[Federal Register Volume 60, Number 245 (Thursday, December 21, 1995)]
[Rules and Regulations]
[Pages 66142-66149]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 95-30989]
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POSTAL SERVICE
39 CFR Part 111
Revisions to Standards for Palletization
AGENCY: Postal Service.
ACTION: Final rule.
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SUMMARY: On July 31, 1995, the Postal Service published a proposed rule
for public comment in the Federal Register (60 FR 39080-39088) to
revise current makeup standards in the Domestic Mail Manual (DMM) for
second-, third-, and fourth-class mail prepared on pallets. The final
rule adopts proposed changes that pertain only to the physical
characteristics of pallet loads (such as minimum/maximum height and
weight limits and provisions for triple-stacking). These changes will
not be affected by the Postal Service's classification reform proposal
currently under consideration before the Postal Rate Commission (Docket
No. MC95-1). The Postal Service has decided not to adopt, at this time,
those elements of the proposed rule that would be affected by
implementation of classification reform to avoid burdening software
developers and mailers with the need to make changes that will be
supplanted shortly after their implementation. Instead, the standards
for levels of pallet sortation and preparation, along with other
related issues, will be addressed with the standards that the Postal
Service proposes to implement with the pending classification reform
filing. The Postal Service expects to publish a proposed rule on
classification reform for public comment in December 1995.
EFFECTIVE DATE: January 1, 1996.
FOR FURTHER INFORMATION CONTACT:
Cheryl Beller, (202) 268-5166.
SUPPLEMENTARY INFORMATION: The July 31 proposed rule discussed in
detail the efforts by the Postal Service to establish certain basic
preparation standards that mailers must meet to ensure that pallets,
and the mail placed on them, maintain their integrity throughout
transportation and postal processing and allow safe handling by postal
employees. At the same time, these standards allow mailers flexibility
to prepare pallets by using recognized industry practices based on
their specific production and service needs.
The 30-day comment period ended on August 30, 1995, and 16 written
comments were received from publishers, mailer associations, printers
and mailers, transportation companies, and presort software developers.
After thorough consideration of these comments, the Postal Service is
publishing its final rule. This final rule removes sections in DMM MO42
through MO48 relating to pallet size and revises and consolidates them
into MO41 under one section on general pallet standards. The final rule
also revises standards related to stacking and top-capping pallets and
to identifying and notifying nonconforming mailers whose preparation
methods result in pallets that fail to meet basic pallet integrity and
safety standards. The final rule also establishes standards for
palletizing trays of letter-size mail. DMM E333 and E416 are also
revised to clarify the availability of third-class carrier route rates
and special fourth-class level A and B rates for mail on pallets; these
revisions also stipulate that the Postal Service will not unload
containerized drop shipment loads that have not maintained their
integrity in transit or that arrive in an unsafe manner. DMM MO33 is
revised to require all trays on BMC, ASF, SDC, and mixed BMC pallets to
be both sleeved and strapped to facilitate processing on sack and
parcel sorters.
The revised DMM standards are set forth after the discussion of
comments to the proposed rule. Many commenters commended the Postal
Service for listening to its customers in developing standards that
were fair and in accord with industry practices. Such comments are not
summarized below.
[[Page 66143]]
Discussion of Comments
I. Maximum Height
A. Single and Stacked Pallets
Eight commenters opposed various parts of the proposal related to
the maximum heights for a single pallet and for stacked pallets. Six
commenters opposed limiting the height of a single pallet of sacks,
parcels, or packages to 77 inches (or letter mail in trays to 12
layers) and asked why the Postal Service proposed a different maximum
height for stacked pallets of 84 inches. They expressed concern over
the possible loss of trailer cube capacity that might result from the
77-inch limit for drop shipments. Two commenters indicated that because
different characteristics of products on pallets affect the stability
of a load, the rule should be amended to allow for taller loads based
on specific product characteristics; one commenter suggested that the
weight limit of 2,200 pounds per pallet or stack of pallets be used as
the controlling maximum rather than the total height of pallet loads.
