Air Freight Pallet Height Limits: Maximum Dimensions by Aircraft Type [2026]
One of the most common reasons air freight shipments get rejected, delayed, or hit with surprise charges is exceeding pallet height restrictions. Airlines enforce strict height limits based on aircraft cargo hold dimensions and ULD (Unit Load Device) specifications — and there is zero flexibility.
This guide covers the exact height limits by aircraft type, how to measure your pallets correctly, U.S.-specific regulations, and the mistakes that cost shippers time and money.
Why Pallet Height Limits Matter in Air Freight
Aircraft cargo holds are precisely engineered spaces. Every centimeter matters. Cargo is loaded into standardized ULDs (containers and pallets) that must fit within the aircraft’s cargo compartment dimensions. If your pallet exceeds the height limit:
- Cargo gets bumped: Your shipment will not make the booked flight
- Repacking at your expense: The handler will repack your cargo and charge you for it
- Rerouting to a freighter: Oversized cargo may need a dedicated freighter — less frequent and more expensive
- Delays: Missing a flight can mean days of delay, especially on less frequent routes
Maximum Pallet Height by Aircraft Type
Height limits depend on whether cargo flies in the belly hold of a passenger aircraft or on a dedicated freighter:
Passenger Aircraft (Belly Hold / Lower Deck)
| Aircraft | Max Height (with pallet) | Usable Height (cargo only) | Notes |
|---|---|---|---|
| Boeing 777-300ER | 160 cm (63″) | 145 cm (57″) | Most common widebody for belly cargo |
| Boeing 787 Dreamliner | 152 cm (60″) | 137 cm (54″) | Lower deck containers vary by position |
| Airbus A350 | 155 cm (61″) | 140 cm (55″) | Similar to 787 configuration |
| Airbus A330 | 155 cm (61″) | 140 cm (55″) | Common on transatlantic routes |
| Boeing 737 / A320 (narrowbody) | 86 cm (34″) | 71 cm (28″) | Bulk cargo only, no ULDs |
Freighter Aircraft (Main Deck)
| Aircraft | Max Height (main deck) | Door Height | Notes |
|---|---|---|---|
| Boeing 747-400F | 300 cm (118″) | 304 cm (120″) | Largest standard freighter capacity |
| Boeing 747-8F | 300 cm (118″) | 304 cm (120″) | Latest 747 freighter variant |
| Boeing 777F | 300 cm (118″) | 307 cm (121″) | Most popular long-range freighter |
| Boeing 767-300F | 244 cm (96″) | 257 cm (101″) | Common for regional freight |
| Airbus A330-200F | 244 cm (96″) | 259 cm (102″) | Medium-range freighter |
Note: Heights include the pallet base (approximately 15 cm / 6″). Always confirm specific limits with your freight forwarder or airline before shipping.
Standard Air Freight ULD Dimensions
ULDs are the standardized containers and pallets used to load cargo onto aircraft. The most common types:
| ULD Type | Base Size | Max Height | Volume | Used On |
|---|---|---|---|---|
| LD3 (AKE) | 153 × 156 cm | 163 cm | 4.3 m³ | Widebody lower deck |
| LD7 (PAG) | 317 × 223 cm | 163 cm | 9.9 m³ | Widebody lower deck (P1 position) |
| PMC (P6P) | 317 × 244 cm | 244 cm | 18.8 m³ | Freighter main deck |
| M1 (AAP) | 317 × 244 cm | 300 cm | 23.1 m³ | 747/777 freighter main deck |
How to Measure Your Pallet Correctly
Incorrect measurements are the #1 cause of air freight pallet rejections. Here is how to measure properly:
- Measure TOTAL height: From the bottom of the pallet to the highest point of your cargo, including any wrapping, strapping, or protective material on top
- Include the pallet base: Standard pallet height is 15 cm (6″). This counts toward the total height limit
- Measure after wrapping: Stretch wrap, corner boards, and top caps all add height
- Account for stacking: If boxes are not perfectly flat on top, measure the highest point
- Verify length and width: Ensure cargo does not overhang the pallet edges — overhang can prevent ULD loading
Pro tip: Build your pallet 5-10 cm below the maximum limit to account for measurement variations and handling tolerances.
