Ti-Hi, BCT, and Freight Class: Pallet Math for Packaging Buyers

What Ti-Hi means and why buyers use it

Ti-Hi is warehouse shorthand for pallet configuration: Ti is the number of cases per layer, Hi is the number of layers. A hypothetical 10 Ti by 5 Hi pallet holds 50 cases. These counts help plan loads, but do not describe the whole unit load: case and pallet dimensions, weight, orientation, stability, and stacking restrictions also matter.

Before you specify packaging, sketch a candidate Ti-Hi and work backward. In a hypothetical example, a 60-inch total load-height limit and a 6-inch pallet leave 54 inches for cases. Divide that allowance by case height and round down to whole layers, then check any required operating clearance with the warehouse.

• Ti equals cases per layer; Hi equals number of layers.
• Total cases per pallet equals Ti multiplied by Hi.
• Ti-Hi constrains case footprint, stacked height, and total unit load weight.

A worked Ti-Hi example with real arithmetic

In this hypothetical example, candle tins ship in cases with outside dimensions of 16 by 12 by 10 inches, weighing 14 pounds each, on a 48 by 40 inch pallet. A uniform layout fits three cases along the 48-inch edge and three along the 40-inch edge, for Ti 9 and 4 inches of unused depth. This is a candidate layout, not the maximum geometric count. A mixed-orientation layout fits 10: one 16-inch-deep row of four cases, each 12 inches wide, plus two 12-inch-deep rows of three cases, each 16 inches wide. The row depths total 40 inches and each row spans 48 inches. The calculations below use the uniform Ti 9 layout for illustration.

If your stacking limit allows 50 inches of product, each layer is 10 inches tall, so Hi is 5. Total cases: 9 times 5 equals 45 cases. Total case weight: 45 times 14 equals 630 pounds, plus roughly 40 pounds for the pallet, about 670 pounds. Stacked height: 5 layers times 10 inches equals 50 inches, plus the pallet at about 6 inches, about 56 inches total.

The uniform Ti 9 layout leaves 4 inches of unused depth. Rotating every case gives Ti 8, but mixing orientations gives the geometric Ti 10 layout described above. At five layers, Ti 10 would hold 50 cases weighing 700 pounds, or 740 pounds including the hypothetical 40-pound pallet, at the same 56-inch total height. These are simplified geometric examples, not validated pallet configurations. Actual outside dimensions, tolerances, deck support, stability, and compression performance must be checked before choosing a layout.

• For a uniform layout, divide each pallet dimension by the corresponding case dimension and round down; also evaluate mixed-orientation layouts.
• Multiply layers by case height and confirm the total plus pallet height stays under your limit.
• Add pallet weight to case weight before comparing against carrier limits.

Box compression strength and the stacking question

BCT, the box compression test value, is the peak compressive force a corrugated box withstands in a laboratory test. The number that matters for your pallet is not BCT alone but the load each box actually carries: the boxes stacked above it in its column, plus its share of any pallets stacked on top during warehouse storage or truck transit.

We recommend designing below the tested BCT to allow for humidity, handling, and time under load. Have a packaging engineer set an appropriate margin for your conditions; this guide does not prescribe one. A short laboratory compression test does not replicate long storage under load. Request BCT results for the finished box construction you are considering, including test conditions, and plan representative loaded stacking trials or laboratory evaluation before a full production run.

Do not treat an ECT rating stamped on a box as equivalent to a Mullen burst rating or as a direct BCT value. They measure different things, and converting between them without a tested basis is guesswork.

• Estimate load on the bottom case: cases above it times case weight, plus its share of any pallet stacked on top (upper pallet weight divided by the number of supporting columns, assuming even distribution).
• Apply a safety factor for humidity, duration, and handling rather than designing at theoretical BCT.
• Confirm with compression testing or stacked storage trials; arithmetic is an estimate, not validation.

How pallet math feeds freight cost

Freight pricing for palletized LTL shipments generally depends on freight class, weight, distance, and your carrier agreement. Freight class in the NMFC system considers characteristics such as density, stowability, handling, and liability. Density is a major place where packaging decisions show up. A dense pallet of heavy cases may classify differently than a bulky, light load of the same dimensions.

