic re p a irs p e rm itte d .
I m p ro ve d C ve n e e r wi th sp li ts li m i te d to 1 /8 -i n ch wi d th a n d kn o th o le s
a n d b o re r h o le s li m i te d to 1 /4 x1 /2 i n ch . A d m i ts so m e b ro ke n g ra i n .
S yn th e ti c re p a i rs p e rm i tte d .
Ti g h t kn o ts to 1 -1 /2 i n ch . K n o th o le s to 1 i n ch a cro ss g ra i n a n d so m e to
1 -1 /2 i n ch i f to ta l wi d th o f kn o ts a n d kn o th o le s i s wi th i n sp e ci fi e d li m i ts.
S yn th e ti c o r wo o d re p a i rs. D i sco lo ra ti o n a n d sa n d i n g d e fe cts th a t d o n o t
i m p a i r stre n g th p e rm i tte d . Li m i te d sp li ts a llo we d . S ti tch i n g p e rm i tte d .
K n o ts a n d kn o th o le s to 2 -1 /2 i n ch -wi d th a cro ss g ra i n a n d 1 /2 i n ch la rg e r
wi th i n sp e ci fi e d li m i ts. Li m i te d sp li ts a re p e rm i tte d . S ti tch i n g p e rm i tte d .
Li m i te d to I n te ri o r a n d E xp o su re 1 o r 2 p a n e ls.
RATED SHEATHING
EXPOSURE 1
SIZED FOR SPACING
32/16
15/32 INCH
000
PRP-108 HUD-UM-40
THE ENGINEERED
WOOD ASSOCIATION
APA
EXPOSURE 1
A-D GROUP 1
000
PS 1-95
THE ENGINEERED
WOOD ASSOCIATION
APA
F I G U R E 1
A
B
C
Plugged
C
D
P a n e l g ra d e
P a n e l g ra d e
S p a n R a ti n g
A P A s
P e rfo rm a n ce -R a te d
P a n e l S ta n d a rd
Th i ckn e ss
M i ll n u m b e r
M i ll n u m b e r
C o d e
re co g n i ti o n
o f A P A a s a
q u a li ty a ssu ra n ce
a g e n cy
E xp o su re
cla ssi fi ca ti o n
S p e ci e s
G ro u p
n u m b e r
E xp o su re
cla ssi fi ca ti o n
P ro d u ct
S ta n d a rd
APA Performance-Rated Panels
described in this publication include
APARated Sheathing and APA Rated
Sturd-I-Floor.
Some grades of plywood are manufac-
tured under the provisions of Voluntary
Product Standard PS 1-83 for Construction
and Industrial Plywood. Other plywood
panels, as well as PerformanceRated
composite and OSB panels, are
manufactured under the provisions of
PRP-108, Performance Standards and Policies
for Structural-Use Panels, or under
Voluntary Product Standard PS 2-92,
Performance Standard for W ood-Based
Structural-Use Panels, that establish
performance criteria for specific designated
construction applications.
Figure 1 shows APA sheathing and
sanded panel trademarks.
By broadening the range of panel
configuration and composition, APA
PerformanceRated Panels allow more
efficient use of raw materials.
Some industrial applications discussed
in this brochure require plywood. When
applicable, the PS-1 designation is
located in the lower portion of the
APAtrademark.
Construction
Grade Designations
Panel grades are generally identified in
terms of the veneer grade used on the
face and back of the panel (e.g., A-B, B-C,
etc.), or by a name suggesting the panels
intended end use (e.g., APA Rated
Sheathing, APA Rated Sturd-I-Floor, etc.).
Veneer grades define veneer appearance
in terms of natural unrepaired growth
characteristics and allowable number and
size of repairs that may be made during
manufacture (see Table 1). The highest
quality veneer grade commonly available
isA. The minimum grade of veneer
permitted in Exterior plywood is C-grade.
D-grade veneer is used for panels intended
for interior use or applications protected
from permanent exposure to weather.
Sanded, Unsanded and
Touch-Sanded Panels
Panels with B-grade or better veneer faces
are always sanded smooth in manufacture
to fulfill the requirements of their intended
end use applications such as cabinets,
shelving, furniture, built-ins, etc. APA
Rated Sheathing panels are unsanded since
a smooth surface is not a requirement of
their intended end use. Still other panels
APA Underlayment, APA Rated Sturd-I-
Floor, APAC-D Plugged, and APA C-C
Plugged require only touch-sanding
for sizing to make the panel thickness
more uniform.
Unsanded and touch-sanded panels,
and panels with A or B face on one side
only, usually carry the APA trademark on
the panel back. Panels with both sides
sanded (panels with B-grade or better
veneer on both sides), or with special
overlaid surfaces (such as High Density
Overlay), usually carry the APA trademark
on the panel edge.
Exposure Classification
APA trademarked panels may be
produced in four exposure classifica-
tions Exterior, Exposure1, Exposure2,
and Interior.
(a)
Exterior panels have a fully waterproof
bond and are designed for applications
subject to permanent exposure to the
weather or to moisture.
(a) Although glue bond durability is described
by exposure classification, panel surfaces may
become uneven and irregular under
prolonged moisture exposure. Panels should
be allowed to dry, and panel joints and
surfaces may need to be sanded before
applying some finish materials.
Exposure 1 panels have a fully
waterproof adhesive and are designed for
applications where long construction
delays may be expected prior to
providing protection, or where high
moisture conditions may be encountered
in service. Exposure 1 panels are made
with the same exterior adhesives used in
Exterior panels. However, because other
compositional factors may affect bond
performance, only Exterior panels should
be used for permanent exposure to
theweather.
(b)
Exposure 2 panels (identified as Interior
type with intermediate glue under PS1)
are intended for protected construction
applications where only moderate delays
in providing protection from moisture
may be expected.
Interior panels which lack further
glueline information in their trademarks
are manufactured with interior glue and
are intended for interior applications only.
Group Number
Plywood can be manufactured from more
than 70 species of wood. These species
are divided on the basis of strength and
stiffness into five groups under U.S.
Product Standard PS 1-83. Strongest
species are in Group 1; the least strong
in Group 5 (see Table 2). The group
number that appears in the trademark on
some APA trademarked panels
primarily sanded grades is based on the
species used for face and back veneers.
Where face and back veneers are not
from the same species group, the higher
group number is used, except for sanded
panels 3/8-inch thick or less and
decorative panels of any thickness. These
are identified by face species because they
are chosen primarily for appearance and
used in applications where structural
strength is not critical. Sanded panels
greater than 3/8 inch thick are identified
by face species if C- or D-grade backs are
at least 1/8 inch thick and are no more
than one species group number higher.
Some species are used widely in plywood
manufacture; others rarely. Check local
availability if a particular species is desired.
Span Ratings
APA Rated Sheathing and APA Rated
Sturd-I-Floor panels carry numbers in
their trademarks called Span Ratings.
The Span Rating is the maximum
recommended center-to-center spacing,
in inches, of supports over which the
panels should be placed in construction
applications.
The Span Rating in APA Rated
Sheathing trademarks appears as two
numbers separated by a slash, such as
32/16, 48/24, etc. The left-hand number
is the maximum recommended spacing
of supports when the panel is used for
roof sheathing with the long dimension
of the panel across three or more
supports. The right-hand number is the
maximum recommended spacing of
supports when the panel is used for
subflooring with the long dimension of
the panel across three or more supports.
A panel marked 32/16, for example, may
be used for roof sheathing over supports
32 inches on center or for subflooring
over supports 16 inches on center.
6
T A B L E 2
Classification of Species
Gr o up 1 Gr o up 2 Gr o up 3 Gr o up 4 Gr o up 5
A p i to n g C e d a r, P o rt M a p le , B la ck A ld e r, R e d A sp e n B a sswo o d
B e e ch , O rfo rd M e n g ku la n g B i rch , P a p e r B i g to o th P o p la r,
A m e ri ca n C yp re ss M e ra n ti , C e d a r, A la ska Q u a ki n g B a lsa m
B i rch D o u g la s- R e d
b )
F i r, C a ti vo
S we e t F i r 2
a )
M e rsa wa S u b a lp i n e C e d a r
Ye llo w F i r P i n e H e m lo ck, I n ce n se
D o u g la s- B a lsa m P o n d E a ste rn We ste rn
F i r
a )
C a li fo rn i a R e d M a p le , R e d
K a p u r R e d Vi rg i n i a B i g le a f C o tto n wo o d
K e ru i n g G ra n d We ste rn P i n e E a ste rn
La rch , N o b le Wh i te J a ck B la ck
We ste rn P a ci fi c S p ru ce Lo d g e p o le We ste rn
M a p le , S u g a r S i lve r B la ck P o n d e ro sa P o p la r
P i n e Wh i te R e d S p ru ce P i n e
C a ri b b e a n H e m lo ck, S i tka E n g e lm a n n E a ste rn
O co te We ste rn S we e tg u m Wh i te Wh i te
P i n e , S o u th e rn La u a n Ta m a ra ck S u g a r
Lo b lo lly A lm o n Ye llo w-
Lo n g le a f B a g ti ka n P o p la r
S h o rtle a f M a ya p i s
S la sh R e d
Ta n o a k Ta n g i le
Wh i te
a ) D o u g la s-F i r fro m tre e s g ro wn i n th e sta te s o f Wa sh i n g to n , O re g o n , C a li fo rn i a , I d a h o ,
M o n ta n a , Wyo m i n g , a n d th e C a n a d i a n P ro vi n ce s o f A lb e rta a n d B ri ti sh C o lu m b i a sh a ll b e
cla sse d a s D o u g la s-F i r N o . 1 . D o u g la s-F i r fro m tre e s g ro wn i n th e sta te s o f N e va d a , U ta h ,
C o lo ra d o , A ri zo n a a n d N e w M e xi co sh a ll b e cla sse d a s D o u g la s-F i r N o . 2 .
b ) R e d M e ra n ti sh a ll b e li m i te d to sp e ci e s h a vi n g a sp e ci fi c g ra vi ty o f 0 . 4 1 o r m o re b a se d o n
g re e n vo lu m e a n d o ve n d ry we i g h t.
(b) Exposure 1 panels may also be used when
exposure to the outdoors is on the underside
only, such as at roof overhangs.
The Span Ratings in the trademarks on
APA Rated Sturd-I-Floor appear as a
single number. APA Rated Sturd-I-Floor
panels are designed specifically for single-
floor (combined subfloor-underlayment)
applications and are manufactured with
Span Ratings of 16, 20, 24, 32 and 48
inches. The Span Ratings for APA Rated
Sturd-I-Floor panels, like those for APA
Rated Sheathing, are based on application
of the panel with the long dimension
across three or more supports.
Selectingand OrderingAPAPanels
Of course, selecting the appropriate APA
panel depends on the specific job. Some
general guidelines for developing an
appropriate APA panel specification follow.
Unsanded panels are suitable for most
industrial applications. If the pallets,
crates, shelving or other products will not
be exposed to the weather, APA Rated
Sheathing Exposure 1 or 2 is appropriate.
If the application will require permanent
exposure to weather, specify an Exterior
panel, such as APA Rated Sheathing
Exterior.
If a smooth surface is required, sanded
plywood is recommended. Refer to the
appropriate load-span table when using
sanded plywood since sanding affects
strength. Plywood is also available with a
Medium Density (MDO) or High Density
(HDO) resin fiber overlay and with
surfaces of fiberglass-reinforced plastic,
hardboard, metal and other materials for
exceptionally smooth or special-use
surfaces.
Where certain applications require
conventional plywood identified as
meeting the requirements of Product
Standard PS 1, look for the designation
PS 1 in the APA trademark.
When ordering APA panels, use the
following formats:
Sanded and Touch-Sanded Panels:
Designate thickness, APA trademark,
grade, group number, exposure
durability classification, dimensions,
number of pieces. For example:
3/8" APA A-A Group 1, Exterior,
48"x96", 100 pcs.
Performance-Rated Panels: Designate
thickness, APA trademark, grade, Span
Rating, exposure durability classification,
dimensions, number of pieces. For
example:
15/32" APA Rated Sheathing,
32/16, Exposure 1,
48"x96", 100 pcs.
Overlaid Panels: Designate thickness,
APAtrademark, grade, group number,
dimensions, number of pieces.
For example:
1/2" APA Medium Density Overlay
(MDO), Group 1,
48"x96", 100 pcs. (Any special
requirements, such as only one side
overlaid, or surface texture or weight
of surfacing material, should be stated
after the standard specification.)
Short Form Specification: Each APA
panel shall be identified with the appro-
priate APA trademark. All panels perma-
nently exposed to the weather shall be
Exterior. Panel thickness shall be as shown
on the drawings. Application shall be in
accordance with APA recommendations.
A P A S
I N D U S T R I A L
P A N E L
S E L E C T I O N
G U I D E
Most application and specification
information for structural wood panels is
based on panel performance in construc-
tion applications such as floor, wall or
roof sheathing, or structural siding.
However, performance in construction
applications may not be relevant to
industrial applications.
APAs Industrial Panel Selection Guide
(Form T200) helps industrial specifiers
select panels based on the specific panel
characteristics required for the applica-
tion in questionnot construction-
related data.
The guide helps users decide what
grade or type of panel they need by
starting with the application and deter-
mining what characteristics the appli-
cation requires. For example, the guide
addresses issues such as smoothness,
overlays, size and number of knots and
knotholes, suitability for painting and
staining, etc.
Through a series of questions, the
guide helps industrial users specify prod-
ucts that will satisfy the demands of the
job in a cost efficient manner.
To order a copy of APAs Industrial
Panel Selection Guide, contact APA head-
quarters or one of the regional field
offices listed on the back cover.
7
While used in a broad range of
commercial and industrial structures,
mezzanine floors are most often designed
to support heavy loads. In addition, the
mezzanine may be required to carry
pallet jacks or carts so that unused
overhead cubage becomes low-cost
working warehouse space.
Tables 3 through 7 provide the
information needed to specify APA
trademarked panels for mezzanine decks.
Table 3 gives recommendations for
uniformly loaded storage areas; Tables 4,
5 and 6 relate to pallet jack loading.
Table 7 provides information on other
types of wheels and recommended loads
on plywood.
All tables assume the use of panels
continuous over two or more spans with
strength axis perpendicular to supports.
Structural edge support must be provided
where high concentrated loads occur.
Finish flooring will vary with antici-
pated use. In some cases, bare panels
have proven satisfactory. However, a
wearing surface should be provided to
resist crushing of floors subject to hard
wheel or caster traffic. An expendable
layer of panels or a dense wear surface,
such as tempered hardboard, should be
used if wheels are small, hard or heavily
loaded. Table 7 may be used as a guide.
For more information see APA Technical
Note X227, Caster Loadings on Plywood.
8
T A B L E 3
Recommendations for Uniformly Loaded Mezzanine Floors
(a)(b)
(Deflection limited to 1/240 of span.) (Span Ratings apply to
APA Rated Sheathing and APA Rated Sturd-I-Floor, respectively.)
Un i f o r m
C e n t e r - t o - C e n t e r S u p p o r t S p a c i n g ( i n c h e s )
L i v e L o a d
N o m i n a l 2 -i n ch -Wi d e S u p p o rts
( p s f ) 1 2 1 6 2 0 2 4
5 0 3 2 /1 6 , 1 6 o c 3 2 /1 6 , 1 6 o c 4 0 /2 0 , 2 0 o c 4 8 /2 4 , 2 4 o c
1 0 0 3 2 /1 6 , 1 6 o c 3 2 /1 6 , 1 6 o c 4 0 /2 0 , 2 0 o c 4 8 /2 4 , 2 4 o c
1 5 0 3 2 /1 6 , 1 6 o c 3 2 /1 6 , 1 6 o c 4 0 /2 0 , 2 0 o c 4 8 /2 4 , 3 2 o c
2 0 0 3 2 /1 6 , 1 6 o c 4 0 /2 0 , 2 0 o c 4 0 /2 0 , 2 4 o c 3 2 o c
2 5 0 3 2 /1 6 , 1 6 o c 4 0 /2 0 , 2 0 o c 4 8 /2 4 , 3 2 o c 4 8 o c
3 0 0 3 2 /1 6 , 1 6 o c 4 0 /2 0 , 2 4 o c 3 2 o c 4 8 o c
a ) U se p a n e ls wi th T& G e d g e s, o r p ro vi d e stru ctu ra l b lo cki n g a t p a n e l e d g e s, o r i n sta ll a
se p a ra te u n d e rla ym e n t.
b ) A -C G ro u p 1 sa n d e d p lywo o d p a n e ls m a y b e su b sti tu te d fo r sp a n ra te d S tu rd -I -F lo o r p a n e ls
1 /2 -i n ch fo r 1 6 o c; 5 /8 -i n ch fo r 2 0 o c; 3 /4 -i n ch fo r 2 4 o c) .
M E Z Z A N I N E F L O O R S
9
T A B L E 4
Recommended Maximum Load per Pallet Jack Load Wheel
(a)(e)
(lb):
23/32 Panel
Ma x i mum Ba r e Ba r e OSB Pl y r o n
(d)
Po l y e t h y l e n e -
Sp a n Pl y wo o d
(b)(c)
Ov e r l a i d Pl y wo o d
Ove r Me t a l
3 0 0 3 0 0 8 0 0 8 0 0
De ck
1 2 o c 3 0 0 3 0 0 8 0 0 8 0 0
1 6 o c 3 0 0 N R
f )
8 0 0 8 0 0
2 4 o c N R N R N R N R
a ) 4 x 3 -1 /4 -d i a m e te r p o lyu re th a n e lo a d wh e e ls.
b ) N o n o ve rla i d p lywo o d sh o u ld b e A P A R a te d S tu rd -I -F lo o r o r U n d e rla ym e n t.
c) M a xi m u m lo a d s fo r b a re p lywo o d a lso a p p ly to M D O a n d H D O .
d ) O ri e n t P lyro n
wi th lo n g a xi s p a ra lle l to su p p o rts o ri e n t o th e r p a n e ls wi th lo n g a xi s a cro ss

su p p o rts u n le ss o th e rwi se re co m m e n d e d b y m a n u fa ctu re r.
e ) A ssu m i n g th a t 7 0 % o f th e p a lle t ja ck i s ca rri e d o n th e ti n e ro lle rs, th e lo a d s i n th e a b o ve
ta b le m a y b e co n ve rte d to p a lle t ja ck g ro ss we i g h ts b y u si n g Ta b le 6 .
f) N R N o t R e co m m e n d e d
T A B L E 5
Recommended Maximum Load per Pallet Jack Load Wheel
(a)(e)
(lb):
1-1/8 Panel
Ma x i mum Ba r e Ba r e OSB Pl y r o n
(d)
Po l y e t h y l e n e -
Sp a n Pl y wo o d
(b)(c)
Ov e r l a i d Pl y wo o d
Ove r Me t a l
3 0 0 5 0 0 8 0 0 8 0 0
De ck
1 2 o c 3 0 0 5 0 0 8 0 0 8 0 0
1 6 o c 3 0 0 5 0 0 8 0 0 8 0 0
2 4 o c 3 0 0 4 0 0 8 0 0 8 0 0
a ) 4 x 3 -1 /4 -d i a m e te r p o lyu re th a n e lo a d wh e e ls.
b ) N o n o ve rla i d p lywo o d sh o u ld b e A P A R a te d S tu rd -I -F lo o r o r U n d e rla ym e n t.
c) M a xi m u m lo a d s fo r b a re p lywo o d a lso a p p ly to M D O a n d H D O .
d ) O ri e n t P lyro n
wi th lo n g a xi s p a ra lle l to su p p o rts o ri e n t o th e r p a n e ls wi th lo n g a xi s a cro ss

