Pallet Height Restrictions for Air Freight in the U.S.: Best Practices and Global Guide

Air freight is the preferred solution for urgent and high-value shipments. But success doesn’t rely solely on speed; it requires compliance. One of the most overlooked aspects is pallet height.

Whether shipping within the U.S. or internationally, understanding pallet height restrictions is crucial; oversized loads may be rejected, delayed, or incur additional costs. In this article, we explain those limits, why they matter, and how to prepare your shipments for a smooth journey.

We also explore global air cargo trends, packaging standards, and how digital platforms like ExFreight simplify the entire process.

Why Height Limits Matter

Aircraft space is limited and precisely structured. Airlines configure their planes to accept specific ULDs (Unit Load Devices) that must fit precisely in the cargo holds. These ULDs have standardized base dimensions, and the height limit depends on the aircraft model.

Exceeding those limits can create major logistical issues. Cargo might be left off the flight, rerouted, or require special loading equipment. That’s why airlines and logistics operators strictly enforce height regulations.

Additionally, air freight is based on volumetric efficiency. The shape and size of your pallet directly affect cost and shipment viability.

Standard Pallet Dimensions

Air cargo is typically placed on standardized pallets or containers. While exact dimensions vary by airline, standard configurations apply:

• Base adapted to ULDs
• Height limits differ between passenger planes and freighters
• Total height includes the pallet base and the load above

Airlines prioritize uniformity to maximize space and ensure safety. An overly tall or poorly packed pallet might need to be repacked, at the shipper’s expense.

Always measure total height, including pallet, protective layers, and wrapping.

U.S. Air Freight Regulations

In the U.S., air freight is regulated by the TSA and specific airline policies. Non-compliant pallets are not accepted.

Key rules:

• Loose cargo is not allowed: all goods must be in boxes or sealed packaging
• Pallets must be secured with straps or film wrap
• Overweight pallets require additional securing
• Maximum height must be confirmed before booking

If a pallet exceeds standard limits, it may require transport on freighter aircraft, which is less frequent and more expensive.

Packaging and Safety Requirements

Proper packaging is essential. Airlines require all cargo to be:

• Properly labeled
• Secured with plastic or metal bands
• Wrapped in plastic film to prevent movement
• On forklift-compatible pallets

Multi-box loads must be consolidated and tightly secured. Please don’t hesitate to avoid overhang.

For international shipments, wood must be heat-treated and stamped with the IPPC mark, complying with ISPM-15 regulations.

International Shipping Considerations

Shipping cargo abroad involves additional rules. Each country may impose its own packaging, labeling, and documentation requirements.

Key considerations:

• Accurately declare products in commercial invoices
• Verify the IPPC stamp on all wooden packaging
• Use proper protective materials for long distances

Some products require special certificates (e.g., engines must be drained and cleaned). Others, like batteries or chemicals, require dangerous goods documentation.

Temporary Imports and Carnet Use

If exporting goods temporarily (for trade shows, demos, or testing), you have two main options:

• Pay import duties (sometimes refundable)
• Use a Carnet, which avoids duties if re-exported within a set timeframe

The ATA Carnet is accepted in dozens of countries, facilitating duty-free entry and exit worldwide. ExFreight doesn’t issue Carnets but manages customs clearance once you have one.

While some countries refund duties upon re-export, the process can be lengthy and complex. Starting with a Carnet is usually the most efficient option.

Digital Freight Management

Traditionally, air freight was managed through emails, calls, and spreadsheets. Today, platforms like ExFreight’s Exfresso enable:

• Instant rate quotes
• Airline space booking
• Digital document uploads
• Real-time shipment tracking

Digitization reduces errors, streamlines processes, and provides complete transparency. Small businesses can now operate globally with tools once reserved for large corporations.

Common Mistakes and How to Avoid Them

1. Incorrect Measurements
2. Many forget to include the pallet or wrap in measurements. This leads to rejections or extra fees.
3. Solution: Measure full pallet height, width, and length after packing. Confirm with your freight agent.
4. Untreated Wood
5. Wood must meet ISPM-15 standards. Without the IPPC stamp, your cargo can be held.
6. Solution: Buy certified pallets and check the stamp before shipping.
7. Overloading the Pallet
8. Excessive weight may cause collapse or rejection.
9. Solution: Check aircraft weight limits. Split loads if needed.
10. Incomplete Documentation
11. Incorrect or missing invoices and airway bills can cause delays in customs clearance.
12. Solution: Ensure all required documents are accurate and reviewed by a freight forwarder.
13. Ignoring Height Limits
14. Optimizing it only for volume and not height could cost you the flight.
15. Solution: Verify aircraft and ULD height limits before packing.

How ExFreight Helps

ExFreight combines technology with logistics expertise to optimize your air shipments. With their platform, you can:

• Get real-time quotes
• Book flights
• Upload documentation
• Coordinate customs
• Detect issues before dispatch

This reduces human error, improves operational speed, and gives you more control over your logistics.

Air Freight Models

Air freight is part of a multimodal network. Cargo is trucked to the airport, flown, and then delivered by ground. It’s chosen over other modes due to:

• Speed: ideal for urgent deliveries
• Value: suitable for high-value or lightweight goods
• Location: connect regions without road or sea routes
• Efficiency: reduce inventory cycle times

Service types include:

• Direct flight: fastest, most expensive
• Consolidated: shared space, lower cost
• Deferred: slower transit, cheapest option
• Express: guaranteed delivery within a time frame

ExFreight helps you choose the best option based on urgency and budget.

International Logistics: Challenges and Best Practices

Moving cargo between countries means complying with various regulations:

• Packaging: treated wood and ISPM-15 compliance
• Incoterms: define responsibilities and costs
• Correct customs valuation and classification to avoid overpayment

Working with experts like ExFreight helps you stay compliant, avoid delays and penalties, and navigate each country’s rules smoothly.

FAQs

Can I ship a tall pallet by air?

Yes, as long as it doesn’t exceed the aircraft’s height limits. Always confirm before booking.

What happens if my pallet is too tall?

It may be rejected, repacked, or rescheduled, resulting in delays and additional costs.

What is the standard pallet size?

It varies by airline but is standardized for use with ULDs. Could you check with your carrier?

Can I use untreated wood?

No. Only heat-treated, IPPC-stamped wood is accepted.

Can I quote and book online?

Yes. ExFreight enables you to quote, book, upload documents, and track shipments all from one platform.

Understanding Incoterms in Air Freight

Incoterms define responsibilities between the buyer and the seller. Commonly used in air freight:

• EXW (Ex Works): Buyer handles everything from the origin
• FCA (Free Carrier): Seller delivers to a designated point
• DAP (Delivered at Place): Seller covers transport; buyer handles duties
• DDP (Delivered Duty Paid): Seller covers everything, including taxes

Choosing the proper term avoids disputes and simplifies customs clearance.

Complying with pallet height restrictions is key to avoiding delays, penalties, and disruptions in air freight. Accurate measurements, proper packaging, and digital tools like ExFreight ensure your shipments arrive on time, without surprises.

Start shipping with confidence today. Get a quote with ExFreight and simplify your air logistics.