Because density is weight divided by cubic feet, your Ti-Hi configuration changes it. Adding a layer adds both weight and height. Overall density rises only if the added cases are denser than the current load, which is often the case when the low-density pallet base is a large share of the volume. Bulky protective packaging that lowers cases per pallet can lower density and raise freight cost per unit. This is the core trade-off between protection and freight efficiency.

Do not assume a specific class number from this guide. Class is assigned per NMFC item and your carrier agreement, and density thresholds shift with commodity and rules. Give your carrier or 3PL the pallet dimensions, weight, and commodity description and let them classify it, then compare how packaging changes move the number.

For parcel shipments instead of freight, dimensional weight applies when a package is light relative to its volume. FedEx publishes a divisor of 139 for U.S. and international shipments: multiply length by width by height in inches, divide by 139, and your chargeable weight is the greater of actual or dimensional weight. That rule rewards compact parcel packaging the same way density rewards compact pallets.

• Density equals total pallet weight divided by total cubic feet including the pallet height.
• More layers on the same footprint can raise density and may lower cost per unit shipped; calculate it rather than assume.
• Confirm freight class with your carrier using actual pallet dimensions, weight, and commodity.
• The supplied FedEx guide uses a 139 dimensional-weight divisor; confirm the applicable service, current divisor, and measurement and rounding rules.

Carrier limits you should check before locking the design

Carrier dimensional and weight limits constrain your Ti-Hi before you even get to compression strength. FedEx Express freight services, for example, accept individual skids of 150 pounds or more, and skids exceeding 2,200 pounds, or exceeding 70 inches in height, 119 inches in length, or 80 inches in width, require prior approval. FedEx Freight shipments can be palletized or non-palletized, up to 20,000 pounds and 21 feet in length.

These are examples from one carrier's published guidance, not universal rules. Your own agreement, lane, and carrier may differ, so verify current limits in your contract or rate confirmation before finalizing packaging. Also check your warehouse racking height, dock door height, and any customer-specific receiving requirements, since a pallet that ships fine can still fail at the destination.

The hypothetical 48 by 40 by 56 inch, 670-pound unit load does not exceed the cited FedEx Express Freight weight and dimensional thresholds for prior approval. That comparison alone does not establish acceptance or eliminate other approval requirements. Two such unit loads would total about 112 inches in height before allowing for any additional separation. Confirm stacking permission, equipment clearance, load support, and whether the carrier treats them as separate skids or one unit.

• Check skid height, weight, length, and width limits with your carrier before finalizing Ti-Hi.
• Verify warehouse racking and customer receiving constraints, not just transport limits.
• Confirm how stacked pallets are treated: as separate skids or one combined unit.

Decision table: choosing where to adjust

When pallet math reveals a problem, you have several levers. This table is Teal Packaging's editorial planning framework to help you pick one based on what is actually failing. The cited sources cover only the specific FedEx limits and dimensional weight facts noted, not the overall process.

Practical checklist before you order packaging

• Record usable pallet dimensions and compare uniform and mixed-orientation layouts; check tolerances, support, stability, and any overhang restrictions before selecting Ti.
• Multiply Ti by Hi and confirm total cases, stacked height including pallet, and total weight.
• Estimate the load on the bottom case, including any pallets stacked above in storage or transit.
• Apply a safety factor to BCT and plan a stacked storage trial or lab compression test before full production.
• Calculate pallet density in pounds per cubic foot and ask your carrier to confirm freight class.
• Confirm current carrier skid limits for height, weight, length, and width in your own agreement.
• Check destination constraints: racking height, dock doors, and customer receiving rules.
• For parcel shipments, confirm the applicable dimensional-weight divisor and measurement and rounding rules, then compare dimensional weight with actual weight.

Scope and limits

This guide covers hypothetical pallet arithmetic and planning questions, not compliance determinations. Confirm the applicable NMFC item, class, and contractual rating treatment with your carrier or freight broker; density alone is insufficient. The cited sources document the quoted FedEx guidance, not the broader BCT or NMFC discussion. The stacking calculations estimate loads, not tested compression capacity. Confirm current carrier limits, dimensional-weight rules, and service requirements before shipment. Hazardous materials, temperature-controlled freight, and regulated substances require separate review with qualified advisors.

Questions about Ti-Hi, BCT, and freight class pallet math