U.S.-Specific Air Freight Regulations
In addition to airline-specific requirements, U.S. air freight is regulated by the TSA and specific federal rules:
- TSA screening: All air cargo on passenger flights must be screened. Oversized pallets may require additional screening time
- Loose cargo prohibited: All goods must be in boxes, crates, or sealed packaging — no loose items on pallets
- Securing requirements: Pallets must be strapped, banded, or film-wrapped to prevent cargo shifting during flight
- Weight limits: Each ULD position has a maximum weight limit in addition to height limits. Exceeding either causes rejection
- ISPM-15 wood treatment: For international shipments, all wood packaging (including pallets) must be heat-treated and bear the IPPC stamp
Common Pallet Height Mistakes and How to Avoid Them
1. Forgetting to Include the Pallet Base
Your pallet base is typically 15 cm tall. If the aircraft height limit is 160 cm, your cargo can only be 145 cm tall — not 160 cm. Always subtract pallet height from the aircraft limit.
2. Not Measuring After Wrapping
Stretch wrap, top sheets, corner protectors, and strapping can add 3-5 cm to total height. Measure the final, wrapped pallet — not the unwrapped stack.
3. Assuming All Aircraft Have the Same Limits
A 747 freighter can handle 300 cm height on the main deck, but a 787 belly hold maxes out at 152 cm. Your forwarder should confirm the specific aircraft type on your route.
4. Overloading Beyond Weight Limits
Even if your pallet fits within height limits, exceeding the ULD position weight limit will still cause rejection. Weight limits range from 1,500 kg to 5,000 kg depending on aircraft and position.
5. Using Untreated Wood for International Shipments
ISPM-15 requires all wood packaging in international trade to be heat-treated and stamped. Customs can hold or reject shipments on non-compliant pallets.
Incoterms and Pallet Responsibility
Who is responsible for correct palletization depends on your Incoterms:
- EXW (Ex Works): The buyer handles everything — including ensuring pallets meet airline requirements
- FCA (Free Carrier): The seller delivers to a named point; the buyer is responsible from there
- DAP (Delivered at Place): The seller handles transport; the buyer handles import duties
- DDP (Delivered Duty Paid): The seller is responsible for everything, including correct palletization
How ExFreight Helps with Pallet Compliance
ExFreight’s platform helps you avoid pallet-related issues by:
- Verifying dimensions and weight against aircraft-specific limits before booking
- Alerting you if your cargo requires freighter service instead of belly hold
- Providing ISPM-15 compliant pallet sourcing guidance
- Managing all documentation including airway bills and customs forms
- Offering real-time tracking from pickup to delivery
Get an instant air freight quote and we will confirm the right aircraft and ULD configuration for your cargo.
Frequently Asked Questions
What is the maximum pallet height for air freight?
It depends on the aircraft. Passenger aircraft belly holds allow 152-163 cm total height (including pallet base). Freighter main decks allow up to 300 cm. Always confirm with your freight forwarder based on the specific aircraft type on your route.
What happens if my pallet is too tall?
It will be rejected at the airline terminal. The cargo handler may repack it at your expense, or it will be bumped to a later flight or rerouted to a freighter aircraft — both causing delays and additional costs.
Do I need to use treated wood for air freight pallets?
For international shipments, yes. ISPM-15 requires all wood packaging materials to be heat-treated and bear the IPPC stamp. Domestic U.S. shipments do not require treated wood, but it is still recommended.
Can I ship oversized cargo by air?
Yes, on freighter aircraft. The Boeing 747F and 777F can handle cargo up to 300 cm tall on the main deck, with door dimensions exceeding 3 meters. For extremely large items, charter flights are available.
How do I calculate if my cargo fits?
Measure total pallet height (base + cargo + wrapping), length, and width. Compare against the ULD specifications for your aircraft type. Your freight forwarder should verify fit before booking. ExFreight’s platform automatically checks dimensions against available aircraft.