su p p o rts u n le ss o th e rwi se re co m m e n d e d b y m a n u fa ctu re r.
e ) A ssu m i n g th a t 7 0 % o f th e p a lle t ja ck i s ca rri e d o n th e ti n e ro lle rs, th e lo a d s i n th e a b o ve
ta b le m a y b e co n ve rte d to p a lle t ja ck g ro ss we i g h ts b y u si n g Ta b le 6 .
T A B L E 6
Estimated Pallet Jack Load
Corresponding to Wheel Load
Lo a d o n Pa l l e t J a ck
Si n g l e Lo a d Gr o ss
Wh e e l ( l b ) We i g h t ( l b )*
1 0 0 2 9 0
2 0 0 5 7 0
3 0 0 8 6 0
4 0 0 1 1 4 0
5 0 0 1 4 3 0
6 0 0 1 7 1 0
7 0 0 2 0 0 0
8 0 0 2 2 9 0
9 0 0 2 5 7 0
1 0 0 0 2 8 6 0
1 1 0 0 3 1 4 0
1 2 0 0 3 4 3 0
1 3 0 0 3 7 1 0
1 4 0 0 4 0 0 0
1 5 0 0 4 2 9 0
* A ssu m e s 7 0 % o f lo a d i s o n fro n t ti n e
ro lle rs.
10
T A B L E 7
Caster Loadings On Plywood
(c)
Re co mme n d e d Re co mme n d e d
Ma x i mum Lo a d i n g Ma x i mum
o n Ba r e Gr o up 1 o r Lo a d i n g o n
Mf r s. Gr o up 2 Pl y wo o d
(a)
Pl y r o n
Ra t e d ( p o un d s) ( p o un d s)
Wh e e l Ca st e r
Sur f a ce Di a . Wi d t h Ca p a ci t y I n t e r mi t t e n t Re p e a t - I n t e r mi t t e n t Re p e a t -
Ma t e r i a l ( i n ch e s) ( p o un d s) Use Tr a ck Use Tr a ck
S o ft 2 " R o u n d B a ll
R u b b e r F u rn i tu re C a ste r 5 0 5 0 2 5 2 0 0 2 0 0
S o ft
R u b b e r 4 x1 -3 /8 3 0 0 3 0 0 1 5 0 3 0 0 3 0 0
S o ft
R u b b e r 6 x2 4 0 0 4 0 0 2 0 0 4 0 0 4 0 0
S o ft
R u b b e r 8 x2 5 0 0 5 0 0 2 5 0 5 0 0 5 0 0
P o lyu re th a n e 4 x1 -3 /8 4 0 0 1 0 0 5 0 3 0 0 2 0 0
P o lyu re th a n e 3 -1 /4 x4 1 5 0 0 4 0 0 2 0 0 8 0 0 6 0 0
P o lyu re th a n e 8 x1 -5 /8 1 1 2 5 2 0 0 1 0 0 4 0 0 2 0 0
S te e l o r
H a rd P la sti c 4 x1 -1 /2 4 2 5 5 0 N /R
b )
2 0 0 1 0 0
S te e l o r
H a rd P la sti c 8 x2 1 0 5 0 5 0 N /R 4 0 0 2 0 0
a ) A p p li e s a lso to M D O , H D O , F R P p lywo o d .
b ) N /R N o t R e co m m e n d e d .
c) M o st o f th e ca ste r-lo a d flo o r co m b i n a ti o n s sh o wn i n th i s ta b le we re te ste d to 1 0 0 0 cycle s o f lo a d i n g i n th e A P A la b o ra to ry. A fe w va lu e s h a ve
b e e n e xtra p o la te d fro m te st d a ta . S o m e va lu e s we re li m i te d b y ca ste r ca p a ci ty ra th e r th a n p a n e l ca p a ci ty.
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Incorporated, RackDeck software helps
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mum load for a wide range of conditions.
RackDeck reduces the amount of
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For more information on RackDeck or
to order the software, phone TMI Inc. at
(253) 529-0900 or write:
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Federal Way, WA 98003
R A C K D E C K
S O F T W A R E S Y S T E M
The strength, fastening capability, dimen-
sional stability and impact resistance of
structural wood panels make them
suitable for scores of materials handling
applications. Structural wood panels have
demonstrated a remarkable adaptability to
the modern demands of more sophisti-
cated and increasingly automated
handling, storage and transport systems.
In many cases, structural wood panels do
a better job for a longer time at lower cost.
More than 30 years of on-the-job
experience have proved plywood pallets
last longer than other types. Life-cycle
cost, therefore, should be considered as
carefully as initial cost when designing,
specifying or purchasing pallets for captive
pallet systems. The longer life of panel
pallets can more than offset initial cost
and reduce the actual cost-per-use.
Studies also show that panel pallets
sustain less damage and require fewer
repairs. All pallets are eventually
damaged by loads or forklifts. But
experience and testing prove that
smooth-decked pallets sustain less
damage and need repair less frequently
than lumber pallets.
One company with detailed cost records
reports that repair of lumber pallets equals
the original cost of the pallets even when
repairs are made under the optimum
condition of 50 or 100pallets at atime.
Five years after switching to plywood
pallets, the company stopped keeping
pallet maintenance records because repair
costs were so minimal.
Another advantage of structural wood
panel pallets is that their smooth decks
reduce the risk of damage to their loads.
This is an important feature since the
cost of damaged goods can far exceed
pallet repair or replacement costs. And
the solid deck makes it easier to keep
stored goods in alignment when loaded
pallets are stacked.
Other advantages of structural wood
panel pallets include light weight and
reduced nail popping.
Pallet Configurations
The components of a pallet are simple
and few: the decks, stringers (or spacers)
and fasteners. Pallets are available with
either two-way or four-way entry. Each
type comprises several variations and
special-purpose designs. Pallet use
dictates type and variation. Figure 2
illustrates the basic two-way entry pallet
and several design variations. Figure 3
shows four-way entry pallet variations.
Figure 4 describes expendable pallets,
while figures 5 and 6 show upgrading
and slave pallets, respectively.
11
M A T E R I A L S H A N D L I N G S Y S T E M S
P A L L E T S
F I G U R E 2
Two-Way Entry Pallet Configuration
12
A b a si c two -wa y e n try p a lle t h a s a p a n e l to p
d e ck, lu m b e r b o tto m d e ck, two stri n g e rs flu sh
wi th d e ck e d g e s, a n d o n e stri n g e r ce n te re d .
Va ri a ti o n : P a n e l d e cks, two stri n g e rs o n ly. Va ri a ti o n : Wi n g p a lle t. C a n b e d o u b le wi n g
wi th fu lly i n se t stri n g e rs) o r si n g le wi n g wi th
p a rti a l i n se t stri n g e rs) .
Va ri a ti o n : P a n e l to p a n d b o tto m d e cks. F o r
stre n u o u s u se , re ve rsi b le p a lle ts wi th two p a n e l
d e cks a re co n si d e ra b ly stro n g e r.
Va ri a ti o n : F o u r stri n g e rs. I f p a lle t lo a d s wi ll
e xce e d th o se a th re e -stri n g e r p a lle t m a y b e
e xp e cte d to ca rry, a n e xtra stri n g e r p ro vi d e s th e
e xtra d e ck su p p o rt a n d ke e p s p a n e l th i ckn e ss
wi th i n a n e co n o m i ca l ra n g e .
A sp e ci a l-p u rp o se va ri a ti o n h a s cu to u ts i n th e
b o tto m to a llo w p a lle t ja ck wh e e ls to ca rry
th e lo a d .
F o u r-wa y e n try p a lle t u se s b lo cks i n ste a d o f
stri n g e rs.
Va ri a ti o n : P a rti a l fo u r-wa y e n try h a s n o tch e d
stri n g e rs to a llo w fo rkli ft e n try.
F I G U R E 3
Four-Way Entry Pallet Configurations
Lu m b e r
b o tto m d e ck
S tri n g e rs
S tri n g e rs
P a n e l
b o tto m d e ck
S tri n g e rs
C u to u ts fo r p a lle t
ja ck wh e e ls
B o tto m
d e ck
P a n e l
to p d e ck
P a n e l
to p d e ck
I n se t
stri n g e rs
P a n e l
to p d e ck
P a n e l
to p d e ck
P a n e l
to p d e ck
P a n e l
to p d e ck
B lo cks
N o tch e d
stri n g e rs
S
t
r
e
n
g
t
h

a
x
i
s
E xp e n d a b le p a lle ts fo r o n e -ti m e o r sh o rt-te rm
se rvi ce ca n b e m a d e o f a si n g le sh e e t o f
re la ti ve ly th i n a n d i n e xp e n si ve stru ctu ra l p a n e l
a n d a lm o st a n y so rt o f b lo ck o r stri n g e r th a t wi ll
h a n d le th e lo a d .
O ld b o a rd p a lle ts th a t h a ve ra cke d o u t o f sh a p e
o r h a ve wo rn o r b ro ke n d e ck m e m b e rs ca n b e
g i ve n su b sta n ti a l n e w li fe a n d li ke -n e w ra ck-
re si sta n ce wi th th e a d d i ti o n o f a th i n , o n e -p i e ce
p a n e l d e ck.
O n ce th e o ld p a lle t i s sq u a re d u p , th e p a n e l i s
n a i le d o r sta p le d th ro u g h th e o ld d e ck i n to th e
stri n g e rs o r sp a ce rs.
S la ve o r ca p tive p a lle ts th a t n e ve r le a ve th e syste m
a re u se d in se m i-a u to m a te d a n d co m p u te r-
co n tro lle d a u to m a te d sto ra g e syste m s. Pa lle t
to le ra n ce s m u st b e clo se ly h e ld . Write fo r APA s
Industrial Use Guide: Slave Pallets Fo rm S 2 2 5 ) .
F I G U R E 4
Expendable Pallets
F I G U R E 5
Upgrading
F I G U R E 6
Slave Pallets
13
N e w p a n e l d e ck
S la ve p a lle t
Pallet Fabrication
Deck Construction. Pallet decks may be a
single piece, or built up from two to four
pieces. Each configuration has
advantages in specific situations, but
each is more durable than decks made of
other materials.
Single-piece decks prevent pallets from
racking out of shape. The smooth surface
will not snag bagged goods or allow them
to sag between deck spaces and be
punctured by fork tines. Heavy goods,
such as paper stocks that crease or
imprint at deck spaces, benefit from a
single-piece deck.
Multiple-piece panel decks protect
against damage because the pallet has
more flexibility to absorb shock while
retaining rack resistance. The user must
evaluate the advantages of each style to
determine the best deck for each purpose.
Edge Treatments. Research proves that a
square edge on a panel deck performs as
well as a bull-nosed edge and slightly
better than a chamfered edge. Splintering
or chipping of the panel edge means that
it has tolerated abuse without the serious
damage that easily renders a lumber
pallet unserviceable.
Panel Orientation. The strength axis, or
original long panel dimension (unless the
strength axis is otherwise identified),
should run across the stringers for greatest
strength. The load-span tables are based
on this orientation. The strength axis may
run parallel to stringers, but only when
pallet design specifically accounts for
reduced strength.
Lower Deck. Research and testing
confirm the outstanding performance of
plywood lower deck strips for certain
loads. (Plywood deck strips less than six
inches wide are not recommended.)
Wa re h o u se
p a lle t
Fasteners for Pallets
Figure 7 shows nail and staple fasteners
and their appropriate spacing.
Nails. Most pallets are fastened with
annular ring or drive screw nails. These
deformed shank nails, as specified in
PP61-80, Specifications for Softwood
Plywood Pallets, are mandatory for
permanent pallets. If economically
feasible, use hardened-steel nails in pallet
construction to achieve greater energy
absorption.
Countersinking is as important to
satisfactory pallet performance as nail
spacing since it reduces the possibility of
nail popping, which can snag and
damage loaded goods. Nails should be
countersunk 1/32to1/16inch to assure
that nail heads will remain even with or
below the surface during use.
Staple Spacing for Stringer Pallets.
Staples cannot be directly substituted for
nails because more staples are required to
develop equivalent strength.
Long-life polymerized plastic-coated
staples, 2-1/2inches long, can be used in
fabricating pallets. A minimum of four
staples should be used at the end of each
stringer starting about 1-1/2inches from
the end. They should be spaced
1-1/2inches on center. Staples used for
the inner area may be spaced up to
6inches on center.
14
F I G U R E 7
Pallet Fasteners and Spacing
S p i ra l sh a n k n a i ls
P o lym e ri ze d sta p le s B o lt a n d T-n u t
N a i li n g sch e d u le
S ta p li n g sch e d u le
1 0 m a xi m u m
6 m a xi m u m
1 -1 /2
2
Stringers
Species and Siz es. Lumber stringers may
be of many species of softwood, medium
density hardwood or dense hardwood. If
lumber stringers are green, shrinkage may
cause fasteners to loosen. Stringers of dry
lumber, or of a moisture content close to
what will be experienced in service are
recommended. PP61-80, Specifications
for Softwood Plywood Pallets, lists species
and acceptable characteristics of lumber for
pallets and is available from APA.
Built-up Stringers and Blocks. Three
block types are illustrated in Figure 8, the
solid wood block, plywood block and
Plyblock. Stringers and spacers histori-
cally have been solid wood blocks or
metal cylinders. Field tests and research
indicate that plywood, stacked to pro-
duce a spacer block or the feet of a
notched stringer-type pallet, give superior
performance. Plywood blocks resist
splitting when nailed one of the biggest
problems with solid blocks. Plywood
blocks also reduce nail popping and
when damage does occur it can often be
repaired with simple nailing. Trim pieces
from cutting pallet decks can be effi-
ciently fabricated into plywood blocks,
reducing pallet material costs by
eliminating the need for lumber blocks.
Plyblock is a term applied to circular
pallet blocks of stacked plywood, three-,
four- or five-inches in diameter.
Interchangeable parts ease repair and
salvage. Several breweries report years of
outstanding performance from more than
one million plyblock pallets.
Stringer Fastening. A 5/16-inch diameter
pallet bolt with a thin, countersunk head
of at least 15/16-inch diameter is typical
for Plyblock pallets. The T-nut should
also have a large bearing surface and some
feature to prevent loosening in service.
Plywood blocks can be joined with
two nails about one inch from the ends
of the block. Table 8 provides specific
nail dimensions for various block heights.
As an example, a 3-inch high block
requires 3-inch by 0.135-inch hardened
steel, spiral threaded pallet nails. Sink the
3-inch nails 1/4inch into the top layer.
To fasten the deck to the block, use four
3-inch nails from the top deck and four
from the bottom deck for each block.
By randomly orienting the face grain
infabrication, plywood blocks can easily
be made at least twice as impact resistant
as lumber blocks. Plywoods natural
strength gives the block rigidity and
resistance to splitting.
Special Details. Occasionally, operational
requirements dictate unusual features in
pallet design, such as hand-holds to
permit picking the pallet up by the deck.
The holes may be drilled 2 or 3inches in
diameter. Hole locations are not standard-
ized, but they should avoid the midspan
between stringers where strength is a
critical factor.
Another special feature is a lower deck
designed to move over rollers. Deck
members must match rollers for spacing,
and rollers must be close enough together
so that the pallet will not sag between
rollers and stop the conveyor system.
Unusual use or storage situations also
require attention to design.
T A B L E 8
Block Fastener Dimensions
Bl o ck He i g h t Bl o ck Fa st e n e r s De ck Fa st e n e r s
3 o r 3 -1 /2 x0 . 1 3 5 1 0 g a . )
3 -1 /2 sp i ra l th re a d e d p a lle t n a i ls
se t 3 n a i ls 1 /4 ) .
3 x0 . 1 3 5 1 0 g a . )
3 3 x0 . 1 3 5 1 0 g a . )
sp i ra l th re a d e d p a lle t n a i ls
2 -1 /2 2 -1 /2 x0 . 1 3 5 1 0 g a . )
F I G U R E 8
Types of Blocks
S o li d b lo ck P lywo o d b lo ck P lyb lo ck
15
Pallet Design
Sound pallet design depends upon
operational requirements relative to size
and weight of load, vertical stacking
loads and allowable deflection of pallet
deck. These factors determine pallet size,
panel deck thickness, stringer material
specification and method of fastening.
Siz e. Pallet size is constrained by
operational requirements such as product
size, storage facilities, shipping space and
available lifting equipment. Some firms
handling products of several sizes find it
convenient to standardize to one pallet
size that will handle all of them.
Standard pallet sizes are defined in the
American National Standard
MH1.2.2-1989 (see Table 9).
Forklift Openings. For normal pallet
handling of loads up to 5,000pounds,
fork openings should be at least 2-1/2
inches high by 7inches wide (Figure9).
Optimal dimensions are 3-1/2inches high
by 10inches wide. For light loads
(2,000pounds or less), openings as small
as 1-1/2 inches high and 6 inches wide
may be used. However, the small fork
openings reduce handling speed and
increase pallet and product damage.
Hand Pallet Truck Requirements. For
movement with hand pallet trucks, lower
decks must have entry spaces at least
6inches wide and must match the wheel
placement of hand pallet jack outriggers.
Figure 10 shows a typical cross section
of a two-way pallet for a hand pallet truck.
Transportation. When loaded pallets are
transported by truck or rail, the size of
the van or car should be considered in
determining pallet size.
Design Example
Wire Reel Pallet
Requirements. Pallet to handle
150-pound wire reels in manufacturers
warehouse and for shipment to
distributors and users. Pallets to be
returned or a fee charged. Reel size is
11-inch diameter by 17inches high.
Use Conditions. Factory handling will
bein open warehouse, no rack storage,
some outside exposure either at plant,
enroute or at destination. Shipment will
be by railroad boxcar from manufacturer
and by truck for distribution. A forklift
will be used in the warehouse, but
customers may use hand trucks.
Restrict total number of units per pallet
to nine since this best fits factory and
distributor sales analysis.
Siz e of Pallet. Size is dictated by number
of units per pallet. Nine units fit on a
36-inch by 36-inch pallet. Analysis of
truck and railroad car capacities shows
that minimum weights can easily be met
by the loaded pallets.
Pallet Load. With 150pounds per unit
and 9units per pallet, the individual pallet
load is 1,350pounds.
Loaded pallets will be stacked a maxi-
mum of four high for a total load of
5,400pounds. At 36inches by
36inches, the pallet has 9square feet of
surface, giving a total load of 600pounds
per square foot (psf).
Pallet Specification. Since two-way entry
is sufficient, a three-stringer pallet with
18-inch spans between stringers is the
obvious choice. The panel for the upper
deck can now be specified by referring to
the span table for two-way entry pallets in
the 18-inch span column for unsanded
panels (see Table10). The highest allow-
able load per square foot is 695psf, which
is greater than the actual load. Therefore,
use APA Rated Sheathing48/24.
16
T A B L E 9
American National Standard
MH1.2.2-1989: Pallet Sizes
Re ct a n g ul a r Sq ua r e
( i n ch e s) ( i n ch e s)
2 4 x3 2 o r 3 2 x2 4 3 6 x3 6
3 2 x4 0 o r 4 0 x3 2 4 2 x4 2
3 2 x4 8 o r 4 8 x3 2 4 8 x4 8
3 6 x4 2 o r 4 2 x3 6
3 6 x4 8 o r 4 8 x3 6
4 0 x4 8 o r 4 8 x4 0
4 4 x5 6 o r 5 6 x4 4
4 8 x6 0 o r 6 0 x4 8
4 8 x7 2 o r 7 2 x4 8
F I G U R E 9
Isometric of Modified Four-Way Entry Pallet for Forklifts
F I G U R E 1 0
Cross Section of Two-Way Entry Pallet for Hand Pallet Truck
17
F o rk o p e n i n g , m i n .
2 -1 /2 h i g h , 7 wi d e
F o rkli ft 2 -1 /2 m i n .
H a n d p a lle t tru ck 3 -1 /2 m i n .
9 re co m m e n d e d
6 m i n i m u m )
6 6
S
t
r
e
n
g
t
h

