Static Compression Thresholds for Double Wall Corrugated Boxes under Moisture
Double wall static compression thresholds drop 40 to 60 percent above 80 percent humidity, requiring safety factor adjustments to prevent warehouse collapse.
Pallet Overhang
Package Placement
Carton positioning where the outer edges of the containers extend beyond the wooden deck of the shipping platform creates severe mechanical vulnerability in the unit load. Warehouse managers must avoid pallet overhang to ensure that the strongest parts of the cartons receive adequate support from below. This incorrect placement exposes the boxes to direct impacts from passing forklifts.
It increases the risk of product damage during transit.
Compression Loss
Stacking strength drops by up to forty percent when the corners of the bottom boxes lack solid support from the pallet deck. Because the corners carry most of the weight, pallet overhang forces the weaker side panels of the carton to bear the compression load. This imbalance causes the bottom box to buckle under the weight of the stack.
It leads to the collapse of the entire unit load.
Structural Prevention
Distribution centers can eliminate this structural weakness by using slightly smaller carton dimensions or by placing protective slip sheets between the pallet deck and the first layer of boxes. These sheets distribute the weight more evenly and bridge the gaps between the wooden slats, which helps to keep the corners of the cartons fully supported even if the alignment is not perfect. Utilizing plastic stretch wrap also stabilizes the load and prevents the boxes from shifting outward during transport, ensuring that the heavy corners remain inside the safe support boundary.