Getting stillage dimensions right is the single most important step in specifying handling equipment that actually works for your product, your forklifts and your vehicles. A stillage that is a few millimetres too tall to stack, too wide to load two-abreast on a trailer, or fitted with fork pockets that do not match your truck can cost you far more in wasted transport space and handling time than the unit itself. This guide explains exactly which stillage dimensions matter, how each one is measured, and how to specify your requirements clearly so that the quotation and finished product match what you need.
Because most industrial storage and transport equipment is made to order, understanding these measurements also helps you interpret the technical information we provide at quotation stage. If you would like the full background before you brief us, our buyer’s and design guide and our guide to giving us the right technical information for an accurate quote are the best places to start.
Standard pallet sizes as a starting point
Standard pallet footprints are widely used across industry, most notably the EPAL/Euro system at around 1200mm x 800mm, with 1200mm x 1000mm also common. These sizes exist because they suit standard transport dimensions and pack efficiently onto vehicle beds.
Stillages, by contrast, are more often bespoke, but they are usually based loosely around these familiar footprints so that they still load and stack predictably. Treat standard pallet sizes as a sensible starting point, then adjust the footprint and height to suit your specific product and vehicles rather than forcing your product to fit a generic size.
The three main stillage dimensions
Every stillage specification starts with three headline measurements. It is important to be clear about where each one is taken from, because small differences in reference point lead to big differences in fit.
- Length – generally measured over the corner posts (the overall footprint), not the internal opening.
- Width – likewise measured over the corner posts to give the true overall footprint.
- Height – measured from the ground to the top of the corner post, i.e. the overall height of the unit as it sits on the floor.
When you send us sizes, always tell us whether a figure is an external (over-post) dimension or an internal one, and state your units. We work in millimetres as standard, and confirming this up front removes the most common source of confusion between what a customer pictures and what gets manufactured.
Further dimensions that affect fit and stacking
Beyond the headline size, several secondary dimensions determine how a stillage stacks, how much it holds, and whether it clears your floor and racking. These are the details that separate a unit that simply exists from one that works cleanly in your operation.
- Ground clearance – the space from the floor to the underside of the stillage base. This governs whether pump trucks or forks can pass underneath and how the unit sits on uneven surfaces.
- Internal or effective height – the usable height from the base of the stillage to the top frame. This is the figure that dictates how much product you can actually load.
- Post extension – the height the corner posts extend above the top frame so that units can be safely stacked, with the feet of the upper stillage locating over the posts of the one below.
Post extension in particular is easy to overlook but critical if you intend to stack. Get it wrong and stacked units can sit unstably or fail to interlock. For a wider look at the features that shape a specification, see our guide to the design factors to consider when customising stillages and post pallets.
Critical dimensions for forklifts and vehicle loading
Two further sets of dimensions decide whether a stillage can be handled safely and transported economically: how it interfaces with your forklift, and how its footprint fits your vehicles.
Forklift and fork-pocket dimensions
The fork centres of your truck must align with any fork guides or fork pockets fitted to the stillage. The guides or pockets also need to accommodate the cross-section and length of your specific forks – both the width and thickness of the tines, and how far they need to enter. If you are unsure which arrangement suits your handling, our article on fork guides and which type is best suited to your application explains the options.
Footprint and vehicle loading
The footprint of the stillage is instrumental when loading onto vehicles, because it determines how many units fit onto a trailer bed and whether that space is used efficiently. As a rule of thumb, a 1200mm x 1000mm footprint fills a vehicle economically, but the ideal size also depends on the type of vehicle – flatbed, curtain-sided or articulated – and on the permissible loading height for that vehicle. It is always worth checking your stillage footprint against your actual transport before committing to a size.
Collapsible metal pallets and folded dimensions
One of our most popular products is the collapsible metal pallet (CMP). Its appeal is largely down to its two very different sets of dimensions: erected and folded.
- Erected – the CMP behaves like a conventional post pallet, carrying product at its full working height.
- Folded – once emptied, the unit folds flat for the return journey, so you are not paying to ship fresh air back.
Typically you can fit three to four collapsed units into the same volume as one erected unit, which frees up significant capacity for return loads. When specifying a CMP, it is worth noting both the erected height and the folded stack height so you can plan storage and transport around both states.
Bespoke sizes and concept design
Because we manufacture in-house here in the UK, we can produce stillages to your own bespoke dimensions and designs rather than limiting you to a fixed catalogue of sizes. When we recommend dimensions, we balance three things:
- The size and weight of the product being stored or transported.
- The vehicles the stillages will travel on, so the footprint fills the bed efficiently.
- Raw material sizes, so we make the most economical use of steel during manufacture.
We can also produce concept designs so you can check fitness for purpose before committing to production – a sensible step when dimensions are tight or the application is unusual.
Getting your stillage dimensions right first time
To summarise, a clear stillage specification comes down to a handful of well-defined measurements:
- Length and width over the corner posts, plus overall height to the top of the post.
- Ground clearance, internal/effective height and post extension for stacking.
- Fork centres and fork-pocket sizes matched to your truck.
- A footprint chosen to fill your vehicles economically.
Confirm your units, state whether each figure is internal or external, and check the numbers against your product, your forklifts and your transport before you order. Do that and your stillages will fit, stack and load exactly as intended.
Ready to specify your stillages?
If you have any stillage, cage or trolley procurement requirements, we are happy to help you nail down the right dimensions. Call us on 01889 563244, request pricing through our get a quote page, or send us your details via our contact form and we will advise on the most suitable and economical sizes for your application.