a
x
i
s
La r g e Si ze Ni n e - Bl o ck Pa l l e t s
Ma xi mum Loa d (l b) Uni f or ml y Di str i buted on Tota l Pa l l et Deck Ar ea
Ni ne bl ock s, 6 x6 bea r i ng a r ea per bl ock . Str ength a xi s a nd bl ock l ength pa r a l l el to l ong di mensi on.
Unsa nded Pa nel s (APA Ra ted Shea thi ng Exposur e 1)
St r u ct u r a l I St r u ct u r a l I
R a t e d Sh e a t h i n g R a t e d R a t e d Sh e a t h i n g R a t e d
Ex p o s u r e 1 Sh e a t h i n g Ex p o s u r e 1 Sh e a t h i n g
4 0 / 2 0 4 0 / 2 0 4 8 / 2 4 4 8 / 2 4
3 , 4 , o r 5 p l y 5 p l y 5 p l y 4 o r 5 p l y 5 p l y 5 p l y
3 l a y e r 5 l a y e r 5 l a y e r 3 l a y e r 5 l a y e r 5 l a y e r
P a l l e t Pl ywood 1 9 / 3 2 , 5 / 8 19/32 Pl ywood 23/32 23/32
Si z e 19/32 3/4 , 7/8 5/8 23/32 3/4 , 7/8 3/4
(i nches) 5/8 , 3/4 Pl ywood or OSB Pl ywood or OSB 3/4 Pl ywood or OSB Pl ywood or OSB
4 8 x4 8 1 4 0 0 2 5 0 0 3 7 0 0 2 5 0 0 3 5 0 0 4 6 0 0
4 8 x6 0 1 7 0 0 3 1 0 0 4 6 0 0 3 1 0 0 4 4 0 0 5 7 0 0
4 8 x7 2 2 1 0 0 3 7 0 0 4 0 0 0 3 7 0 0 4 6 0 0 5 1 0 0
T A B L E 1 0 :
Load Span Tables Unsanded Panels
18
RATED SHEATHING
EXTERIOR
SIZED FOR SPACING
48/24
23/32 INCH
000
PRP-108
THE ENGINEERED
WOOD ASSOCIATION
APA
S tre n g th a xi s
D e ck sp a n D e ck sp a n
Two - Wa y En t r y Pa l l e t s
Ma xi mum Uni f or m Loa d (psf )* Str ength Axi s Acr oss Suppor ts
Mi n i mum
Sp a n ( i n ch e s)
Sp a n Th i ck n e ss
Ra t i n g ( i n ch e s) 1 6 1 8 2 0 2 2 2 4 3 0 3 2 3 6
2 4 /0 3 /8 2 8 5 2 2 5 1 8 0 1 5 0 1 2 5 8 0 7 0 5 5
2 4 /1 6 7 /1 6 3 6 5 2 8 5 2 3 5 1 9 0 1 6 0 1 0 5 9 0 7 0
3 2 /1 6 1 5 /3 2 4 0 0 3 1 5 2 5 5 2 1 0 1 7 5 1 1 5 1 0 0 8 0
4 0 /2 0 1 9 /3 2 7 1 0 5 6 0 4 5 5 3 7 5 3 1 5 2 0 0 1 8 0 1 4 0
4 8 /2 4 2 3 /3 2 8 8 0 6 9 5 5 6 5 4 6 5 3 9 0 2 5 0 2 2 0 1 7 5
* T o fi n d to ta l a llo w a b le p a lle t lo a d , m u lti p ly ta b le va lu e b y p a lle t a re a sq . ft. )
N o te A : I f th e stro n g d i re cti o n o f th e p a n e l i s p la ce d p a ra lle l to th e
stri n g e rs th i s sh o u ld n e ve r b e d o n e u n le ss so sp e ci fi e d ) th e lo a d va lu e s
a b o ve m u st b e m o d i fi e d b y th e fo llo wi n g p e rce n ta g e s:
4 0 /2 0 R a te d S h e a th i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 % o f 4 0 /2 0 ta b le va lu e
4 8 /2 4 R a te d S h e a th i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 % o f 4 8 /2 4 ta b le va lu e
P a n e ls wi th sm a lle r S p a n R a ti n g s a re n o t su i te d to th i s o ri e n ta ti o n .
N o te B : Wh e n 4 -stri n g e r p a lle ts a re sp e ci fi e d a n d th e d i sta n ce b e twe e n
th e ce n te r stri n g e rs i s n o t le ss th a n 1 /1 0 th n o r m o re th a n 1 /3 rd o f th e
p a lle t wi d th , a d d 2 5 % to th e lo a d va lu e s i n th i s ta b le a s a
g e n e ra li za ti o n . U se th e lo n g e st sp a n o f th e 4 -stri n g e r p a lle t wh e n
u si n g th e ta b le . F o r m o re p re ci se ca lcu la ti o n i n vo lvi n g g re a te r va lu e s,
co n ta ct yo u r n e a re st A P A re p re se n ta ti ve .
Ni n e - Bl o ck Fo ur - Wa y En t r y Pa l l e t s
Ni ne bl ock s, 4 x6 bea r i ng a r ea per bl ock . Str ength a xi s a nd bl ock l ength pa r a l l el to l ong di mensi on.
St r u ct u r a l I St r u ct u r a l I
R a t e d Sh e a t h i n g R a t e d R a t e d Sh e a t h i n g R a t e d
Ex p o s u r e 1 Sh e a t h i n g Ex p o s u r e 1 Sh e a t h i n g
4 0 / 2 0 4 0 / 2 0 4 8 / 2 4 4 8 / 2 4
3 , 4 , o r 5 p l y 5 p l y 5 p l y 4 o r 5 p l y 5 p l y 5 p l y
3 l a y e r 5 l a y e r 5 l a y e r 3 l a y e r 5 l a y e r 5 l a y e r
P a l l e t Pl ywood 1 9 / 3 2 , 5 / 8 19/32 Pl ywood 23/32 23/32
Si z e 19/32 3/4 , 7/8 5/8 23/32 3/4 , 7/8 3/4
(i nches) 5/8 , 3/4 Pl ywood or OSB Pl ywood or OSB 3/4 Pl ywood or OSB Pl ywood or OSB
3 2 x4 0 1 7 0 0 3 1 0 0 4 1 0 0 3 1 0 0 4 4 0 0 5 0 0 0
3 6 x3 6 1 3 0 0 2 4 0 0 3 5 0 0 2 4 0 0 3 4 0 0 4 4 0 0
3 6 x4 2 1 6 0 0 2 8 0 0 4 1 0 0 2 8 0 0 4 0 0 0 5 0 0 0
3 2 x4 8 2 1 0 0 3 7 0 0 4 1 0 0 3 7 0 0 5 0 0 0 5 0 0 0
4 2 x4 2 1 3 0 0 2 3 0 0 3 4 0 0 2 3 0 0 3 3 0 0 4 3 0 0
3 6 x4 8 1 8 0 0 3 2 0 0 4 1 0 0 3 2 0 0 4 6 0 0 5 0 0 0
4 0 x4 8 1 6 0 0 2 8 0 0 4 1 0 0 2 8 0 0 4 0 0 0 5 0 0 0
19
T A B L E 1 1
Load Span Tables Sanded Panels
General Note: E xce p t fo r S tu rd -I -F lo o r, th e ta b le s b e lo w a p p ly to G ro u p 1 P S 1
p lywo o d o n ly. Wh e re G ro u p s 2 , 3 o r 4 p lywo o d s a re u se d , th e ta b le va lu e s sh o u ld b e
m o d i fi e d b y th e fo llo wi n g p e rce n ta g e s:
G ro u p 2 o r 3 : 7 3 % o f ta b le va lu e G ro u p 4 : 6 7 % o f ta b le va lu e .
EXPOSURE 1
B-D GROUP 2
000
PS 1-95
THE ENGINEERED
WOOD ASSOCIATION
APA
RATED STURD-I-FLOOR
EXPOSURE 1
THE ENGINEERED
WOOD ASSOCIATION
APA
1-1/8 INCH
48oc
SIZED FOR SPACING
000
PS 1-95 UNDERLAYMENT
PRP-108
T&G
Two - Wa y En t r y Pa l l e t s
Ma xi mum Uni f or m Loa d (psf )* Str ength Axi s Acr oss Suppor ts
Sa nded Gr a des
Th i ck n e ss
( i n ch e s) 1 6 1 8 2 0 2 2 2 4 3 0 3 2 3 6
1 1 /3 2 1 7 5 1 4 0 1 1 0 9 0 8 0 5 0 4 5 3 5
3 /8 2 3 5 1 8 5 1 5 0 1 2 5 1 0 5 6 5 6 0 4 5
1 5 /3 2 4 0 0 3 1 5 2 5 5 2 1 0 1 8 0 1 1 5 1 0 0 8 0
1 /2 4 4 5 3 5 0 2 8 5 2 3 5 1 9 5 1 2 5 1 1 0 8 5
1 9 /3 2 2 0 o c) 5 4 5 4 3 0 3 5 0 2 9 0 2 4 0 1 5 5 1 3 5 1 1 0
5 /8 6 3 5 5 0 0 4 0 5 3 3 5 2 8 5 1 8 0 1 6 0 1 2 5
2 3 /3 2 2 4 o c) 7 3 0 5 7 5 4 6 5 3 8 5 3 2 5 2 0 5 1 8 0 1 4 5
3 /4 7 7 5 6 1 0 4 9 5 4 1 0 3 4 5 2 2 0 1 9 5 1 5 5
1 3 2 o c) 1 1 8 5 9 3 5 7 6 0 6 2 5 5 2 5 3 3 5 2 9 5 2 3 5
1 -1 /8 4 8 o c) 1 5 4 0 1 2 1 5 9 8 5 8 1 5 6 8 5 4 3 5 3 8 5 3 0 5
* T o fi n d to ta l a llo w a b le p a lle t lo a d , m u lti p ly ta b le va lu e b y p a lle t a re a sq . ft. )
stri n g e rs th i s sh o u ld n e ve r b e d o n e u n le ss so sp e ci fi e d ) th e lo a d va lu e s
1 5 /3 2 Th i ckn e ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 % o f ta b le va lu e
1 /2 Th i ckn e ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7 % o f ta b le va lu e
1 Th i ckn e ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6 % o f ta b le va lu e
1 -1 /8 Th i ckn e ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 0 % o f ta b le va lu e
Th i n n e r p a n e ls a re n o t su i te d to th i s o ri e n ta ti o n .
N o te B : Wh e n 4 -stri n g e r p a lle ts a re sp e ci fi e d a n d th e d i sta n ce b e twe e n
th e ce n te r stri n g e rs i s n o t le ss th a n 1 /1 0 th n o r m o re th a n 1 /3 rd o f th e
p a lle t wi d th , a d d 2 5 % to th e lo a d va lu e s i n th i s ta b le a s g e n e ra li za ti o n .
U se th e lo n g e st sp a n o f th e 4 -stri n g e r p a lle t wh e n u si n g th e ta b le . F o r
m o re p re ci se ca lcu la ti o n i n vo lvi n g g re a te r va lu e s, co n ta ct yo u r n e a re st
A P A re p re se n ta ti ve .
N o te C : S p a n R a tin g s in p a re n th e sis a p p ly to APA R a te d S tu rd -I -Flo o r.
Ni n e - Bl o ck Fo ur - Wa y En t r y Pa l l e t s ( Pl y wo o d o n l y )
Ni ne bl ock s, 4 x6 bea r i ng a r ea per bl ock . Pl ywood f a ce gr a i n a nd bl ock l ength pa r a l l el to l ong di mensi on.
Sa nded Gr oup 1 PS 1 Pl ywood wi th exter i or gl ue
Pa l l e t
Pl y wo o d Th i ck n e ss ( i n ch e s)
Si ze
( i n ch e s) 1 9 /3 2 5 /8 2 3 /3 2 3 /4 1 1 - 1 /8
3 2 x4 0 2 6 0 0 3 1 0 0 4 4 0 0 5 3 0 0 8 6 0 0 1 0 , 2 0 0
3 6 x3 6 2 0 0 0 2 4 0 0 3 4 0 0 4 2 0 0 8 7 0 0 1 0 , 2 0 0
3 6 x4 2 2 4 0 0 2 8 0 0 4 0 0 0 4 9 0 0 9 0 0 0 1 0 , 2 0 0
3 2 x4 8 3 1 0 0 3 4 0 0 3 9 0 0 4 2 0 0 6 7 0 0 9 9 0 0
4 2 x4 2 1 9 0 0 2 3 0 0 3 3 0 0 4 1 0 0 8 4 0 0 1 0 , 2 0 0
3 6 x4 8 2 7 0 0 3 2 0 0 4 4 0 0 4 7 0 0 7 6 0 0 1 0 , 2 0 0
4 0 x4 8 2 4 0 0 2 8 0 0 4 0 0 0 4 9 0 0 8 4 0 0 1 0 , 2 0 0
La r g e Si ze Ni n e - Bl o ck Pa l l e t s ( Pl y wo o d o n l y )
Ni ne bl ock s, 6 x6 bea r i ng a r ea per bl ock . Pl ywood f a ce gr a i n a nd bl ock l ength pa r a l l el to l ong di mensi on.
Sa nded Gr oup 1 PS 1 Pl ywood wi th exter i or gl ue
Pa l l e t
Pl y wo o d Th i ck n e ss ( i n ch e s)
Si ze
( i n ch e s) 1 9 /3 2 5 /8 2 3 /3 2 3 /4 1 1 - 1 /8
4 8 x4 8 2 1 0 0 2 5 0 0 3 5 0 0 4 3 0 0 9 0 0 0 1 1 , 3 0 0
4 8 x6 0 2 6 0 0 3 1 0 0 4 4 0 0 4 7 0 0 7 7 0 0 1 1 , 3 0 0
4 8 x7 2 2 9 0 0 3 1 0 0 3 6 0 0 3 8 0 0 6 1 0 0 9 0 0 0
20
Since the loaded pallet will sometimes
be handled by pallet hand truck,
provision for the truck wheels must be
made in the bottom of the pallet. This
can be accomplished in one of two ways:
1) use a panel bottom with holes cut for
wheels, or 2) use a board bottom deck
with boards left out where wheels would
be positioned. Before deciding,
determine if the top of the pallet load
presents any unevenness which would
affect the bottom deck of a loaded pallet
stacked on top of it. The reel tops
present no problem because they have a
uniform surface. At this point the choice
is between a solid panel bottom deck or
one made up of either structural panel
strips or lumber. Since the standard
panel width is 48 inches, a 12-inch-wide
strip left from top deck cutting has the
strength axis running the long way.
Using these cuttings combined with
lumber for the bottom deck is therefore
recommended for maximum efficiency.
Two six-inch outer boards and a
12-inch center structural panel strip leave
6-inch openings for the hand truck wheels
and use the panels most economically as
far as trim is concerned. The specification
put out for bid would therefore call for a
12-inch structural panel bottom strip plus
two six-inch boards.
Stringers may be either hardwood or
softwood. Nails should be located
according to the specifications in Figure7.
Since the pallets will sometimes be stored
outdoors, the use of APA Rated Sheathing
Exposure1 is appropriate.
Design Example
Fertilizer BagPallet
Requirements. Pallet to handle 80-pound
sacks of fertilizer within producers
warehouse.
Use Conditions. Movement is fast and
pallets should be reversible. Storage is
basically open so product unit size
governs size of pallet. Handling by
standard forklift.
Size of Pallet. The 80-pound sacks of
fertilizer laid flat measure roughly
16inches wide by 24inches long. Five
sacks per layer will fit on a 42-inch by
48-inch pallet. Investigation proves that
the sacks will stack solidly five layers high.
Pallet Load. Planned total load is 25sacks
of fertilizer or 2,000pounds total load per
pallet. At times, the loaded pallets will be
stacked four high, giving a total load on
the bottom pallet of 8,000pounds. At
42inches by 48inches, the pallet surface
has 14square feet. This yields a load of
571pounds per square foot.
Pallet Specification. Since the pallet
must be reversible, standard three-
stringer construction is the obvious
choice. Because of the size of the pallet
and the heavy load, 3-inch by 4-inch
stringers are specified. This is particularly
important because the uneven top of the
pallet load provides an unstable base for
the top two pallet loads in the stack.
The three-stringer pallet in the 48-inch
width gives a span between stringers of
24inches. The load-span table for 48/24
Rated Sheathing panels shows that the
571psf load exceeds the allowable load
in the table for a 24-inch span (390psf).
At this point a four-stringer pallet
should be considered. This would reduce
the span and add stiffness when the
pallet loads are stacked. Centering the
two middle stringers 8inches apart
reduces the span to 20inches without
interfering with the fork tines. In addi-
tion, note B on the two-way-entry span
table shows that the four-stringer con-
struction adds 25percent to the table
values. (This is because the three spans
of the four-stringer pallet build in extra
strength.) For ease in using the table, a
25percent increase in table values is
effectively the same as a 20percent
decrease in the load. Thus 80percent
of 571 is 457psf.
The 20-inch span column of the table
shows that this load can be easily handled
by a 48/24panel, which has a 565psf
allowable load.
For a smooth, snag-free surface, options
are sanded 23/32-inch panels, or 24o.c.
APA Rated Sturd-I-Floor, which both have
a 465psf allowable load, exceeding the
457psf requirement.
Pallet Collars
Pallet collars turn ordinary pallets into cost
efficient, reusable, collapsible containers.
Structural wood panels held together with
metal tabs make pallet collars both strong
and lightweight. Pallet collars are stackable
to make efficient use of storage and cargo
space. And because they are collapsible,
return shipment and storage between uses
is easy and cost effective.
Pallet collars provide excellent
protection and security for a wide range
of palletized cargo.
21
C o lla p si b le se cti o n s m a d e o f A P A p a n e ls a n d m e ta l h i n g e s a tta ch to p a lle t b a se .
S e cti o n s m a y b e sta cke d to cre a te a wi d e ra n g e o f co n ta i n e r si ze s. S li p sh e e ts m a y b e i n se rte d b e twe e n se cti o n s to se p a ra te a n d
p ro te ct p ro d u cts.
F I G U R E 1 1
Pallet Collars
22
Pallet bins can reduce handling costs while
providing superior protection for a wide
variety of products ranging from heavy
machine parts to farm produce to liquids.
Bins can be fabricated fixed or demount-
able. They may have covers and doors and
can accommodate field and in-plant
handling, interplant shipping, or both.
Pallet Bin Configuration
Four basic factors dictate pallet bin
dimensions: size, shape and weight of
commodity; plant storage facilities;
materials handling equipment; and the
mode of bin transportation. Dimensions
of a pallet bin are normally given as
length, width and height, respectively.
The width refers to the side with the fork
openings. Usually, the dimensions are
given in inches; however, some users still
describe a bin by the approximate load
size in feet. For example, a 4x4x2foot
bin may be only 47x47inches and have a
load depth of 24inches.
If bins will be stacked, the plant ceiling
height may limit bin depth to obtain
optimum use of storage space. Large bins
require consideration of doorway size,
aisle width and other obstacles.
Generally, any plant area accessible to
materials handling equipment can
accommodate average-sized pallet bins.
In some specialized operations, pallet
bins transport a number of smaller
cartons. In such situations the size and
number of cartons directly influence the
size of the pallet bins.
If pallet bins will be shipped between
plants, or from manufacturer to user, the
type and capacity of truck or railroad car
should be considered in determining size.
In agriculture, where flatbed trucking
is common, the 8-foot wide load limit
accommodates the standard 47-inch bin.
Two unit loads arranged side-by-side
on a truck bed leave just enough room
for load binding.
Bin Type
The type of equipment used in materials
handling operations has a profound
influence on pallet bin design. The bin
base or pallet, commonly called the deck,
should be designed to facilitate the
various types of handling equipment
used in-plant, as well as those used for
transportation to outside destinations.
While in no way an exhaustive list,
several common pallet bin types are
described below.
Two-way entry and full four-way entry
pallet bins, manufactured with 4-inch
(nominal) high stringers or blocks,
permit access with lift truck tines and
hand pallet truck outriggers. Lift trucks
have four-side access to partial four-way
entry (notched stringer) pallet bins, while
hand pallet trucks can gain entry from
only two sides.
A specialized system uses hydraulically
actuated clamps that lift bins by their top
edge. Bins used with this so-called
lightning loader require an external top
rail or rib for the clamp fingers to grip in
lifting. Current standards limit the overall
width of the bin so there is some
decrease in material volume, per bin,
with this type of top-handling system.
Demountable Bins. Ademountable bin
performs the same functions as a fixed
bin, but after it is used, it can be
knocked down flat and conveniently
stored until needed again (see Figure
12). When the bin is transported from
one location to another, after its contents
are removed it can be filled with a
different cargo and returned to its point
of origin, saving costly shipping space.
When considering bin type, bear in mind
the demountable design yields a bin that
is somewhat less strong and rigid than its
fixed bin counterpart.
There are numerous fabricators of
proprietary demountable pallet bins
located in most areas of the country.
Information is available from the
National Wooden Pallet and Container
Association, Washington, D.C.
P A L L E T B I N S
23
Pallet Bin Fabrication
Components required to fabricate pallet
bins include stringers, decks, covers and
doors, sides and fasteners.
Stringers. Most bins are designed for
two-way fork lift entry, but partial and full
four-way entry pallet bins meet a variety
of operational needs (see Figure13).
Normally, three stringers are used to
support a pallet bin. If two stringers are
used, a thicker bin deck may be needed
because of the longer span. A four-stringer
design should be considered if the bin
decks support extremely heavy loads.
Decks. Bin decks deserve special care in
both design and fabrication. The deck
must have adequate stiffness to minimize
deflection and damage, especially when
loaded bins are lifted for stacking.
Although structural panels are strong
in both directions, they are stronger and
stiffer parallel to the original long dimen-
sion. A single piece of structural panel
placed with this strength axis across the
stringers is one of the simplest, most
rigid forms of decks (seeFigure14).
In two-way and partial four-way entry
pallet bins, the panel deck should be
fabricated with the strength axis
perpendicular to the stringers. In full four-
way entry designs, the strength axis
should run parallel to the longest span
between blocks (see Pallets).
F I G U R E 1 2
Demountable Bin Assembly
F I G U R E 1 3
Stringer Designs
Two -wa y e n try
P a rti a l fo u r-wa y e n try
F u ll fo u r-wa y e n try
Two -wa y e n try wi th
re ce sse d stri n g e rs
F I G U R E 1 4
Single-Piece Panel Deck
S
tre
n
g
th
a
x
i s
24
In addition to supporting the bin
decks, stringers play an important part in
stacking. The narrow top edges of the bin
sides provide little support area for the
upper bin, so the bins must rely on the
friction between them to remain stacked.
The contact area can be increased by:
1) making the stringers longer than the
bin to project beyond the sides;
2) shortening the stringers to interlock
with the top of the lower bin in the
stack; 3) adding corner posts to provide
greater contact area.
Lumber for pallet stringers or blocks
may be either softwood or hardwood.
Softwood species are generally lighter,
reducing tare weight of the bins.
Hardwood species are usually denser,
providing greater durability and fastener-
holding strength.
To satisfy pallet requirements, lumber
species are grouped in three classifications
in the APA publication, Specifications for
Softwood Plywood Pallets, (PP61).
Sides. The sides of a pallet bin confine the
contents and provide protection. In some
cases, they carry the loads of stacked bins.
The type of framing, corner connections
and fasteners selected depends upon the
commodity, the type and size of bin and
whether the bins are stacked.
Framing. The two general types of
framing are internal and external (see
Figure15). Internal framing gives greater
cubage and the sides are flush with deck
edges. Framing can be combined with
the panel deck to simplify attachment of
the bin sides to the pallet base.
