Pallet strapping patterns: positioning straps without guesswork

A pallet can be strapped and still arrive damaged, because the straps went where they were easy to apply rather than where the load needed them. Where strapping runs on habit, one operator uses two straps, the next uses three, and nobody can say which is the approved method. A written strapping pattern removes that guesswork and gives purchasing a clear basis for buying strap and closures.

This guide covers how to decide strap direction, position and count for a palletised load, and how the European roadside-inspection rules adopted in 2014 frame the packing brief.

What the pattern has to achieve

A strapping pattern has three jobs. It holds the layers together so the load behaves as one unit. It ties that unit to the pallet so the two cannot separate when the pallet is lifted or braked. And it does this without crushing the product or the packaging underneath.

Those jobs pull in different directions. More tension improves unitisation but can crush cartons at the top edges. More straps spread the force but add cost and time at the line. The pattern is the agreed compromise for a specific load, and it should be recorded per load type rather than as one rule for the whole warehouse.

Directions, positions and counts

Start by naming the direction of each strap, then its position, then the number.

Pattern	Typical use	What to watch
One-way, lengthwise	Uniform, stable stacks on a standard pallet	The load can still spread sideways if the layers are not interlocked
Two-way, crossed	Mixed or tall loads that need restraint in both directions	Joints and crossings concentrate pressure on the top layer
Horizontal girth bands	Holding layers together around the outside of the stack	Girth bands alone do not tie the load to the pallet
Combined with corner boards	Cartons, bags or compressible packs	The boards must sit where every strap crosses an edge

A few positioning habits make any of these more reliable:

• Pass vertical straps through the pallet entries and under the top deck, so they bear on the deck boards rather than sliding over the pallet ends.
• Position vertical straps close to the pallet blocks or stringers where possible, so tension pulls against solid timber rather than an unsupported board.
• Keep straps a consistent distance in from the load edges, and keep the pattern symmetrical so the unit is not pulled out of square.
• Put the joint on a vertical face rather than on the top surface, where a seal or buckle can dent the top layer and is exposed to the forks of the next pallet.
• Where a strap crosses a sharp or soft edge, use edge protection. Our guide to sharp edges and abrasion explains what to record.

The count is the last decision, not the first. Begin with the minimum that holds the layers and ties them to the pallet in both directions you need, test it, and add straps only where the trial shows movement.

The regulatory frame in January 2017

For road transport in the European Union, the relevant text is Directive 2014/47/EU. Member States have until 20 May 2017 to adopt the national measures and must apply them from 20 May 2018. Article 13 allows a roadside inspection of cargo securing, and Annex III sets out the principles.

Annex III states that cargo securing should withstand forces of 0.8 times the cargo weight in the driving direction and 0.5 times sideways and rearwards. Those values describe what the securing of the cargo on the vehicle must cope with. They are not a rating for a pallet strap, and nobody should divide them across the straps on a pallet to arrive at a strap specification.

Two points in the annex do matter to packers. The list of applicable standards includes EUMOS 40509 for transport packaging. And the table of deficiencies opens with transport packaging that does not allow proper load securing. In other words, an unstable pallet can be treated as part of the securing problem, even when the lashing on the truck is correct.

For containers, the 2014 IMO/ILO/UNECE CTU Code gives non-mandatory guidance on packing and securing cargo in transport units. Its published text (MSC.1/Circ.1497) describes bundling, strapping or wrapping cargo as an auxiliary measure that should always be combined with direct or friction securing. A well-strapped pallet still needs to be blocked, braced or lashed inside the unit.

Write the pattern into a packing instruction

A pattern that lives only in an experienced operator’s head will drift. Record it in a short instruction that the line and the buyer can both use:

• Load type, pallet type and the maximum stack height and mass the pattern covers.
• Strap material, nominal width and supplier reference.
• Direction and number of straps, with a simple top-view sketch showing positions.
• Edge protection: type and where it sits.
• Joint method, joint position and the tool used.
• How tension is set, and who checks it at the start of a shift.
• When to review the pattern: new product, new pallet, new route or a damage report.

Joints and strap choice

The joint is often the weakest point in the system. With PET strap, the closure may be a friction weld, a sheet metal clip crimped with a sealer, or a wire buckle; woven strap is usually closed with a wire buckle. ASTM D3950-16 addresses nonmetallic strapping and its joining methods together, including joint strength where applicable. That is a useful reminder: the strap’s data sheet does not describe the closed joint.

When the pattern changes the strap or the closure, treat it as a system change. Agree the evidence you need, run a trial on real loads and record the result before the new method becomes standard. Our joint selection guide covers the questions to ask.

Turning the pattern into a purchase

A written pattern tells purchasing exactly what to buy: strap width and type, the closure, edge protection and the expected consumption per pallet. To discuss closures for a defined pattern, browse the PET strap, woven strap and galvanized wire buckle ranges, then send the pattern and load details through the enquiry page. Performance data for a specific combination is on request.