Metal pallets, made from steel, stainless steel or aluminium, are chosen when a pallet must carry very heavy loads, withstand heat or washdown, stay clean, or last for many years in a closed loop. They cost far more than wood or plastic to buy and are rarely used in open trade, but in the right application their long service life and consistency can justify the investment.
Types of metal pallets
Metal pallets are made from three main materials:
- Carbon steel, often galvanized or powder-coated, for heavy industrial loads. Steel is strong, stiff and inexpensive relative to other metals, but it is heavy and corrodes if its coating is damaged.
- Stainless steel, used in food, pharmaceutical and chemical plants where corrosion resistance and washdown are mandatory. It is more expensive than carbon steel.
- Aluminium, a light metal with good corrosion resistance, used where weight, cleanliness or non-sparking behavior matters. It is not as stiff as steel at the same thickness, so designs use tube frames or welded sections.
Construction is generally welded or bolted tubes and sheets, with fork openings on two or four sides. Some designs are collapsible or have integrated sides, which makes them box pallets, a category covered in pallet collars and related packaging.
Where metal pallets are used
| Sector | Why metal is chosen |
|---|---|
| Heavy industry and automotive | Very high static and dynamic loads, repeated use in closed loops with heavy components |
| Pharmaceutical and biotech | Smooth, washable, particle-free surfaces; stainless or aluminium |
| Food and meat processing | Washdown, no wood contamination, heat resistance for ovens and smokehouses |
| Cleanrooms and electronics | No splinters or dust |
| Aviation and air cargo | Lightweight aluminium platforms with defined profiles |
| Automated warehouses | Uniform dimensions and rigid, repeatable geometry |
| Hazardous areas | Non-sparking behavior of aluminium |
One US manufacturer of welded aluminium pallets states that its products are valued for strength, cleanliness and long life in cleanroom and pharmaceutical environments, and that aluminium pallets are replacing wood and plastic in many meat processing and pharmaceutical facilities. Its standard model has a 48 × 40 in footprint and 5.25 in height, with options such as solid decks, point-loaded wide-span racking and non-slip coatings. These are manufacturer claims, not independent figures.
For the hygiene requirements that push buyers toward metal, see food safety pallets and pharma pallets and GDP.
Aluminium in air cargo
The aluminium platforms used in aviation are not ordinary pallets. Air cargo pallets and containers, known as unit load devices (ULDs), have special contours and edge rails to lock into aircraft cargo compartments. They are built to aviation industry specifications and are designed to carry freight within the aircraft's weight limits. Their rules and sizes are covered in air cargo pallets and ULDs.
Weight, load and lifespan
Metal pallets are valued for strength and long service life. Several practical points apply:
- Weight. Steel pallets are heavy, which increases freight cost and can exceed manual handling limits. Aluminium is considerably lighter than steel but may still be heavier than a plastic or paper pallet of the same footprint, depending on design.
- Load capacity. Capacity depends on the section sizes and welding, and can be far higher than wood. Load ratings, including racking, should come from the manufacturer's tests, using methods such as ISO 8611 or ASTM D1185. See pallet load capacity.
- Stiffness. Metal pallets are high-stiffness designs, so rating is driven mainly by strength rather than deflection, as the Virginia Tech Center for Packaging and Unit Load Design explains for wood and metal.
- Lifespan. With proper maintenance, a metal pallet can remain in service for years or decades in a controlled loop. Damage typically takes the form of bent sections, cracked welds or coating loss rather than splintering.
Corrosion protection and finish
Carbon steel pallets are usually hot-dip galvanized, which coats the steel with zinc to protect it from corrosion, or powder-coated or painted for lighter use. Galvanizing extends service life outdoors and in humid sites; damage to the coating should be repaired. Stainless steel needs no coating but requires correct grade selection and cleaning protocols. Aluminium forms a natural oxide layer, but it can be damaged by strong alkaline cleaners, and the cleaner should be specified accordingly.
Non-slip coatings or rubber strips are often added because bare metal decks can be slippery for wrapped or smooth-based loads. See stretch wrapping pallets for securing loads.
Cost and when it makes sense
Metal pallets have a high purchase price compared with wood or plastic. They make financial sense when:
- The pallet circulates in a closed loop and is returned reliably.
- A wooden pallet would fail repeatedly under the load or conditions.
- Hygiene, fire, or temperature needs rule out other materials.
- Automation requires strict dimensional tolerance.
The principal price drivers are the metal used, the mass of metal, welding and finishing work, and whether the design is custom. A cost-per-trip calculation, as in one-way vs reusable pallets, gives a fair comparison. For open-loop trade, theft, loss and the value of scrap metal make metal pallets a poor choice.
Metal pallets are not subject to ISPM 15 because they are not wood. They are rarely the right choice for general export, and the main alternatives are compared in wood vs plastic pallets.
Frequently asked questions
Are metal pallets better than wood?
They are stronger and last longer, and they are cleaner, but they cost much more and are heavier in the case of steel. They are best in closed loops with demanding conditions.
Do metal pallets need ISPM 15 treatment?
No. ISPM 15 applies to wood packaging material only.
Why is aluminium used in aviation?
Aluminium is light and strong, so the platforms add little weight to the aircraft. Air cargo platforms follow specific contours so they lock into the aircraft hold.
How are steel pallets protected from rust?
Usually by hot-dip galvanizing or powder coating. Stainless steel resists corrosion without a coating.
Sources
- Aluminum Pallets — Cherry's Industrial Equipment
- How Much Load Can My Pallet Carry? — Virginia Tech Center for Packaging and Unit Load Design
- Heavy Duty Metal & Galvanized Steel Pallets — Container Exchanger