External framing utilizes rails or ribs
framed horizontally. The framing is
fastened at the corners, and the panel
sides are attached to the framing from
the inside. Horizontal framing restrains
the sides and is a connecting member
between the side and deck joint.
For maximum strength and stiffness,
the panels strength axis should be
perpendicular to this framing.
The required size and spacing of framing
depends upon bin size and contents.
Asbin size increases, framing generally
increases in size and/or frequency.
Corner Connections. Corner connections
hold bin sides together, secure the bottom
to the sides, transmit loads developed in
stacking, and carry the panels strength
around corners (seeFigure 16).
Resting panel sides on top of the deck
and extending corner posts slightly above
the sides increases the allowable loads for
stacked bins. It does so by providing
contact area for the upper bin in the
post, allowing the top bin to rest more
securely and at the same time stabilizing
the post with the side panels. Inside
corner posts also permit lapping the
panels over the stringers on two sides of
the bin where it can be securely fastened.
Wood members nailed to the bin sides
provide adequate and economical corner
fastening. Sheet metal corners used with
nailed lumber posts produce a neat, rigid
connection. The sheet metal corners uti-
lize the nails more effectively by loading
them in shear rather than in withdrawal.
Sheet metal corners fastened with bolts
and T-nuts perform and stack only fairly
well. Square corners with no posts can be
securely fastened with bolts.
F I G U R E 1 5
Framing
I n te rn a l fra m i n g
P a n e l d e ck/b i n fra m i n g
E xte rn a l fra m i n g
E xte rn a l fra m i n g /co rn e r p o sts
F I G U R E 1 6
Side-to-Deck Connections
25
Fasteners for Pallet Bins. Figure 17
illustrates the most common type of cor-
ner fastening for pallet bins. Nails are the
most commonly used fasteners. Galva-
nized nails or those made from special
rust-resistant alloys are recommended for
long service. If the nails will come in
contact with corrosive materials, stainless
steel nails are recommended. Annular
ring, threaded and other types of
deformed nails have higher withdrawal
strength than smooth-shank nails.
Although cement-coated nails have high
initial withdrawal strength, tests have indi-
cated aloss in strength with time. Thus,
cement-coated nails are not generally
recommended for pallet bin assembly.
The fabricator should take advantage
of the nails high lateral load (shear)
strength, rather than the relatively low
withdrawal resistance. Rivets, screws, and
lag screws all have greater holding power
than nails, and can be used where
withdrawal resistance is critical.
Construction and repair are faster
when bolts are used. Bolts can be
tightened if shrinkage occurs in the
lumber parts. Using U-bolts and angle
bolts with T-nuts or Di-nuts provides a
flush connection. This eliminates
possible damage to the bins contents
and injury to warehouse personnel.
A number of fasteners are available to
hold the sides to the bottom. One is a
metal Allen tab, which mounts on the
outside between the deck and stringers. A
bolt is then passed through the bin
bottom, the Allen tab and the stringer.
Attaching a Di-nut to the bolt draws the
entire assembly together. The vertical
portion of the Allen tab is punched to
receive rivets, and becomes a template for
drilling the side of the bin as it is
positioned. The side is then riveted to the
tab, tying the base and sides together.
Four Allen tabs per bin are fastened at the
midpoint of bin sides and ends.
If the bin sides tend to spring out under
heavy loads, tie rods can provide restraint.
Short steel straps or wire can be used
as corner fasteners. The steel straps or
wire run through holes in the sides and
bottom and are usually recessed into the
wood framing members and panels. This
prevents snagging other bins.
Other fasteners include hinges, corner
angles and catches. The ordinary hinge is
excellent for assembling a demountable
bin or attaching a bin cover.
A more complete specification for
pallet fasteners is given in Specifications
for Softwood Plywood Pallets (PP61).
Fasteners can be eliminated altogether
by pressure gluing the panels to the
framing members with resorcinol or
melamine- based glue. However, these
rigid adhesives may fracture under high
impact loads.
Construction adhesives having a high
solid content and resiliency can be used
effectively since they can absorb energy
from misdirected fork tines without
fracturing. For additional information on
selection and use of elastomeric adhe-
sives see the appendix of PP61.
Plastic fittings and hardware are
available for certain corrosion require-
ments and some general uses. These
include hinges, corner caps for demount-
able bins, brackets and liners. Most are
special purpose items, but these new
plastic fittings are developing rapidly and
the specifier should keep them in mind.
F I G U R E 1 7
Corner Fastening
26
Un sa n d e d Gr a d e s ( APA Ra t e d Sh e a t h i n g ) Va lu e s re p re se n t a llo wa b le u n i fo rm lo a d s i n p o u n d s p e r sq . ft.
Sp a n
St r e n g t h
Ra t i n g 1 6 1 8 2 0 2 2 2 4 3 0 3 2 3 6 4 0 4 2 4 8 6 0 7 2 Fa ct o r
(c)
2 4 /0 2 8 5 2 2 5 1 8 0 1 5 0 1 2 5 8 0 7 0 5 5 4 5 4 0 3 0 2 0 0 . 2 2
2 4 /1 6 3 6 5 2 8 5 2 3 5 1 9 0 1 6 0 1 0 5 9 0 7 0 6 0 5 0 4 0 2 5 2 0 0 . 2 0
3 2 /1 6 4 0 0 3 1 5 2 5 5 2 1 0 1 7 5 1 1 5 1 0 0 8 0 6 5 6 0 4 5 3 0 2 0 0 . 2 6
4 0 /2 0 7 1 0 5 6 0 4 5 5 3 7 5 3 1 5 2 0 0 1 8 0 1 4 0 1 1 5 1 0 5 8 0 5 0 3 5 0 . 2 4
4 8 /2 4 8 8 0 6 9 5 5 6 5 4 6 5 3 9 0 2 5 0 2 2 0 1 7 5 1 4 0 1 3 0 1 0 0 6 5 4 5 0 . 3 5
Pallet Bin Design
The weight of each unit of a commodity
and the number of units making up the
total load determine the required panel
thickness for the bottom and sides of the
pallet bin. Stresses induced by handling
equipment and load also influence panel
selection.
The total handling, stacking and load
stresses affecting the performance of a bin
are sometimes difficult to calculate
precisely. It is wise to test five or more bins
in normal use prior to final specification.
Deflection is another important factor
to consider. Excessive deflection can
hamper bin stacking and shipping, and
may result in damage to fragile products.
Table 12 indicates loads based on the
strength of the panel. The sanded
plywood table values are based on
plywood designated as Group 1 (for
Group information, see Table 2, page 6).
Adjustment factors are shown for Groups
2, 3 and 4. In unsanded panel grades,
strength variations are expressed for the
panel by the Span Rating and adjustment
factors are necessary. After the load has
been determined, these tables can be
used to select the proper panel. Where
deflection under load is important,
tables13 and 14 should be used.
Some agricultural products can be
damaged by excessive deflection. When
designing bins for such fragile projects,
use values from the tables that limit
bottom and side deflection to 1/4 inch.
Data on side pressures of various
products can be obtained from the U.S.
Department of Agriculture. These values
will be the equivalent fluid density of the
T A B L E 1 2
Structural Panel Pallet Bin Load Based on Strength
(a)
Uniform Load with Strength Axis Across Supports
S tre n g th a xi s S tre n g th a xi s
M u lti p le sp a n S i n g le sp a n
S S S
Sa n d e d Gr a d e s
(b)
Va lu e s re p re se n t a llo wa b le u n i fo rm lo a d s i n p o u n d s p e r sq . ft.
Pa n e l
St r e n g t h
Th i ck n e ss
(d)
1 6 1 8 2 0 2 2 2 4 3 0 3 2 3 6 4 0 4 2 4 8 6 0 7 2 Fa ct o r
(c)
1 1 /3 2 1 7 5 1 4 0 1 1 0 9 0 8 0 5 0 4 5 3 5 3 0 2 5 2 0 0 . 1 7
3 /8 2 3 5 1 8 5 1 5 0 1 2 5 1 0 5 6 5 6 0 4 5 4 0 3 5 2 5 0 . 1 8
1 5 /3 2 4 0 0 3 1 5 2 5 5 2 1 0 1 8 0 1 1 5 1 0 0 8 0 6 5 6 0 4 5 3 0 2 0 0 . 3 1
1 /2 4 4 5 3 5 0 2 8 5 2 3 5 1 9 5 1 2 5 1 1 0 8 5 7 0 6 5 5 0 3 0 2 0 0 . 3 7
1 9 /3 2 2 0 o c) 5 4 5 4 3 0 3 5 0 2 9 0 2 4 0 1 5 5 1 3 5 1 1 0 8 5 8 0 6 0 4 0 2 5 0 . 3 0
5 /8 6 3 5 5 0 0 4 0 5 3 3 5 2 8 5 1 8 0 1 6 0 1 2 5 1 0 0 9 0 7 0 4 5 3 0 0 . 4 8
2 3 /3 2 2 4 o c) 7 3 0 5 7 5 4 6 5 3 8 5 3 2 5 2 0 5 1 8 0 1 4 5 1 1 5 1 0 5 8 0 5 0 3 5 0 . 4 0
3 /4 7 7 5 6 1 0 4 9 5 4 1 0 3 4 5 2 2 0 1 9 5 1 5 5 1 2 5 1 1 0 8 5 5 5 4 0 0 . 6 9
1 3 2 o c) 1 1 8 5 9 3 5 7 6 0 6 2 5 5 2 5 3 3 5 2 9 5 2 3 5 1 9 0 1 7 0 1 3 0 8 5 6 0 0 . 6 6
1 -1 /8 4 8 o c) 1 5 4 0 1 2 1 5 9 8 5 8 1 5 6 8 5 4 3 5 3 8 5 3 0 5 2 4 5 2 2 5 1 7 0 1 1 0 7 5 0 . 6 0
a ) S tre n g th va lu e s g i ve n a re m a xi m u m fo r p a lle t b i n s. Wh e n fu lly
lo a d e d p e rm a n e n tly, o cca si o n a l fa i lu re m a y o ccu r.
b ) Ta b u la te d va lu e s fo r sa n d e d p lywo o d p a n e ls a re b a se d o n S p e ci e s
G ro u p 1 o n ly. F o r sa n d e d p lywo o d o th e r th a n G ro u p 1 m u lti p ly th e
ta b u la te d lo a d s b y th e fo llo wi n g fa cto rs: G ro u p 2 o r G ro u p
3 0 . 7 3 ; G ro u p 4 0 . 6 7 . Lo a d s fo r S p a n R a te d p a n e ls a re va li d fo r
a ll G ro u p s a n d p a n e l typ e s.
c) I f th e p a n e l i s a p p li e d wi th stre n g th a xi s p a ra lle l to su p p o rts
m u lti p ly th e ta b u la te d lo a d s b y th e fa cto rs sh o wn i n la st co lu m n .
d ) S p a n R a ti n g s i n p a re n th e se s a p p ly to A P A R a te d S tu rd -I -F lo o r.
27
(b)
Pa n e l
Th i ck n e ss
(d)
1 6 1 8 2 0 2 2 2 4 3 0 3 2 3 6 4 0 4 2 4 8 6 0 7 2
1 1 /3 2 9 0 5 5 4 0 1 5 1 0
3 /8 1 2 5 8 0 5 5 2 0 1 5 1 0
1 5 /3 2 2 0 0 1 3 5 5 0 3 5 2 0 1 5 1 0
1 /2 2 3 0 1 5 5 6 0 4 5 2 5 1 5 1 5 1 0
1 9 /3 2 2 0 o c) 2 2 5 8 5 6 5 4 0 2 5 2 0 1 0
5 /8 2 6 0 9 5 7 5 4 5 3 0 2 5 1 5
2 3 /3 2 2 4 o c) 1 2 5 9 5 5 5 3 5 3 0 1 5
3 /4 1 5 0 1 1 0 6 5 4 0 3 5 2 0 1 0
1 3 2 o c) 2 3 0 1 7 5 1 0 5 6 5 5 5 3 0 1 0
1 -1 /8 4 8 o c) 4 1 0 3 1 0 1 8 5 1 2 0 9 5 5 5 2 0 1 0
product in pounds per cubic foot. To
convert to pounds per square foot, multi-
ply the equivalent fluid density by the
depth at the point being designed. The
critical point is the lower edge of the bin
side, if that edge is free. If it is restrained,
the critical point moves up, to about 1/3
the height of the bin side, or 1/3 the dis-
tance up to the first framing member, if
any. Pressure at the critical point should
be used to determine the panel specifi-
cation from the appropriate tables.
There are three categories of contents,
solid, granular and liquid, and each apply
a different type of force. Solid and granular
materials are discussed here, while a
section on the design and fabrication of
liquid tanks appears later in this brochure.
Solid Materials. Pipe fittings, castings
and machinery parts are all classified as
solid materials, yet they each possess
unique load characteristics.
For example, the solid material may
bridge from one stringer to another with
the panel carrying minimal direct load.
Conversely, irregularly shaped material
may impose severe concentrated loads on
the deck. Except in extreme conditions,
the panel which will bear the load figured
on a uniform basis, as determined by the
tables, will handle most load variations.
In designing agricultural pallet bins,
fruits, nuts, cotton, vegetables and meat
may all be classified as solid materials,
although each product has very different
load characteristics. For example, cotton
a ) Ta b u la te d va lu e s fo r p a n e ls wi th stre n g th a xi s o ri e n te d
p e rp e n d i cu la r to su p p o rts. S e e n o te c) .
ta b u la te d lo a d s b y th e fo llo wi n g fa cto rs: G ro u p 2 0 . 8 3 ;
G ro u p 3 0 . 6 7 ; G ro u p 4 0 . 5 6 . Lo a d s fo r S p a n R a te d p a n e ls a re
va li d fo r a ll G ro u p s a n d p a n e l typ e s.
c) S tre n g th a xi s sh o u ld a lwa ys b e p e rp e n d i cu la r to su p p o rts wh e re
sti ffn e ss g o ve rn s.
T A B L E 1 3
Structural Panel Pallet Bin Load Based on 1/4 Deflection Single Span
(a)(c)
S tre n g th a xi s
S
S i n g le sp a n
Sp a n
Ra t i n g 1 6 1 8 2 0 2 2 2 4 3 0 3 2 3 6 4 0 4 2 4 8 6 0 7 2
2 4 /0 1 5 5 1 0 0 7 0 2 5 2 0 1 0
2 4 /1 6 2 0 5 1 3 0 9 0 3 5 2 5 1 5 1 0 1 0
3 2 /1 6 1 9 5 1 3 0 5 0 3 5 2 0 1 5 1 0
4 0 /2 0 3 6 5 2 4 5 9 0 7 0 4 0 2 5 2 0 1 0
4 8 /2 4 1 6 5 1 2 5 7 5 5 0 4 0 2 0 1 0
S p e ci a l N o te : S e e
stre n g th ta b le s fo r
va lu e s i n th i s a re a .
D e fle cti o n w i ll b e
le ss th a n 1 /4 .
le ss th a n 1 /4 .
Sp a n
Ra t i n g 1 6 1 8 2 0 2 2 2 4 3 0 3 2 3 6 4 0 4 2 4 8 6 0 7 2
2 4 /0 6 0 4 5 2 5 1 5 1 5 1 0
2 4 /1 6 1 6 0 7 5 5 5 3 5 2 0 2 0 1 0
3 2 /1 6 1 1 0 8 5 5 0 3 0 2 5 1 5
4 0 /2 0 1 6 0 9 5 6 0 5 0 3 0 1 0
4 8 /2 4 1 7 5 1 1 0 9 0 5 0 2 0 1 0
28
must be tightly packed in a large bin if
the weight is to be sufficient to permit
economic handling. With tight packing,
the controlling design factor becomes the
packing pressure on the bin sides.
On the other hand, during transport
leaf spinach intertwines into a mass and
exerts little or no pressure on the bin
sides. As a third example, research
indicates that the pressures developed by
fruit in a 2-foot deep bin approximates
15 pounds per square foot on the lower
portion of the bin sides.
Vibration of bins in transit is another
important factor in bin loadings, and
vibration tests have been developed
which simulate bin overloads to help
determine design criteria.
Granular Materials. Granular materials
in pallet bins generally exert uniform
bottom and side pressures. Bottom
pressures are determined by dividing the
total weight of the contents by the square
footage of the deck. Side pressures are
not as easily computed, because
pressures adjacent to the bin sides vary
with the depth and frictional
characteristics of the material.
Factors for determining the side
pressures of granular materials are
generally available from the supplier or
manufacturer of the material.
Feeds, fertilizers and grains are usually
considered granular materials and
bottom pressures govern bin design. In
processed feeds, bridging lessens the
pressures developed. In most instances,
feed bins are used also as grain bins so
le ss th a n 1 /4 .
T A B L E 1 4
Structural Panel Pallet Bin Load Based on 1/4 Deflection Two Spans
(a)(c)
S tre n g th a xi s
S S
Two -sp a n
(b)
Pa n e l
Th i ck n e ss 1 6 1 8 2 0 2 2 2 4 3 0 3 2 3 6 4 0 4 2 4 8 6 0 7 2
1 1 /3 2 3 5 2 5 1 5 1 0 1 0
3 /8 4 5 3 5 2 0 1 5 1 0
1 5 /3 2 8 5 5 0 3 5 2 5 1 5
1 /2 1 0 0 6 0 4 0 3 0 2 0
1 9 /3 2 2 0 o c) 9 0 5 5 4 5 2 5 1 0
5 /8 1 0 0 6 5 5 5 3 0 1 0
2 3 /3 2 2 4 o c) 1 3 0 8 5 7 0 4 0 1 5 1 0
3 /4 1 5 5 1 0 0 8 0 4 5 2 0 1 0
1 3 2 o c) 1 5 5 1 2 5 7 0 3 0 1 5
1 -1 /8 4 8 o c) 2 2 5 1 3 0 5 0 2 5
a ) Ta b u la te d va lu e s fo r p a n e ls wi th stre n g th a xi s o ri e n te d
p e rp e n d i cu la r to su p p o rts. S e e n o te c) .
ta b u la te d lo a d s b y th e fo llo wi n g fa cto rs: G ro u p 2 0 . 8 3 ;
G ro u p 3 0 . 6 7 ; G ro u p 4 0 . 5 6 . Lo a d s fo r S p a n R a te d p a n e ls a re
va li d fo r a ll G ro u p s a n d p a n e l typ e s.
c) S tre n g th a xi s sh o u ld a lwa ys b e p e rp e n d i cu la r to su p p o rts wh e re
sti ffn e ss g o ve rn s.
le ss th a n 1 /4 .
29
they must be designed for the heavier
grain loads. Bins for agricultural use
should be fabricated from plywood
panels (see page 31).
Special Design Considerations
Cooling, Ventilation and Drainage
Provisions. Frequently, agricultural
commodities require cooling, both in
transit and in storage.
One particularly effective method is
hydrocooling, which involves chilled
water and top-icing. The bin which has
slots or holes in the bottom is first
flooded with chilled water and allowed to
drain. Then chipped ice is placed over
the top layer of the contents. As the ice
melts, it filters down through the already
cooled contents, and through the holes
in the deck.
The ice, besides cooling the bin
contents, acts as a damper. Its weight
holds the contents in place, eliminating
much of the vibration damage that
occurs in transit.
The most common cooling method
provides for movement of air by drilling,
notching, or cutting slots in the bin sides
or deck (see Figure 18). The slots should
run parallel to the face grain of the
plywood. Since slotting or drilling affects
strength, a thicker panel may be necessary
for extensive slotting or drilling.
Beveling each opening at 20degrees
on all sides minimizes bruise damage to
produce resting on the openings (see
Figure 19).
The amount of open space needed in
the deck varies with the crop being
carried and its cooling requirements.
Vent openings vary from 2percent to
10percent of the bottom area.
Bin Stacking. In nearly every agricultural
use, pallet bins are stacked. Bins often
are stacked as high as 24feet, imposing
loads up to 12,000pounds on the
bottom bin. Thus, bins must have
adequate rigidity and proper design to
ensure safe stacking.
Bins without interlocking stacking
connectors rely on friction and the
weight of the bins to maintain their posi-
tion. Corner posts and caps, extended
stringers, and rail-type bins contribute to
safe stacking.
When used in well-designed bins,
panels provide the strength necessary for
safe, efficient stacking.
Filling and Emptying Considerations.
The manner in which an agricultural bin
is loaded or unloaded also influences
design. For instance, the bin height for
hand-picked crops is limited to about
30inches because pickers cannot con-
veniently empty their bags into taller bins.
Mechanical filling equipment, such as
scoop-equipped tractors, can be used for
grain and fertilizers. This permits use of
larger, deeper bins having more capacity.
Bins can also be filled by water
flotation. In this operation, bins are
immersed in a tank, filled with fruit and
then lifted by mechanical means. As the
bins are lifted, the water drains through
the holes, leaving only the fruit.
Forklifts are often used to empty bins.
It may be necessary to strengthen the
base of the bin to compensate for
unloading stresses when using a rotating
head forklift not equipped with a hold-
down clamp. Rotating heads or forward
dumping mechanisms designed to
support the bin on top, sides and
bottom, allow any standard bin to be
dumped with ease.
Edge and Corner Protection. Frequently,
bin damage results from carelessness by
equipment operators.
When forklifts back out of a stack, the
top edge of the lower bin is sometimes
damaged. This damage can be minimized
by: 1) chamfering panel sides at a
45degree angle. 2) using replaceable
hardwood strips along the top edge of
the panel. 3) installing metal caps in the
form of an inverted U. 4) allowing as
S tre n g th A xi s
A
A
5
7 8 " C . to E d g e
5
7 8 " C . to C .
5
1 2 " 4 " 6 "
F I G U R E 1 8
Slotted or Drilled Sides
F I G U R E 1 9
Slotted Plywood for Fruit and Vegetable Pallet Bin Bottom
M i n i m u m re q u i re d
o p e n a re a o f slo ts
= 1 0 0 sq u a re i n ch e s
1 9 /3 2 E XTE R I O R TYP E E XT-A P A )
C -C P lu g g e d ) , B -C o r A -C ,
S TR U C TU R A L I , G R O U P 1 O R G R O U P 2 ,
P R O D U C T S TA N D A R D P S 1 -8 3
2 0
1 2 " 1 2 " 1 2 "
5 /8 " slo t wi d th i s
a lso p e rm i ssi b le
Pl a n Vi ew
4
7
4 7
large an opening as possible for forklift
entry. 5) beveling the leading edge of the
bin deck and bottom boards.
Metal protective and reinforcing edges
are advantageous when the bins will be in
constant use during each harvest season.
Impact damage from the support at the
back of the fork tines can be prevented by
attaching large panel bumpers to the front
face of the support (see Figure20).
Water Repellent and Preservative
