VARIATIONS: Load contravened manufacturers recommendations. It failed to cover the full area of the pallet deck.

PROCESS: The pallet was placed on the ground and a block of paving tiles weighing 1.2t was placed upon it. The load base was smaller than the pallet deck area by approx. 125mm all around, and due to the nature of the surface, its left-hand front corner contacted the deck first.

The pallet was then lifted to a height of 2 mtr and photographed from all angles to observe and distortion of the deck. It was noted that the unevenly distributed load caused the deck to distort downwards 15 mm between the tines and 15mm outboard of the tines.

The pallet was then transported for a distance of 50 mtr at typical yard speed with the forklift executing a number of sharp turns in both directions. The vehicle evidenced considerable response the rough ground, imposing moderate to high shock loads on the pallet and its load. The pallet was then returned to its original position and further measurement confirmed that it had maintained its dimensional stability, with no further distortion in any direction.

This procedure was then repeated four times with no change in the condition of the pallet. The load was then removed and the pallet checked for any damage or remaining distortion. It was found that the area of initial contact with the load was depressed approx. 1 mm and that the deck had returned to its original configuration. A depression of approx. .5mm was noted in the under deck areas contacted by the tines. No evidence of cumulative damage was found.

CONCLUSION: Whilst the primary design brief for this pallet was as an economical one-way unit with particular relevance to the perishables and general food industry, these test confirmed that it is capable of carrying loads weighing 400 or more times its empty weight and withstanding multiple cycles in the harsh environment in which the test were conducted.

LIMITATIONS: The low density of EPS renders it susceptible to accidental impact damage as well as to abrasion if pushed/dragged over rough surfaces whilst loaded. Uncoated EPS is soluble in contact with some hydrocarbon-based paints and solvent.