Treatments. Treating panel bins with a
water repellent solution helps maintain a
smooth finish and makes cleaning,
maintenance and sanitizing much easier.
Water repellent treatment also helps
prevent moisture pick-up, and its conse-
quent increased weight and transportation
costs. A dip treatment with a urethane-
thinner mixture has proven both econom-
ical and effective. The proportion of ure-
thane to thinner influences the benefits
and the cost. A minimal surface film
results, but wood pores are sealed and
face checking is reduced.
30
Material To Be Handled: ______________________________
Fragile: Yes I NoI
Material Unit Weight: _________________________lb./cu.ft.
Product Unit Weight:__________________________lb./cu.ft.
Concentrated Load:________________________________lb.
Exposure In Use: InsideI Outside I
Exposure In Storage: Inside I OutsideI
Demountable:
HandlingEquipment:
I Hand pallet truck Load capacity ________________lb.
Outrigger spacing and length _____________________
I Forklift (inplant) Load capacity ________________lb.
Fork spacing and length _________________________
I Forklift (field) Load capacity ________________lb.
Fork spacing and length _________________________
Transportation Equipment:
I Truck Load capacity ________________lb.
Van size ______________________
I Rail Load capacity ________________lb.
Car size_______________________
I Other Load capacity ________________lb.
Size__________________________
Bin Size:
Max. length______ Max. width_______ Max. height________
Entry: I 2-way I Partial 4-way I Full 4-way
Stacked: No. high ______________
Special stacking requirements_________________________
________________________________________________
Stringer Restrictions:_________________________________
__________________________________________________
Bottom Deck Boards: YesI NoI
Number and Size __________________________________
Ventilation Requirements:_____________________________
__________________________________________________
Pallet Deck: Solid I Slotted I
Thickness or Span Rating____________________________
Panel grade_______________________________________
Bin Sides: Thickness or Span Rating ____________________
Panel grade_______________________________________
Special side conditions______________________________
Filling _______________________________________
Emptying ____________________________________
Doors: Type _________________ Size__________________
Bin Covers: __________________Temporary I Permanent I
Preservative:________________________________________
Water Repellent: ____________________________________
Edge Protection:_____________________________________
Use Cycle:__________________________________________
Structural Panel Pallet Bin Design Check List
F I G U R E 2 0
Panel Bumper
31
With Exterior type plywood, no preser-
vative treatment is necessary to protect
the glue bond. However, treatment
retards mold growth when handling
materials that cause continual dampness.
Only nontoxic preservatives and water
repellents should be used on foodstuffs
bins. A list of acceptable preservatives
and repellents can be obtained from the
U.S. Department of Agriculture.
Nature of the Commodity. Bins designed
to handle soft fruits or delicate vegetables
require sanded or touch-sanded
plywood. Bins to handle more durable
commodities (feed, fertilizer and grain)
can be constructed with APA Rated
Sheathing Exterior.
Bin Exposure. Agricultural pallet bins
must withstand severe exposures and
rigorous use, demanding both durable
material and sound design.
Exposure to all forms of weather,
rough field handling, frequent immersion
in water dumpers, and even steam
cleaning severely challenge any material.
Exterior type plywood bearing the APA
trademark has proven its worth under
these conditions. Specify only Exterior
type plywood in agricultural pallet bins.
DesignExample
Industrial Pallet Bin
A bin 48"x40"x48" is needed to carry
plastic beads weighing 45pounds per
cubic foot (pcf). Deck loading will be
180pounds (4ft.x45pcf) per square
foot. Three stringers (48"long) will
support the deck. This will be a two-span
application and the panels strong
orientation should be applied across the
stringer (spanS=20").
Table 12 shows that APA Rated
Sheathing bearing a Span Rating of 24/0
will support 180 pounds per square foot
(psf). If the strength axis is oriented
parallel to the stringers (48" direction),
the 24/0 Span Rated panel can carry only
40psf (180x0.22 = 40psf).
In this example, the bin sides, with
lateral restraint at the bottom and hori-
zontal ribs at the top and midheight, act
as two-span continuous beams (see
Figure21). The critical point is midway
between the bottom and middle rib, at an
approximate depth of 3feet, i.e., 1foot
from the bottom.
Assuming lateral pressure is one-half
the vertical pressure at any depth, lateral
pressure at this point will be 68psf
(1/2x45pcfx3ft.). Table12 shows that
APA Rated Sheathing bearing a Span
Rating of 24/0 will support 125psf when
loaded in this manner.
Stiffness, with the 1/4-inch deflection
limitation, is not critical for either of the
load-span conditions.
DesignExample
Agricultural Pallet Bin
A bin is needed to handle two-ton units
of bulk fertilizer weighing about 65lbs.
per cubic foot (pcf). A 4'x4'x5' bin with
ribbed framing is selected. By using three
4x4 stringers, the plywood deck will have
two spans. The pressure on the deck is
calculated as follows: 5feet of depth,
times 65pcf, or approximately 325lbs.
per square foot (psf). Table12 shows
that with span S equal to 24inches,
Rated Sheathing 48/24 plywood can
carry 390psf or that 23/32inch sanded
Group1 plywood can
carry 325psf. The tables indicate the
deflection at design load will be less than
1/4inch since these load situations are
blank on Table14. (Loads in the blank
areas of Tables13 and 14 will deflect less
than 1/4inch.)
The lateral pressure exerted by bulk
fertilizer varies with chemical compo-
sition; however, for this example, a
maximum equivalent fluid density of
23lbs. per cubic foot is assumed. The
lateral pressure at the base of the side is
calculated as follows: 5feet of depth,
times 23pcf, or about 115psf. This
pressure will diminish uniformly to 0 at
the top of the bin.
Horizontal ribs at the top, bottom and
center of the bin side give a two-span
condition. With S of 30inches, Table12
indicates Rated Sheathing 32/16 plywood
or 15/32 inch thick sanded Group1
plywood can carry 115psf safely. Table14
indicates that for the 32/16 unsanded the
deflection at design load would be greater
than 1/4inch. Because the side is fully
restrained at the base, point of maximum
pressure, the calculations are conservative.
For economy, APA Rated Sheathing
Exterior could be used. The open face
defects will not be objectionable when
handling bulk fertilizer. However, if a
smoother surface is desired for appear-
ance, or to display an advertising message,
a sanded grade of Exterior type plywood
may be used.
C ri ti ca l la te ra l p re ssu re p o i n t
l2
l2
l
F I G U R E 2 1
32
BigBin
Big Bin is an engineered plywood pallet
bin, specially designed for shipment and
handling of a wide range of products.
It consists of demountable plywood
sides, top and bottom, an aseptic plastic
liner and steel strapping. Big Bin can also
be used without the plastic liner to hold
and transport parts. A built-in pallet base
simplifies forklift handling.
A typical Big Bin has a 300-gallon,
3,000-pound capacity. Equivalent to five-
and-one-half steel drums, Big Bin
requires 3percent less space and, when
utilized to its full capacity, can be safely
stacked five high. Once the contents of
Big Bin are emptied, Big Bin folds down
to one-fourth its size for convenient
return shipping; or it can be refilled with
a different material for the return trip.
Smaller bins can be constructed for those
industrial uses not requiring a 300-gallon
or 3,000pound capacity.
Slim Bin
Like Big Bin, Slim Bin is fabricated of
APA-trademarked structural wood panels
and lined with a replaceable bag. Slim
Bins capacity is 55gallons the same as
a steel drum. But unlike steel drums, its
shape allows for easy stacking and han-
dling. With its built-in pallet base, Slim
Bin can be moved with a hand truck. Or,
four Slim Bins can be strapped together
and moved or stacked as a unit by a
forklift. Empty, the bin collapses to a
compact 32x24x4-1/2-inch bundle.
For more information on Big Bin and
Slim Bin, refer to APA Industrial Use
Guide: Big Bin and Slim Bin, Form L230.
Big Bin and Slim Bin can be used for
shipping products ranging from foods
such as fruits, vegetables, orange juice and
tomato paste to chemicals, whether
liquid, powdered or granular. Each Big Bin
uses just six structural panels. Only one
panel is needed for each Slim Bin. The
remaining materials (lumber and
hardware) also are relatively inexpensive.
Routine maintenance costs are low and
controllable because durable Exterior
wood panels can withstand permanent
exposure to weather and moisture. If bins
are protected during storage, shipment
and use, Exposure1 panels may be used.
Big Bin and Slim Bin are easy to repair
with basic carpentry tools and skills. And
replacement of the plastic liner allows the
bins to be used over and over. In fact,
depending on use, Big Bin and Slim Bin
may have a serviceable life of as much as
10 or 15 years.
For information on Big Bin and Slim
Bin fabricators, contact APA and ask for
the Big Bin Manufacturers Source List,
Form FSD60-2. For a list of liner bag
andhardware manufacturers, ask for
FormFSD60-1.
B I G B I N A N D S L I M B I N
B i g B i n S li m B i n
Sometimes pallet bins or tanks carry
liquids; plywood is ideal for this use since
it is resistant to most corrosive chemicals.
Plywood tanks are suited for metal
etching, electroplating, anodizing, litho-
graphing, engraving and other operations
that employ acids. They have also per-
formed well in metal pickling operations
(a process for cleaning metals), a wide
range of food processing applications,
paint shops and countless other uses.
Liquid Bin Fabrication
Fasteners for Liquid Bins. Plywood
should be fastened with screws, lag
screws or bolts of stainless steel.
Cadmium plated screws may be used
for liquids other than acids. Nailing is
not recommended.
Metal fasteners should be on the
outside of the tank or bin if possible. If on
the inside, the heads should be counter-
sunk and coated with a caulk which is
resistant to the liquid. Galvanized fasteners
may be used on the inside if the tank
contains only water or other mild solution.
3
33
L I Q U I D T A N K S A N D B I N S
F I G U R E 2 2
Joint Details
34
Framing Details. Attention to joint
details is important because joints in the
liquid tank or bin must be leak-proof. A
number of typical joints are illustrated in
Figure22. The one selected depends on
your requirements for the tank.
The following guidelines will help you
in designing the tank:
1. If possible, exclude exposed metal
fasteners from inside of tanks.
2. When fasteners must be driven from
the inside, countersink the heads
andcaulk.
3. For sealing exposed edges and other
leak-proofing, use materials such as
Thiokol, epoxy, neoprene, silicone,
urethane or asphalt-based sealants.
Glass fiber tape and resin can be used
for added protection.
4. For strength and leak-proofing, joints
may be glued with melamine or
resorcinol adhesives.
5. Although Figure22 shows only
outside framing joint details, inside
framing (preferably wood) can be used
to provide additional strength, or in
some cases, in lieu of outside framing.
Design Considerations
When designing liquid tanks, consider
the type and amount of liquid to be
handled and select fasteners and framing
details accordingly. Also bear in mind
that tank liners may be appropriate when
designing a bin for a particular product.
For a list of liner manufacturers, request
APAs Big Bin Source List for Bag
Manufacturers.
Chemical Resistance. Exterior-type
plywood has excellent resistance to a
wide range of chemicals, as a result of the
resistance of both the phenolic resin
glues and the wood itself.
Its strength is not significantly affected
by organic chemicals, neutral and acid
salts, or by most substances in the pH
range of 3to 10.
Interior-type plywood with exterior
glue (Exposure 1) has nearly the same
chemical resistance as Exterior plywood,
but is not recommended for long-term
exposure to water, except where some
localized separation of veneers can
betolerated.
T A B L E 1 5
Chemical Resistance of Overlays After 24 Hours of Contact
Re a g e n t Ef f e ct o n HDO Ef f e ct o n MDO
A m yl A ce ta te N N
A ce ti c A ci d 1 0 % a n d 9 9 . 5 % N N
A ce to n e N N
A m yl A lco h o l N N
B e n ze n e N N
C a lci u m H yp o ch lo ri te 3 0 % N D -re d -b ro wn
C a rb o n Te tra ch lo ri d e N N
C h lo ro fo rm N N
C re so l N N
F o rm a li n 3 7 % N N
F o rm i c A ci d 8 8 -9 0 % S , D -g re y R , S , D -ye llo w-re d
H yd ro ch lo ri c A ci d 1 0 % N S , D -ye llo w-b ro wn
H yd ro ch lo ri c A ci d 3 7 % S , R , D -p i n k S , R , D -re d -b ro wn
H yd ro g e n P e ro xi d e 3 0 % N D , ye llo w
M e th yl A lco h o l N N
M o n o ch lo ro b e n ze n e N N
N i tri c A ci d 1 % D -b ro wn D -ye llo w
N i tri c A ci d 5 % S , R , D -b ro wn S , D -ye llo w-b ro wn
N i tri c A ci d 3 0 % S , R , D -b ro wn R , S , D -ye llo w-b ro wn
N i tri c A ci d 7 0 % S -to p lywo o d , R , D -b ro wn su rfa ce g o n e ) R , S , D -o ra n g e -ye llo w
P h o sp h o ri c A ci d 8 5 % S , R R , S , D -ye llo w-re d -b ro wn
S o a p le ss D e te rg e n t D re ft) N N
S o d i u m C a rb o n a te 2 5 % D -b ro wn D -re d -b ro wn
S o d i u m C h lo ri d e 1 0 % N D -ye llo w-b ro wn
S o d i u m C h lo ri d e 2 5 % N N
S o d i u m H yd ro xi d e 1 % D -re d -b ro wn R , S , D -re d -b ro wn
S o d i u m H yd ro xi d e 3 0 % S , R , D -b ro wn R , S , D -re d -o ra n g e
S u lfu ri c A ci d 1 0 % N R , S , D -ye llo w-p u rp le
S u lfu ri c A ci d 3 5 % N R , S , D -ye llo w-p u rp le
S u lfu ri c A ci d 5 0 % D -p i n k-o ra n g e R , S , D -ye llo w-p u rp le
S u lfu ri c A ci d 7 0 % S , R , D -b ro wn R , S , D -ye llo w-p u rp le
S u lfu ri c A ci d 9 7 % S , R , D -b la ck R , S , D -ye llo w-p u rp le
Z i n c C h lo ri d e 5 0 % N D -b ro wn
N = N o E ffe ct S = S o fte n e d R = R o u g h e n e d D = D i sco lo re d
35
High Density Overlay (HDO) and
Medium Density Overlay (MDO)
plywood are more resistant to chemicals
than Exterior plywood because of the
relative impermeability of the treated
fiber overlay on both sides of the panel.
They have relatively good resistance to
most strong mineral acids and fair
resistance to solutions of strong alkalies
at normal temperatures.
Table15 gives the effects of various
chemicals to the overlaid surface of HDO
and MDO after 24hours of contact.
Exterior type, HDO and MDO ply-
wood are used regularly for acid tanks,
corrosive liquid containers, fume ducts,
and other equipment and structures
which come in contact with chemicals.
Computing Pressures. Compute
pressures exerted by liquids by multiply-
ing the density of the solution or liquid
times depth to the point in question.
Since liquids surge easily, the calcu-
lated pressure should be increased 10 to
20percent to allow for the extra stresses.
Table 16 lists allowable pressures for
plywood of various thicknesses and can
be helpful in selecting the proper
plywood for the job.
T A B L E 1 6
PS 1 Plywood Liquid Tanks
Al l o wa b l e Pr e ssur e s ( p sf ) , a n d Re sul t i n g De f l e ct i o n s ( i n ch e s) A P A B -B G ro u p 1 E XT, A P A B -C G ro u p 1 E XT,
A P A C -C P lu g g e d G ro u p 1 E XT, A P A R a te d S tu rd -I -F lo o r E XT. S tre n g th A xi s a cro ss su p p o rts. P lywo o d co n ti n u o u s o ve r 3 o r m o re sp a n s.
a )
We t co n d i ti o n s.
b )
Th i ck n e ss
Sp a n , Ce n t e r - t o - ce n t e r o f sup p o r t s ( i n ch e s)
( i n ch e s)
(c)
8 1 0 1 2 1 4 1 6 1 9 . 2 2 4
1 1 /3 2
2 1 0 1 3 5
. 0 1 . 0 2
3 /8
2 8 0 1 8 0 1 2 5
. 0 1 . 0 2 . 0 3
1 5 /3 2
4 7 5 3 0 5 2 1 0 1 5 5 1 2 0
. 0 1 . 0 1 . 0 2 . 0 3 . 0 4
1 /2
5 2 5 3 3 5 2 3 5 1 7 0 1 3 0
. 0 1 . 0 1 . 0 2 . 0 3 . 0 3
1 9 /3 2 7 0 5 4 5 0 3 1 0 2 3 0 1 7 5 1 2 0
2 0 o c) . 0 1 . 0 1 . 0 2 . 0 2 . 0 3 . 0 4
5 /8
7 5 5 4 8 5 3 3 5 2 4 5 1 9 0 1 3 0
. 0 1 . 0 1 . 0 2 . 0 2 . 0 3 . 0 4
2 3 /3 2 8 7 0 5 5 5 3 8 5 2 8 5 2 1 5 1 5 0
2 4 o c) . 0 1 . 0 1 . 0 2 . 0 2 . 0 3 . 0 4
3 /4
9 1 5 5 9 0 4 1 0 3 0 0 2 3 0 1 6 0 1 0 0
. 0 1 . 0 1 . 0 2 . 0 2 . 0 3 . 0 4 . 0 6
7 /8
1 1 1 0 7 3 5 5 1 0 3 7 5 2 8 5 2 0 0 1 3 0
. 0 1 . 0 1 . 0 2 . 0 2 . 0 3 . 0 4 . 0 5
1
1 2 0 0 9 2 0 6 6 0 4 8 5 3 7 0 2 5 5 1 6 5
. 0 1 . 0 1 . 0 2 . 0 2 . 0 2 . 0 3 . 0 5
1 -1 /8 1 3 4 0 1 0 2 5 8 1 5 5 9 5 4 5 5 3 2 0 2 0 5
4 8 o c) . 0 1 . 0 1 . 0 2 . 0 2 . 0 3 . 0 4 . 0 5
a ) F o r 1 - o r 2 -sp a n co n d i ti o n s, a llo wa b le lo a d i s 8 0 % o f th o se sh o wn .
b ) Fo r d ry co n d itio n s, a llo wa b le lo a d m a y b e in cre a se d 2 0 % . D e fle ctio n s
sh o wn in ta b le m a y b e u se d fo r in cre a se d lo a d a n d d ry co n d itio n s.
c) S p a n R a ti n g s i n p a re n th e se s a p p ly to A P A R a te d S tu rd -I -F lo o r E XT
o r sp a n -ra te d C -C P lu g g e d E XT.
36
Crates made of structural wood panels are
cost-effective in three ways, compared to
crates made of lumber. First, labor for fab-
rication can be cut by 50 to 75percent.
Second, crates made of panels are lighter: a
1,000 cubic-foot crate weighs 700 pounds
less than the same crate made of lumber.
Third, they reduce outside volume: the
same crate of 1,000 cubic foot interior
capacity is 21 cubic feet smaller than its
lumber counterpart. All three factors result
in saving money, with no sacrifice in per-
formance. Structural panel crates are
unsurpassed for resisting rough handling,
withstanding top loading and providing
cargo anchorage.
Crate Configuration
Design data for structural panel crates is
based on the individual members of the
crate structure working as an integral unit.
For example, a particular skid size
considered alone may appear too light for
the supported load. But the structural
panel crate sides, fastened securely to the
skids, form the web of a box beam.
When the crate is sling-lifted from its
ends, this beam carries the load in a
simple span. When the crate is forklifted
from its center, the beam carries the load
in a semi-cantilever.
Choosingthe Right Structural Panel
In most crating applications, 3/8-inch
panels are adequate. In applications
where crates are subjected to exception-
ally rough handling, 15/32-inch thick
panels may be necessary. Rack- resistant
panels develop their greatest strength
when held in the flat plane. If the span
exceeds two feet and the panel thickness
is 3/8 inch, panels may tend to buckle,
decreasing structural rigidity. Struts
prevent this buckling.
For spans two feet or less, use 3/8-inch
panels. For spans between 2 and 4 feet,
or crate loads exceeding 10,000 pounds,
use 15/32 inch or thicker panels.
Lumber Components
Dozens of species of dimension and
board lumber with varying performance
characteristics are available. These
species have been roughly categorized
into four groups specifically for crating
purposes, using density as an index of
strength. Group1 contains the least
dense woods, Group4 those of greatest
density. Crate fabricators generally use
either surfaced or rough lumber in one-
inch and two-inch thicknesses, and only
rough lumber when thicker than
twoinches (3x3s, 3x4s, etc.).
CratingFabrication
Figure23 illustrates four types of corner
constructions, which are compatible with
standard and demountable crates. For
three types, struts are shown inside
because most crate interiors include room
for these members. The interior location
leaves smooth, snag-free exterior surfaces
and helps minimize outside volume.
Lapped Double-Post Corners are the
recommended corner construction
system. One inset strut allows fastening
from both the end and the side, so that a
load against the withdrawal resistance of
one set of fasteners is resisted by the
shear strength of the other set of
C R A T I N G
F I G U R E 2 3
Typical Corner Constructions
Si ngl e- Post Cor ner Doubl e- Post Cor ner Outsi de Post Cor ner
S tra p
La pped Doubl e- Post Cor ner
fasteners. The ultimate strength of the
joint also depends on wood density and
fastener size, type andstiffness.
The Single-Post Corner is recommended
when only the side panel has a strut; the
end panel is simply fastened to the end
strut of the side panel. The corners
integrity depends entirely on the with-
drawal resistance of the fasteners holding
the end to the strut. It performs satisfac-
torily for limited handling and relatively
light, short-duration top loading.
The Double-Post Corner offers stronger
construction for vertical loads. The struts
at the end of both side and end panels
are jointed by lapping one over the other.
Nails pass through the panels from the
first strut into the second. Like the
single-post corner, double-post corner
fastening depends on the withdrawal
resistance of the nails. While the struc-
ture performs adequately for vertical
loads, some handling methods may
loosen the joint. The joints in both
corners may be reinforced with banding
or corner ties.
Outside-Post Corners are appropriate
where a projection-free crate interior is
necessary. Strapping must be used to
achieve maximum corner strength, since
sides and ends cannot be lapped using
this method unless an extra strut is added.
Fasteners for Crates
The structural integrity of any crate
depends on its fasteners typically lag
screws, nails, bolts or metal connectors.
Lag Screws. Lag screws are the most
popular fasteners for securing crate sides
to bases especially demountable crates.
Lag screws have excellent resistance to
direct withdrawal, high lateral resistance
and are often used where high handling
stresses are expected. Figure24 shows
proper lag screw spacing.
Wherever lag screws are used, observe
the following guidelines:
1. Drill an entry hole of the same
diameter as the shank of the lag
screw through the first member.
2. Drill a lead hole of a diameter slightly
less than the root diameter of the
threaded portion of the lag screw into
the second member. Table17 gives
lead hole diameters for common sizes
of lag screws.
3. The combined depth of the lead and
entry holes should equal the total
length of the shank and the threaded
portion of the lag screw.
4. Use a flat washer or other reinforcing
device under the head of each lag
screw.
5. Turn lag screws completely into their
holes to obtain maximum withdrawal
resistance. Never hammerdrive
lagscrews.
6. Lag screws should penetrate the
second member between seven and
ten times the shank diameter.
7. Select the lag screws diameter
according to the size of the skid or
fastening member. Use lag screws
1/4inch or 5/16inch in diameter for
small crates with two-inch thick
members; 3/8-inch lag screws for
three-inch thick members; 1/2-inch
for four-inch deep skids; and
5/8-inch and larger lag screws for six
inch and deeper skids.
37
F I G U R E 2 4
Lag Screw Spacing
M a xi m u m La g S cre w S p a ci n g
5 /1 6 la g scre ws 1 2
3 /8 la g scre ws 1 6
1 /2 a n d 5 /8 la g scre ws 2 0
T A B L E 1 7
Lag Screws
No mi n a l Fa c e Wi d t h L a g S c r e w L e a d Ho l e De p t h o f
o f Me mb e r Di a me t e r Di a me t e r P e n e t r a t i o n
( i n c h ) ( i n c h ) ( i n c h ) ( i n c h )
2
1 /4 3 /1 6 2
5 /1 6 1 /4 2
3 3 /8 1 /4 2
4 1 /2 3 /8 2 -1 /2
6 o r w i d e r
5 /8 3 /8 3
3 /4 1 /2 3 -1 /2
N o te : P e n e tra ti o n i s th e m i n i m u m d e p th e a ch la g scre w sh o u ld si n k i n to th e re ce i vi n g m e m b e r.
Th e re co m m e n d e d m i n i m u m le n g th o f la g scre w fo r a n y a p p li ca ti o n ca n b e o b ta i n e d b y a d d i n g
th e th i ckn e ss o f th e fi rst m e m b e r a n d th e d e p th o f p e n e tra ti o n .
38
T A B L E 1 8
Nail Sizes
Ty p e 4 d 6 d 8 d 1 0 d 1 2 d 1 6 d 2 0 d 3 0 d 4 0 d 5 0 d 6 0 d
L e n g t h C o mmo n o n l y
C o m m o n , b o x o r 1 -1 /2 2 2 -1 /2 3 3 -1 /4 3 -1 /2 4 4 -1 /2 5 5 -1 /2 6
d e fo rm e d sh a n k
C e m e n t co a te d 1 -3 /8 1 -7 /8 2 -3 /8 2 -7 /8 3 -1 /8 3 -1 /4 3 -3 /4 4 -1 /4 4 -3 /4 5 -3 /4
No . p e r
p o u n d
C o m m o n o r 2 9 4 1 6 7 1 0 1 6 6 6 1 4 7 2 9 2 2 1 7 1 3 1 0
d e fo rm e d sh a n k
B o x 4 5 3 2 2 5 1 3 6 9 0 6 9 5 0
C e m e n t co a te d 4 9 3 2 7 8 1 4 4 1 0 5 8 1 6 4 3 9 2 9 2 2 1 3
Nails. Crating nails are divided into three
categories: smooth, cement-coated and
deformed-shank. In general, use smooth
nails when they are to be clinched. Where
nails are not clinched, use cement-coated
or deformed-shank types because of their
greater holding power. Hot-dip galvanized
nails have withdrawal resistance equal to
cement-coated nails. Refer to Table18 for
information on nail sizes, and Figure25
for proper nail spacing.
Cement-coated nails perform well in
softwood lumber crates and are the most
common type used. However, cement-
coated nails may lose some of their holding
power in situations where crates must
endure prolonged wetting and drying.
Observe the following guidelines when
using nail fasteners.
1. Drive nails through the panels into
the framing member.
2. When nailing panels to two-inch
nominal frame members, the nail
should penetrate at least 1-1/2inches
into the framing member (i.e., a
6dnail). Where framing members are
thicker, nails should penetrate at
least 2inches.
3. Drive nails no closer to the edge of a
lumber member than one-half of its
thickness and no closer to the end
than its thickness.
4. To reduce lumber splitting, stagger or
align nails in two or more rows.
5. When nailing panels to struts or
other members, space nails no more
than three inches on center and
staggered in rows not less than
3/4inch apart.
The greater the row spacing, the
stronger the joint. When framing
members are six inches or greater in
width, use three rows of nails.
6. When two pieces of panel sheathing
are butt-jointed, position joints at the
center of a vertical or horizontal
frame member. Use the staggered
nail pattern to fasten each edge to the
framing member.
F I G U R E 2 5
Nail Spacing
3
4 "
3 "
39
Staples. Staples reduce the chance of
splitting lumber framing and may
sometimes be substituted for nails in
crate construction.
However, 25 to 100percent more
staples than nails are required to develop
equivalent strength. Due to the wide
variety of types, sizes and coatings
available, contact staple manufacturers
for suitable substitutions.
When using staples, observe the
following guidelines.
1. Use maximum length possible
andclinch.
2. Crown width should be at least
3/8inch.
3. Orient crown 45degrees to grain of
veneer-faced panels, such as
plywood.
4. When fastening, mating members
must be in contact, since staples do
not draw components together.
Bolts. Bolts are used primarily for
fastening large base members, anchoring
the contents to the base and holding
blocking in place.
Follow these guidelines when
usingbolts.
1. Use carriage or step bolts to fasten
skids to cross members.
2. Drill bolt holes 1/32inch to
1/16inch wider than the diameter of
the bolt shank and install washers
under all nuts and bolt heads.
3. Secure nuts with lock washers, lock
nuts, thread sealing compound or by
spoiling the threads.
Steel Strapping. Strapping is an extra
precaution except in sill-type and export
crates. In sill crates the frame joints are all
butted and the sill base may be subject to
inertial racking, making reinforcement
with steel strapping imperative, as shown
in Figure29, page41.
A crate destined for export may be
subjected to unusual handling condi-
tions, making it wise to reinforce crate
corners (vertical and horizontal) as
shown in Figure26.
The following guidelines will assist in
the use of steel strapping.
1. Each leg of nail-on strapping should
be a minimum of 6inches long.
2. Drive three 3d to 6dcommon nails
1-1/2inches to 2inches apart per six
inches of leg length.
3. Drive strapping nails into a frame
member.
4. Use tension straps at least 3/4-inch
wide by 0.028-inch thick for gross
loads up to 10,000pounds, and
1-1/4-inch wide by 0.025-inch thick
for gross loads over 10,000pounds.
Use corner reinforcing straps at least
3/4-inch wide by 0.028-inch thick for
gross loads up to 20,000pounds, and
1-1/2inch by 0.025inch for gross
loads exceeding 20,000pounds.
Corner reinforcing strap should
beannealed.
5. Metal strapping also provides
reinforced bearing for lag screws (see
Figure27). Such strapping should be
1-1/4inches by .035inch for
3/8inch or less diameter lag screws,
and a minimum of 2inches by
0.050inch for 1/2inch and larger
diameter lag screws.
Panel Wirebound Crates. Wirebound
containers, manufactured as four-sided
panel mats and quickly assembled
around a base when needed, are
spreading into new industries for two
reasons ease of loading and reusability.
The number of reuses depends upon
the abuse the containers building
materials can withstand. Wirebound
containers, constructed of strong, rigid
and impact resistant structural panels, far
outlast conventional units.
3
6
"
3 6 "
F I G U R E 2 6
Crate Strapping
F I G U R E 2 7
Steel Strap Reinforcing for Lag Screws
Te n si o n stra p s D o u b le se a l N a i l to fra m e
m e m b e rs
A n ch o r
p la te
C o rn e r stra p
6 - 8 m i n i m u m
p e r le g typ i ca l)
P a n e l sh e a th i n g
S tru t
Lo we r fra m e
m e m b e r
C li n ch n a i ls wi th
3 /8 m i n i m u m cli n ch
La g scre w stra p , a n n e a le d
La g scre w h o le s
40
CratingDesign
As in any structure, satisfactory crate
performance demands good workman-
ship. All joints should be square and
fasteners should be properly installed.
Panel edges should always be centered
over a framing member and spaced
1/4inch apart. Since vertical struts are
recommended on two-foot centers,
centering should occur normally for
standard 4x8-foot panels. Where it does
not, an extra member should be added
or the position of a regular member
shifted to compensate.
Ventilation. Since crates may be
subjected to various climactic conditions,
ventilation design must take into account
crate contents, destination and transit
time. Structural panel crates are
weathertight, but heat and humidity can
cause interior condensation.
Drainage holes in the crate floor will
provide limited ventilation, but where
excessive heat and humidity are
expected, additional ventilation is
necessary. Drill holes through the panel
ends near the top, avoiding any of the
frame members. These holes should be
no more than 1-1/2inches in diameter,
nor spaced more than three holes per
two linear feet of crate length and width.
Limiting the holes to a maximum of
1-1/2inches in diameter keeps contents
relatively dry except from wind-driven
water encountered on the deck of ship,
flatbed truck or railroad flatcar.
When protection against rain, spray or
sea water is critical, a plastic shroud over
the crate or contents is usually adequate.
This should be fastened securely, but
only as a cover. The bottom of the shroud
should be loose for air circulation.
Demountable Crates. Crates are generally
designed for one-time use. However,
when they must be demountable, use
screws, lag screws and bolts to fasten the
sides, ends, top and base together. There
are also several removable and
replaceable patented fasteners available.
The Base. Crate design begins with the
base, which performs several crucial
functions. It forms the foundation for the
crate and anchors the contents. In
combination with the side structures, it
supports the weight of the contents
during handling.
Product weight, shape and expected
handling methods must be fully consid-
ered in designing the crate base.
The weight of the contents and their
distribution govern the strength require-
ments of the base. For example, a machine
lathe supported at each end requires a
stronger base than a product with the
F I G U R E 2 8
Skid-Type
1 /4 sp a ce b e twe e n p a n e ls
D ra i n a g e h o le s
E n d h e a d e r Ta b le 1 9 )
P a n e l flo o ri n g
F o rkli ft h e a d e rs Ta b le 1 9 )
B o lt th ro u g h ski d
R u b b i n g stri p Ta b le 1 9 )
S ki d Ta b le 1 9 )
Lo a d -b e a ri n g m e m b e rs Ta b le 2 0 )
F o u r-ski d d e si g n s p ro vi d e
b e tte r sta b i li ty wh e n h a n d le d
fro m th e si d e b y fo rk tru ck
wi th fo rks le ss th a n fu ll wi d th .
S e t b a ck h e a d e r
th i ckn e ss o f lo we r
fra m e m e m b e r
41
same weight distributed evenly along the
entire length particularly when forklift
handling is involved, as it usually is.
A second base design consideration is
support requirements for the contents. A
machine lathe may need no special
support. But a long cylindrical shape,
such as a military rocket, may require
support at several points.
Electronic components often demand
considerable cushioning.
Two types of bases dominate crate
design: the skid-type and the sill-type
(see Figures 28 and 29).
Both base types require rub strips on
the bottom. These should always be
beveled because they serve as slide surfaces
for skidding. They also raise crates enough
for forklift tine and sling clearance.
The panel floor in both base types serves
two functions. It protects the product and,
more importantly, gives rigidity to the base
structure to help keep it square and true
under all but destructive handling
conditions. If the crate superstructure is
not weatherproof, or if condensation is
anticipated, drainage holes should be
drilled through the panel floor.
1. Skid-Type. The skid-type is more
common because it is easier to fabricate
and accommodates a wider range
of products.
The skid-type crate base consists of two
or more parallel longitudinal members, a
panel floor across the longitudinals, load-
bearing cross members, and rub strips.
The rub strips permit forklifting from the
side. For forklifting from the end,
additional cross members must be added
20inches and 40inches from each end to
transfer the load to the forklift times.
Table 19 lists longitudinal skid sizes
for various total loads and container
lengths. Two skids are used on crates up
to 42inches wide, three from 42inches
to 84inches wide, four when the crate is
wider than 84inches. The table also
shows minimum rub strip sizes and
minimum diameters for bolts fastening
rub strips to longitudinal skids.
A 2,000-pound load, 20feet long and
four feet wide, for instance, requires
three 3x3 skids and 2x4 rub strips held
together with 3/8-inch bolts.
Determine the size of load-bearing
cross members from Table20. Several
small members may perform better than
a few large ones, since larger members
generally increase crate volume. This
example assumes the load is fairly evenly
distributed along its length.
Standard practice is to use at least
three load-bearing cross members where
possible. With this minimum a
2,000-pound product would load each
member with 667pounds. Table20
shows that a four-foot wide crate with a
667-pound member load requires 4x4
cross members.
F I G U R E 2 9
Sill-Type
Lo a d -b e a ri n g m e m b e r
I n te rm e d i a te si ll Ta b le 2 0 )
S i d e si ll Ta b le 2 1 )
B o tto m p a n e l sh e a th i n g
D ra i n a g e h o le s
M e ta l stra p p i n g
R u b b i n g stri p Ta b le 1 9 )
E n d si ll Ta b le 2 0 )
42
T A B L E 1 9
Minimum Size of Forklift Supports, Skids and Rub Strips
Ma xi mum Ma xi mum Le ngt h Mi ni mum Si ze Mi ni mum Si ze Mi ni mum Si ze Bol t
Ne t Loa d of Cont a i ne r For k l i f t Suppor t of Sk i d of Rub St r i p Di a me t e r
( l b. ) ( f t . ) ( i n. ) ( i n. ) ( i n. ) ( i n. )
3 0 0 1 6 2 x4 2 x4 o n fla t) 2 x3 3 /8
1 , 0 0 0 1 2 2 x4 2 x4 o n fla t) 2 x4 3 /8
2 , 0 0 0 2 0 3 x3 3 x3 2 x4 3 /8
1 0 , 0 0 0 4 8 4 x4 4 x4 2 x4 1 /2
3 0 , 0 0 0 3 2 4 x4 4 x6 o n e d g e ) 2 x4 1 /2
Since crate volume is important,
always determine how many 2x4s laid
flat are required to carry the load. This
can be done with Table20 by following
the four foot line up to the 2x4 area and
then reading across to the left at the
highest load in the area 200pounds.
2,000pounds divided by 200 requires
ten 2x4s.
Since increased wood weight and more
members to handle nullifies volume
savings, three 4x4s are the logical choice.
As previously discussed, the crate floor
should be 3/8-inch APA Rated Sheathing
Exposure1. It should be applied on top of
the skids and under the cross members.
2. Sill-Type. The sill-type crate base is
generally used for items that project below
their support points, such as truck rear
axle assemblies or gasoline engines.
Sometimes blocking on a skid-type base
can achieve the same result.
Sill foundation members capable of
supporting the load may not be deep
enough to accommodate the shape
below the support points. This problem
can be solved with sufficiently deep
members, or with blocking on top of the
sill to raise the product.
For example, assume the same crate
width, length and load as used for the
skid-type example that is, a 2,000pound
load 20feet long and four feet wide
but add the requirement that the load
projects seven inches below the plane of
the supports.
First, determine the size of the side, or
longitudinal, sills. Table21 shows that a
20-foot-long product weighing
2,000pounds requires a 2x6 side sill.
Obviously this is not deep enough to
meet the seven-inch requirement, so
either a 2x8 member should be used or
the load should be blocked up two
inches. As noted in the table, 2x8s should
also be used for the end members. The
depth of intermediate sill members is also
determined by the side members. The
placement of these intermediate members,
whether crosswise or longitudinally, is
governed by the needs of the product.
Here again, the panel floor specifi-
cation is 3/8-inch APA Rated Sheathing
Exposure1. The panel should be
installed on top of the rub strips and
under the sill members.
Sides and Ends. Crate sides and ends
perform an important structural function
besides covering the contents.
Designing crate sides is relatively
simple with the following tables and
step-by-step instructions.
When the sides are securely fastened to
the base the complete unit becomes a
built-up structural beam that helps
support the weight of the product during
handling. In forklift handling, it may sup-
port the weight in a cantilevered condition.
In sling lifting from the ends, the weight
may be carried over asimple span. Also,
the beam formed by the base (flange) and
the sides (web) adds structural rigidity and
improves content protection.
Assembly requirements govern
placement of side framing members. The
bottom member, for instance, should be
sufficiently raised from the bottom edge
of the panel side to achieve the desired
overlap of the base. End struts may or
may not be inset, depending on corner
construction. Top member placement
varies according to the joint required
between the top and sides, which varies
with the weights and loads anticipated
during shipping and storage.
43
1
x
4

1
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
1 0 0
9 0
2 0 0
3 0 0
4 0 0
5 0 0
6 0 0
7 0 0
8 0 0
1 0 0 0
9 0 0
2 0 0 0
3 0 0 0
4 0 0 0
5 0 0 0
6 0 0 0
7 0 0 0
8 0 0 0
1 0 0 0 0
9 0 0 0
1 . 5 2 2 . 5 3 3 . 5 4 5 6 7 8 9 1 0
1
x
6

1
x
8

1
x
1
0

1
x
4
/
o
r 2
x
4

2
x
6

1
x
6
/
o
r 2
x
4

2
x
1
2

2
x
6
/
o
r 4
x
4

4
x
6

2
x
8
/
4
x
6
/
2
x
1
0
/
6
x
6

2
x
1
2
/
4
x
1
2
/
T A B L E 2 0
Load Bearing Cross Member and Intermediate Sill Sizes* Member Flat /Member on Edge
L
o
a
d

l
b
.
Cr a te wi dth- di sta nce between outsi de sk i ds or si de si l l s f t.
* G ro u p 2 wo o d s D o u g la s-fi r, so u th e rn ye llo w p i n e ) . F o r G ro u p 1 wo o d s sp ru ce -p i n e -fi r, ye llo w p o p la r , re d u ce a llo wa b le lo a d s b y 1 0 % . F o r G ro u p
3 o r 4 wo o d s o a k, swe e tg u m ) , i n cre a se a llo wa b le lo a d s b y 1 0 % .
44
Lower and Upper Frame and Strut
Members. Use Tables22, 23 and 24 to
determine framing member sizes for crate
sides and ends. Each of the five graphs in
the tables applies to a specific crate height.
Choose the proper height graph, then
read crate weight and length along the
graph axes to determine member sizes.
All members on a given panel should be
the same thickness. To achieve that
uniformity, 2x4s may be substituted for
the 1x6s shown in these tables.
Refer to Figures30, 31 and 32 for
illustrations of lower frame members,
upper frame members and strut
members, respectively.
The text in the upper left corner of
Tables22, 23 and 24 gives the procedure
for selecting the lower and upper frame
and strut members (2feet on center) for
the crate described in the example below.
If this step-by-step procedure is observed,
use of the tables will be simplified.
Example:
Determine the framing member sizes
for crate sides and ends where the
product weighs 6,000 pounds, and
requires a crate 18' long, 5' high, and
4' wide.
T A B L E 2 1
Side Sill Sizes
Gr o ss We i g h t
No mi n a l Si ze o f Si d e Si l l s o r Fr a mi n g Me mb e r s ( i n . )
o f
Co n t a i n e r
Le n g t h o f Co n t a i n e r ( f t . )
( l b . )
4 8 1 2 1 6 2 0 2 4 2 8 3 2
U p to 1 , 0 0 0 1 x4 1 x4 1 x4 1 x4 2 x4 2 x4 2 x4 2 x4
1 , 0 0 0 - 2 , 0 0 0 2 x4 2 x4 2 x4 2 x4 2 x4 2 x6 2 x6 2 x6
2 , 0 0 0 - 4 , 0 0 0 2 x4 2 x4 2 x4 2 x4 2 x6 2 x6 2 x6 2 x8
4 , 0 0 0 - 6 , 0 0 0 2 x4 2 x4 2 x4 2 x6 2 x6 2 x6 2 x8 2 x8
6 , 0 0 0 - 8 , 0 0 0 2 x4 2 x4 2 x6 2 x6 2 x6 2 x8 2 x8 2 x8
8 , 0 0 0 -1 0 , 0 0 0 2 x4 2 x6 2 x6 2 x6 2 x8 2 x8 2 x8 2 x1 0
1 0 , 0 0 0 -1 2 , 0 0 0 2 x4 2 x6 2 x6 2 x8 2 x8 2 x8 2 x1 0 2 x1 0
1 2 , 0 0 0 -1 4 , 0 0 0 2 x4 2 x6 2 x8 2 x8 2 x8 2 x1 0 2 x1 0 2 x1 0
1 4 , 0 0 0 -1 6 , 0 0 0 2 x4 2 x8 2 x8 2 x8 2 x1 0 2 x1 0 2 x1 0 2 -2 x8
1 6 , 0 0 0 -1 8 , 0 0 0 2 x4 2 x8 2 x8 2 x1 0 2 x1 0 2 x1 0 2 -2 x8 2 -2 x8
1 8 , 0 0 0 -2 0 , 0 0 0 2 x4 2 x8 2 x1 0 2 x1 0 2 x1 0 2 -2 x8 2 -2 x8 2 -2 x8
N o te : M e m b e r si ze s g i ve n a re fo r co n ta i n e rs m o re th a n 3 6 h i g h . F o r co n ta i n e rs le ss th a n 3 6 h i g h se le ct lu m b e r fra m i n g o n e si ze wi d e r th a n th a t
i n d i ca te d .
2 x 4 1 x 4
2 x 6
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
2 x 6 2 x 8
2 x 4
1 x 4
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
2 x 4
* 1 x 4
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
2 x 4
1 x 4
1 2 4 6 8 1 0 1 5 2 0 2 5 3 0
2 x 4
1 x 4
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
Determine the lower frame member first.
Since the crate is 5' high, use the 6' high
graph. Next find the weight
(6,000pounds) on the scale across the
bottom, then the crate length (18') on
the scale up the center of the table. Since
the vertical and horizontal lines from
these points intersect in the 1x4area,
that is the size of the lower member.
45
F I G U R E 3 0
Lower Frame Members
T A B L E 2 2
Lower Frame Member Sizes
Wei ght i n 1000 l b. uni ts Length (f t)
F o r 1 0 a n d 1 2 h i g h cra te s: * Wh e n cra te i s
8 o r wi d e r u se 2 x4 s. * * Wh e n cra te i s 1 0
wi d e u se 2 x4 s.
4 H i g h
6 H i g h
1 0 H i g h
8 H i g h
1 2 H i g h
46
F I G U R E 3 1
Upper Frame Members
The upper frame members of the crate are
found by the same process, i.e., finding the
crate weight on the scale across the bottom
and the length on the center scale. Again,
the lines cross in the 1x4 area for the size
of the upper frame member.
T A B L E 2 3
Upper Frame Member Sizes
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
2 x 4
1 x 4
1 x 6
2 x 6
2 x 8
2 x1 0
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
2 x 4
1 x 4
2 x 6
2 x 8
2 x1 0
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
2 x 4
* * 1 x 4
2 x 6
2 x 8
1 2 4 6 8 1 0 1 5 2 0 2 5 3 0
2 x 4
* 1 x 4
2 x 6
2 x 8
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
1 x 4
2 x 6
2 x 8
2 x1 0
1 x 6
2 x 4
2 x1 2
wi d e u se 2 x4 s.
4 H i g h
6 H i g h
1 0 H i g h
8 H i g h
1 2 H i g h
F I G U R E 3 2
Strut Members
Use the same procedure to find the strut
size. Plot the weight (6,000 pounds) and
the length (18') on the 6' high graph: it
shows that 1x4s may also be used for the
struts. Note that the values are based on
struts 2' on center.
Using the same crate dimensions, but
increasing the product weight to 10,000
pounds would provide the following
side-frame member sizes: lower frame
members, 2x4; upper frame members,
2x4; struts, 2x4.
47
T A B L E 2 4
Strut Sizes
2 x 4
1 x 4
2 x 6
2 x 8
2 x 6
1 x 4
2 x 6 2 x 8
1 x 6
2 x 4
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
2 x 4
1 x 4
2 x 6
2 x8
2 x1 0
2 x 6
2 x1 0
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
2 x 4
1 x 4
2 x 6
2 x 8
1 x 6
2 x1 0
2 x 6
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
1 2 4 6 8 1 0 1 5 2 0 2 5 3 0
2 x 4
1 x 4
2 x 6
2 x 6
2 x 8
2 x1 0
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
6
8
1 0
1 2
1 6
2 0
2 4
2 8
3 2
wi d e u se 2 x4 s.
4 H i g h
6 H i g h
1 0 H i g h
8 H i g h
1 2 H i g h
48
Top Members. The top joist members of
a crate serve two functions. They frame
the roof, which protects the contents,
and they also support any top loading
(see Figure33). Since the amount and
type of top loading cannot usually be
anticipated, crate designers generally
recognize a uniformly distributed
maximum top load of 50pounds per
square foot. Some applications, however,
may require higher load criteria.
Table25 presents joist sizes for various
crate widths. For the four-foot-wide
example crate, the table calls for 2x6s
flat. Note that values are based on top
joists two feet on center.
Like the crate floor, sides and ends,
top panels should be 3/8-inch APA Rated
Sheathing Exposure1. Where extensive
pilferage is expected, however, many
shippers prefer 15/32inch or thicker
panels for crate tops. Since most pilferage
occurs through crate tops, thicker panels
reduce losses.
Grabhook Reinforcing Joists. Where
lifting by the top with grabhooks is
anticipated, crates must be designed to
resist compression. Check whether grab-
hook lifting points coincide with top joists;
if so, no extra support is required. If not,
specify extra supports where necessary.
The size of reinforcing members can be
computed from Table26. A 2,000-pound
load, for instance, requires 2x4s across
the top of the crate between the grab-
hook lifting points. These lifting points
should always be marked on the outside
of the crate.
F I G U R E 3 3
Top Members
T A B L E 2 5
Top Joist Sizes
U n i fo rm ly D i stri b u te d To p Lo a d o f 5 0 lb . p e r sq . ft. J o i sts 2 fe e t o n ce n te r.
Gr o up 1 Sp e ci e s Gr o up 2 Sp e ci e s
S p a n ( i n . ) J o i s t S i z e ( i n . ) S p a n ( i n . ) J o i s t Si z e ( i n . )
1 2 - 4 2 2 x4 F la t 1 2 - 5 4 2 x4 F la t
4 2 - 5 0 2 x6 F la t 5 4 - 6 6 2 x6 F la t
5 0 - 6 0 2 x4 E d g e 6 6 - 8 0 2 x4 E d g e
6 0 - 6 6 3 x4 F la t 8 0 - 8 8 3 x4 F la t
6 6 - 7 8 3 x4 E d g e 8 8 - 1 0 2 3 x4 E d g e
7 8 - 9 0 4 x4 F la t 1 0 2 - 1 2 0 4 x4 F la t
9 0 -1 0 2 4 x6 F la t 1 0 2 - 1 2 0 4 x6 E d g e
T A B L E 2 6
Size of Grabhook Reinforcing Joists
Gr o ss Lo a d s
Sp a n ( up t o ) J o i st Si ze
( i n . ) ( l b . ) ( i n . )
7 2 1 , 0 0 0 2 x4
6 0 2 , 0 0 0 2 x4
4 8 3 , 0 0 0 2 x4
3 6 5 , 0 0 0 2 x4
9 6 1 0 , 0 0 0 4 x4
7 2 1 5 , 0 0 0 4 x4
6 0 2 2 , 0 0 0 4 x4
49
Shelving constitutes a key element of
most modern materials handling systems
because it offers the simplest, most
economical way to efficiently organize,
store, retrieve and display goods. The
advantages of structural wood panels
make them ideal shelving materials for
many situations. They are also one of the
most economical shelving materials
because the grade and thickness can be
selected to match the particular
application. In situations where the load
will be heavier, thicker panels can be
chosen. Lighter load situations wont
require as much support, so less
expensive, thinner panels can be selected.
ShelvingFabrication
Cutting. When hand sawing, use a saw
with 10to 15points to the inch. A
combination or fine-toothed blade
without much set is recommended for
power sawing. Use a sharp saw and
remember that planning and layout can
minimize waste.
Edge Treatments. In most industrial
applications, no special edge treatment is
required for structural panel shelving.
However, for appearance, or uses where
panel edges may need protection from
careless loading procedures, edges may
be chamfered or protected with stock
wood half-round or standard metal or
plastic edge strippings.
Finishing. Because structural panels are
real wood, they will accept any standard
wood finish if the surface is clean and the
manufacturers directions are followed.
For durability on frequently cleaned
surfaces, use washable enamels or high
density overlaid (HDO) plywood.
In situations where panel shelves may
be exposed to unusual edge damage or
abrasive wear on their surfaces, they can
be economically covered with
expendable hardboard, thin sheet metal
or other protective surfacing.
ShelvingDesign
The tables on the following pages show
shelf loads based on allowable stresses,
and calculated deflections at those loads.
Specific tables include single- and
multiple-span shelves.
A typical entry in the tables shows two
numbers. The left-hand number is the
maximum load on the shelf in pounds
per square feet. The right-hand number
is the calculated deflection at that load.
If shelving has no deflection limitations,
ignore the right-hand number. In some
cases, however, deflection may be limited
to some arbitrary amount. A deflection of
1/180th of the span is a common crite-
rion, so these values have been listed in
the second column of each table. If a
deflection criterion is applied to the shelf
design, and calculated deflection exceeds
the allowable deflection, then the load
must be reduced proportionately.
S H E L V I N G
50
Tables 27 and 28 are based on Group1
sanded plywood grades such as B-D
Exposure1, B-C Exterior, A-D Exposure
1, A-C Exterior, and APA Rated Sturd-I-
Floor, or APA Underlayment, Group1.
For other species groups, the allowable
loads can be adjusted by the factors
shown in Table 31 on page 53.
Tables29 and 30 apply to unsanded
panels, such as APA Rated Sheathing.
In most cases, panels should be applied
with strength axis across supports. Some-
times, however, it may be necessary to
place the strength axisparallel to
supports. Adjustment factors for this
orientation are shown below the table.
F I G U R E 3 3
Typical Shelf Support Systems
Wo o d su p p o rt
Le d g e r
P a te n te d
ste e l su p p o rt
A n g le
su p p o rt
H o ri zo n ta l
p i p e su p p o rts
P a te n te d
p i p e co rn e r
M e ta l sh e lf
o r ra ck b e a m
T A B L E 2 7
Group 1 Sanded Plywood and Sturd-I-Floor Strong Axis Across Supports Single Span
Maximum Shelf Loads (psf)*
Th i ck n e ss
Sp a n ( i n ch e s) 1 2 1 6 2 0 2 4 3 2 3 6 4 0 4 8 6 0
( i n ch e s) /1 8 0 ( i n . ) 0 . 0 6 7 0 . 0 8 9 0 . 1 0 7 0 . 1 3 3 0 . 1 7 8 0 . 2 0 0 0 . 2 2 2 0 . 2 6 7 0 . 3 3 3
1 1 /3 2 lo a d p sf) 1 5 5 8 0 5 5 3 5 2 0
d e fl. i n . ) . 0 4 . 0 8 . 1 2 . 2 0 . 3 9
3 /8 lo a d p sf) 2 0 5 1 1 0 7 5 4 5 2 5 2 0
d e fl. i n . ) . 0 4 . 0 7 . 1 1 . 1 9 . 3 7 . 4 8
1 5 /3 2 lo a d p sf) 3 5 5 1 8 5 1 2 5 7 5 4 0 3 5 2 5 2 0
d e fl. i n . ) . 0 3 . 0 5 . 0 8 . 1 4 . 2 6 . 3 4 . 4 3 . 5 8
1 /2 1 6 o c) lo a d p sf) 3 9 0 2 0 5 1 3 5 8 5 4 5 3 5 3 0 2 0
d e fl. i n . ) . 0 3 . 0 5 . 0 8 . 1 3 . 2 5 . 3 2 . 4 0 . 5 5
5 /8 lo a d p sf) 5 6 0 2 9 5 1 9 5 1 2 0 6 5 5 0 4 0 3 0 2 0
d e fl. i n . ) . 0 2 . 0 5 . 0 7 . 1 1 . 2 2 . 2 8 . 3 5 . 4 7 . 6 9
2 3 /3 2 2 4 o c) lo a d p sf) 6 4 5 3 3 5 2 2 5 1 4 0 7 5 6 0 5 0 3 5 2 0
d e fl. i n . ) . 0 2 . 0 4 . 0 6 . 1 0 . 1 9 . 2 5 . 3 1 . 4 2 . 6 1
3 /4 lo a d p sf) 6 8 0 3 5 5 2 4 0 1 5 0 8 0 6 5 5 0 4 0 2 5
d e fl. i n . ) . 0 2 . 0 4 . 0 6 . 0 9 . 1 7 . 2 2 . 2 8 . 3 8 . 5 5
7 /8 lo a d p sf) 8 5 0 4 4 5 3 0 0 8 1 5 1 0 0 8 0 6 5 4 5 3 0
d e fl. i n . ) . 0 2 . 0 4 . 0 5 . 0 9 . 1 6 . 2 0 . 2 5 . 3 4 . 4 9
1 3 2 o c) lo a d p sf) 1 0 4 5 5 5 0 3 7 0 2 3 0 1 2 5 9 5 8 0 6 0 3 5
d e fl. i n . ) . 0 3 . 0 5 . 0 6 . 1 0 . 1 8 . 2 3 . 2 9 . 3 8 . 5 5
1 -1 /8 4 8 o c) lo a d p sf) 1 3 5 5 7 1 0 4 7 5 2 9 5 1 6 0 1 2 5 1 0 0 7 5 4 5
d e fl. i n . ) . 0 2 . 0 4 . 0 5 . 0 8 . 1 3 . 1 7 . 2 1 . 2 8 . 4 0
* Lo a d va lu e s i n sh a d e d a re a ca u se d e fle cti o n g re a te r th a n /1 8 0 . Le ss d e fle cti o n m a y b e a ch i e ve d b y u si n g a sm a lle r lo a d .
51
Design Example
Single Span
In this example, sanded plywood is to be
used on a 24" single span. The design
load is 65psf and deflection must be
limited to 0.133".
Assuming face grain across supports,
Table27 indicates 15/32" plywood to
have 75psf allowable load and 0.14"
deflection. This will be suitable from
astrength standpoint, but the allowable
0.133" deflection limit may be exceeded.
Check the deflection for a 65psf load:
Deflection =
65psf
x 0.14" = 0.12"
75psf
0.12" < 0.133" ok
Use 15/32" sanded Group 1 plywood,
with face grain perpendicular to
supports.
S
p
a
n
S i n g le sp a n
EXPOSURE 1
B-D GROUP 2
000
PS 1-95
THE ENGINEERED
WOOD ASSOCIATION
APA
RATED STURD-I-FLOOR
EXPOSURE 1
THE ENGINEERED
WOOD ASSOCIATION
APA
1-1/8 INCH
48oc
SIZED FOR SPACING
000
PS 1-95 UNDERLAYMENT
PRP-108
T&G
N o te A : I f th e stre n g th a xi s o f th e p a n e l i s p la ce d p a ra lle l to th e
su p p o rts th i s sh o u ld n e ve r b e d o n e u n le ss so sp e ci fi e d ) th e lo a d va lu e s
b e lo w m u st b e m o d i fi e d b y th e fo llo wi n g p e rce n ta g e s:
1 5 /3 2 " Th i ckn e ss . . . . . . . . . . . . . . 3 1 % o f ta b le va lu e
1 /2 " Th i ckn e ss . . . . . . . . . . . . . . . . . . 3 7 % o f ta b le va lu e
1 " Th i ckn e ss . . . . . . . . . . . . . . . . . . . . . 6 6 % o f ta b le va lu e
1 -1 /8 " Th i ckn e ss. . . . . . . . . . . . . . . 6 0 % o f ta b le va lu e
Th i n n e r p a n e ls a re n o t su i te d to th i s o ri e n ta ti o n .
N o te B : S p a n R a ti n g s i n p a re n th e si s a p p ly to A P A R a te d S tu rd -I -F lo o r.
52
T A B L E 2 8
Group 1 Sanded Plywood and Sturd-I-Floor Strong Axis Across Support Multiple Spans
Th i ck n e ss
Sp a n ( i n ch e s) 1 2 1 6 2 0 2 4 3 2 3 6 4 0 4 8 6 0
( i n ch e s) /1 8 0 ( i n . ) 0 . 0 6 7 0 . 0 8 9 0 . 1 0 7 0 . 1 3 3 0 . 1 7 8 0 . 2 0 0 0 . 2 2 2 0 . 2 6 7 0 . 3 3 3
1 1 /3 2 lo a d p sf) 1 4 5 8 5 5 5 3 5 2 0
d e fl. i n . ) . 0 4 . 0 7 . 1 0 . 1 6 . 2 9
3 /8 lo a d p sf) 2 0 0 1 1 0 7 5 5 0 3 0 2 0
d e fl. i n . ) . 0 3 . 0 6 . 0 9 . 1 5 . 2 7 . 2 2
1 5 /3 2 lo a d p sf) 3 4 0 1 9 0 1 3 0 8 5 5 0 3 0 2 5
d e fl. i n . ) . 0 3 . 0 5 . 0 7 . 1 1 . 1 9 . 1 6 . 2 0
1 /2 1 6 o c) lo a d p sf) 3 7 5 2 1 0 1 4 5 9 5 5 0 3 5 2 5 2 0
d e fl. i n . ) . 0 3 . 0 4 . 0 6 . 1 0 . 1 8 . 1 6 . 1 9 . 2 5
1 9 /3 2 2 0 o c) lo a d p sf) 4 6 0 2 6 0 1 8 0 1 1 5 6 5 4 0 3 5 2 5
d e fl. i n . ) . 0 2 . 0 4 . 0 6 . 0 9 . 1 6 . 1 3 . 1 7 . 2 1
5 /8 lo a d p sf) 5 3 5 3 0 0 2 1 0 1 3 5 7 5 5 0 4 0 2 5
d e fl. i n . ) . 0 3 . 0 4 . 0 6 . 0 9 . 1 6 . 1 3 . 1 6 . 2 0
2 3 /3 2 2 4 o c) lo a d p sf) 6 1 5 3 4 5 2 4 0 1 5 5 8 5 5 5 4 5 3 0 2 0
d e fl. i n . ) . 0 3 . 0 4 . 0 6 . 0 8 . 1 5 . 1 2 . 1 5 . 1 8 . 3 0
3 /4 lo a d p sf) 6 5 0 3 6 5 2 5 5 1 6 5 9 0 6 0 4 5 3 5 2 0
d e fl. i n . ) . 0 2 . 0 4 . 0 5 . 0 8 . 1 3 . 1 1 . 1 3 . 1 7 . 2 7
7 /8 lo a d p sf) 8 1 5 4 6 0 3 2 0 2 0 5 1 1 5 7 0 6 0 4 0 2 5
d e fl. i n . ) . 0 2 . 0 4 . 0 5 . 0 7 . 1 2 . 1 0 . 1 2 . 1 5 . 2 4
1 3 2 o c) lo a d p sf) 8 7 5 5 6 5 3 9 0 2 5 0 1 4 0 9 0 7 0 5 0 3 0
d e fl. i n . ) . 0 3 . 0 5 . 0 6 . 0 9 . 1 4 . 1 1 . 1 4 . 1 7 . 2 7
1 -1 /8 4 8 o c) lo a d p sf) 1 1 4 5 7 3 0 5 0 5 3 2 5 1 8 0 1 1 5 9 5 6 5 4 0
d e fl. i n . ) . 0 2 . 0 4 . 0 5 . 0 7 . 1 1 . 0 9 . 1 0 . 1 3 . 2 0
Design Example
Multiple Span
Find the recommended uniform load for
a 32"x48" Rated Sheathing 48/24. The
strength axis is parallel to the 48-inch
dimension and deflection is limited to
1/180 of the 48-inch dimension or
0.267inch.
For a 48-inch span and strength axis
across supports, Table29 shows 45psf
load and 0.38-inch deflection.
Uniform load =
.267
x 45 = 32 psf
.38
S
p
a
n
S
p
a
n
M u lti p le sp a n
T A B L E 3 0
Unsanded Panels (APA Rated Sheathing) Strong Axis Across Supports Multiple Spans
Sp a n
Ra t i n g / Sp a n ( i n ch e s) 1 2 1 6 2 0 2 4 3 2 3 6 4 0 4 8 6 0
Th i ck n e ss
( i n ch e s) /1 8 0 ( i n . ) 0 . 0 6 7 0 . 0 8 9 0 . 1 0 7 0 . 1 3 3 0 . 1 7 8 0 . 2 0 0 0 . 2 2 2 0 . 2 6 7 0 . 3 3 3
2 4 /0 , 3 /8 lo a d p sf) 2 4 0 1 3 5 9 5 6 0 3 5 2 0
d e fl. i n . ) . 0 3 . 0 6 . 0 9 . 1 5 . 2 7 . 2 2
2 4 /1 6 , 7 /1 6 lo a d p sf) 3 0 5 1 7 5 1 2 0 7 5 4 5 2 5 2 0
d e fl. i n . ) . 0 4 . 0 6 . 0 9 . 1 5 . 2 7 . 2 2 . 2 7
3 2 /1 6 , 1 5 /3 2 lo a d p sf) 3 3 5 1 9 0 1 3 0 8 5 4 5 3 0 2 5
d e fl. i n . ) . 0 3 . 0 5 . 0 7 . 1 1 . 2 0 . 1 6 . 2 0
4 0 /2 0 , 1 9 /3 2 lo a d p sf) 5 2 5 3 3 5 2 3 5 1 5 0 8 5 5 5 4 5 3 0 2 0
d e fl. i n . ) . 0 8 . 0 5 . 0 7 . 1 1 . 1 9 . 1 6 . 1 9 . 2 4 . 3 9
4 8 /2 4 , 2 3 /3 2 lo a d p sf) 6 8 0 4 2 0 2 9 0 1 8 5 1 0 5 6 5 5 5 3 5 2 5
d e fl. i n . ) . 0 2 . 0 4 . 0 5 . 0 8 . 1 3 . 1 1 . 1 3 . 1 7 . 2 7
53
T A B L E 2 9
Unsanded Panels (APA Rated Sheathing) Strong Axis Across Supports Single Span
Sp a n
Ra t i n g / Sp a n ( i n ch e s) 1 2 1 6 2 0 2 4 3 2 3 6 4 0 4 8 6 0
Th i ck n e ss
( i n ch e s) /1 8 0 ( i n . ) 0 . 0 6 7 0 . 0 8 9 0 . 1 0 7 0 . 1 3 3 0 . 1 7 8 0 . 2 0 0 0 . 2 2 2 0 . 2 6 7 0 . 3 3 3
2 4 /0 , 3 /8 lo a d p sf) 2 5 0 1 3 0 9 0 5 5 3 0 2 5 2 0
d e fl. i n . ) . 0 3 . 0 7 . 1 1 . 1 9 . 3 6 . 4 7 . 6 0
2 4 /1 6 , 7 /1 6 lo a d p sf) 3 2 0 1 7 0 1 1 5 7 0 4 0 3 0 2 5 2 0
d e fl. i n . ) . 0 4 . 0 7 . 1 1 . 1 9 . 3 6 . 4 7 . 5 9 . 8 0
3 2 /1 6 , 1 5 /3 2 lo a d p sf) 3 5 0 1 8 5 1 2 5 7 5 4 0 3 5 2 5 2 0
d e fl. i n . ) . 0 3 . 0 5 . 0 8 . 1 4 . 2 7 . 3 5 . 4 4 . 5 9
4 0 /2 0 , 1 9 /3 2 lo a d p sf) 6 2 5 3 3 0 2 2 0 1 3 5 7 5 6 0 4 5 3 5 2 0
d e fl. i n . ) . 0 3 . 0 5 . 0 8 . 1 4 . 2 6 . 3 3 . 4 2 . 5 6 . 8 2
4 8 /2 4 , 2 3 /3 2 lo a d p sf) 7 7 5 4 0 5 2 7 5 1 7 0 9 0 7 0 6 0 4 5 2 5
d e fl. i n . ) . 0 2 . 0 4 . 0 6 . 0 9 . 1 8 . 2 3 . 2 8 . 3 8 . 5 6
su p p o rts th i s sh o u ld n e ve r b e d o n e u n le ss so sp e ci fi e d ) th e lo a d va lu e s
4 0 /2 0 R a te d S h e a th i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 % o f 4 0 /2 0 ta b le va lu e
4 8 /2 4 R a te d S h e a th i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 % o f 4 8 /2 4 ta b le va lu e
P a n e ls wi th sm a lle r S p a n R a ti n g s a re n o t su i te d to th i s o ri e n ta ti o n
S
p
a
n
S i n g le sp a n
T A B L E 3 1
Plywood Species Group Adjustment Factor
Gr o up St r e n g t h Ax i s Acr o ss Sup p o r t s St r e n g t h Ax i s Pa r a l l e l t o Sup p o r t s
2 0 . 7 3 0 . 9 9
3 0 . 6 7 0 . 9 8
4 0 . 5 6 0 . 9 7
54
APA The Engineered W ood Association is
a nonprofit trade association whose
member mills produce approximately 80
percent of the structural wood panel
products manufactured in the United
States and a significant number of panels
produced in Canada.
Founded in 1933 as the Douglas Fir
Plywood Association and widely recog-
nized today as the foremost authority in
the structural wood panel industry, APA
performs numerous functions and
services on behalf of panel product users,
specifiers, dealers, distributors, schools
and universities and other key groups.
Among the most important of these
functions is quality inspection and
testing. APA trademarks appear only on
products manufactured by APA member
mills and signify that panel quality is sub-
ject to verification through APA audit a
procedure designed to assure manufac-
ture in conformance with APA perfor-
mance standards or Voluntary Product
Standard PS 1-83 for Construction and
Industrial Plywood or Voluntary Product
Standard PS 2-92, Performance Standard
for W ood-Based Structural-Use Panels. APA
maintains five quality testing laboratories
in key producing regions and a
37,000-square foot research center at
Association headquarters in Tacoma,
Washington.
But quality validation is only one of
APAs many functions. The Association
also:
Operates the most sophisticated
program for basic panel research in
theworld.
Maintains an international network of
field representatives to assist panel
product users, specifiers, dealers, distrib-
utors and other segments of the trade.
Conducts informational buyer and
specifier seminars and provide dealer
and distributor sales training.
Publishes a large inventory of publi-
cations on panel grades, applications,
design criteria and scores of
other topics.
Advertises and publicizes panel product
systems and applications in national
trade and consumer magazines.
Sponsors annual design competitions
for architects, builders, students and
do-it-yourself home craftsmen.
Works to secure acceptance of
structural wood panel products and
applications by code officials, insuring
agencies and lending institutions.
Develops and maintains performance
and industry product standards.
Conducts in-depth market research
and development programs to identify
and penetrate new panel markets in
the U.S. and abroad.
Works in conjunction with other
wood product industry organizations
on solutions to problems of common
concern.
Always insist on panels bearing the
mark of quality the APA trademark.
Your APA panel purchase or specification
is your highest assurance of quality. It is
also an investment in the many trade
services and programs that APA
undertakes on your behalf.
For More Information
APA has several brochures to help
industrial users make the most of the
panel products manufactured by APA
member mills. The titles listed below
may be of particular interest.
Membership and Product Directory,
FormK815
Lists all APA member mills and the
products they manufacture. Includes
key sales personnel.
Grades and Specifications, Form J20
Complete Guide to Product Standard
PS 1 and APA proprietary grades, plus
standard architectural specifications.
Transport Equipment, Form G210
Describes ways APA panels can be used
to fabricate a wide range of transporta-
tion equipment including truck, trailer
and container bodies and liners. Also
includes information on estimating
allowable design loads for fasteners.
Big Bin and Slim Bin, Form L230
Description, specification guide and
fabrication instructions for 300-gallon
and 55-gallon collapsible, reusable
pallet bins.
Slave Pallets, Form S225
Includes description of slave pallet
features, grade specifications and
design recommendations.
Industrial Panel Selection Guide, Form T200
Guides industrial users through APA
panel specification process for
applications such as materials
handling, furniture and components
for other manufactured items.
Contact one of the APA offices listed on
the back of this brochure to request any
of the above titles.
A B O U T A P A T H E E N G I N E E R E D W O O D A S S O C I A T I O N
A P A
M A T E R I A L S H A N D L I N G
I N D U S T R I A L U S E G U I D E
We have field representatives in most
major U.S. cities and in Canada who can help
answer questions involving APA trademarked
products. For additional assistance in specifying
APA engineered wood products, get in touch with
your nearest APA regional office. Call or write:
WESTERN REGI ON
7011 So. 19th St.
I
P.O. Box 11700
Tacoma, Washington 98411-0700
(253) 565-6600
I
Fax: (253) 565-7265
EASTERN REGI ON
2130 Barrett Park Drive, Suite 102
Kennesaw, Georgia 30144-3681
(770) 427-9371
I
Fax: (770) 423-1703
U. S. HEADQUARTERS
AND I NTERNATI ONAL
MARKETI NG DI VI SI ON
7011 So. 19th St.
I
P.O. Box 11700
Tacoma, Washington 98411-0700
(253) 565-6600
I
Fax: (253) 565-7265
PRODUCT SUPPORT HELP DESK
(253) 620-7400
E-mail Address: help@apawood.org
(Offices: Antwerp, Belgium; Bournemouth,
United Kingdom; Hamburg, Germany; Mexico
City, Mexico; Tokyo, Japan.) For Caribbean/Latin
America, contact headquarters in Tacoma.
The product use recommendations in this publica-
tion are based on APA The Engineered Wood
Associations continuing programs of laboratory
testing, product research, and comprehensive field
experience. However, because the Association has
no control over quality of workmanship or the con-
ditions under which engineered wood products are
used, it cannot accept responsibility for product
performance or designs as actually constructed.
Because engineered wood product performance
requirements vary geographically, consult your
local architect, engineer or design professional to
assure compliance with code, construction, and
performance requirements.
Form No. M200A/Revised January 1995/0300
www.apawood.org
@
W
e
b
Addre
s
s
:

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