The maximum height of 77 inches for a single pallet is derived from
the general acceptance throughout the Postal Service of the Postal-PAK
and pallet (with a height of 75 inches), plus allowance for packing
material. Pallet loads exceeding a 77-inch height are a problem when
loaded onto and unloaded from many smaller trucks and vehicles used to
transport mail between postal facilities and when handled within many
smaller postal facilities. The type of transportation used to move
pallet loads and the facilities through which they are processed vary,
depending on the level of pallet sortation and the office of entry. Low
dock-door heights and limited ceiling heights within some facilities,
as well as low door and internal heights of many Postal Service
trailers and vehicles, were factors in establishing this maximum
height. By establishing a maximum height of 77 inches for all single
pallets, the Postal Service is promoting consistency in preparation
standards while ensuring that postal employees can handle pallets
safely and efficiently on all transportation and at all facilities,
regardless of office of entry or level of sortation. The higher maximum
of 84 inches for stacked pallets allows mailers to take advantage of
trailer cube capacity for lighter weight pallets and allows the Postal
Service to unstack the pallets where necessary to ensure compatibility
with Postal Service equipment, transportation, or facilities. The
maximum heights of 77 inches for a single pallet and 84 inches for
stacked pallets are adopted in the final rule.
The Postal Service has also determined to limit the number of
layers of trays of letter mail to 12, which is equivalent to the
maximum height of 77 inches for a single pallet. Mailers will need to
monitor their loads carefully to ensure that fuller trays are placed on
the bottom and interspersed nearer the top to avoid crushing. As the
height and weight of the pallet load increase, so does the likelihood
of the lower trays being crushed and causing the entire load to
collapse, particularly if the trays are older cardboard managed mail
(MM) trays. If a mailing consists of many less-than-full trays, mailers
should consider building loads containing less than the maximum number
of layers.
B. Pallet Boxes
A maximum height of 84 inches was proposed for a single pallet box
on a pallet, with a possible 60-inch maximum height restriction at some
non-BMC facilities. Two commenters suggested that the Postal Service
publish a listing of facilities that cannot handle the taller pallet
boxes so that software developers can build varying height restrictions
into their sortation programs. Ideally, the commenters preferred that
all postal facilities be modified to handle pallet boxes that are 84
inches tall (pallet, box, and mail). The Postal Service was in error
when it proposed a maximum height of 84 inches for any pallet box
because the pallet unloaders being deployed by the Postal Service in
bulk mail centers (BMCs) and many processing and distribution centers
(P&DCs) can accommodate only pallets with pallet boxes that do not
exceed a total height of 77 inches. The Postal Service must cut taller
boxes or otherwise alter them to remove the contents manually,
resulting in slower service for customers, additional handlings, and
inefficient use of newly deployed mechanized equipment. Accordingly,
the Postal Service has determined to adopt a 77-inch maximum, which is
also consistent with the height of the Postal-PAK and pallet. Because
the Postal Service proposed a maximum height of 84 inches and some
mailers might have a stock of pallet boxes designed to meet the
proposed maximum, the mandatory compliance date will be July 1, 1996,
to allow mailers to deplete current stocks of these taller boxes.
II. Pallet Boxes
A. Providing Boxes
One commenter stated that the Postal Service should provide a
pallet box ``for sack mail shippers that would conform to the specifics
outlined in the revisions'' to facilitate uniformity and unloading at
BMCs. The Postal Service has no plans to purchase additional equipment
to provide to sack mailers. The Postal Service is purchasing additional
trays and pallets, however, to meet customer demand in preparation for
implementation of classification reform.
B. Securing Pallet Boxes
One commenter requested that the proposed requirement that mailers
secure boxes to the pallet be optional and indicated that mailers had
been entering unsecured boxes on pallets for many years, without any
negative comment from the Postal Service. The proposed standard is
modified in the final rule to require securing a pallet box to the
pallet only if the pallet requires transportation by the Postal Service
to move it from the entry office to another postal facility for
distribution of the contents and the weight of the mail in the box is
insufficient to hold the box in place on the pallet during
transportation and processing. This modification is consistent with how
the Postal Service prepares and processes mail in its own Postal-PAKs
on pallets and ensures that pallets can be loaded and transported
safely on Postal Service vehicles and processed as a single unit to the
point where the contents are distributed.
C. Construction of Pallet Boxes
No comments were received on the proposal to allow mailers to use
pallet boxes constructed of single-, double-, or triple-wall corrugated
fiberboard. Single-wall corrugated fiberboard may be used only for
light loads (such as lightweight parcels) that do not require
transportation beyond the entry office. The Postal Service will monitor
mailings presented in pallet boxes to ensure that the box construction
maintains its integrity to the point of distribution of the contents.
III. Pallet Load Integrity
Failure of pallets to meet basic DMM standards negates efforts to
ensure safe and efficient handling of palletized loads. Accordingly,
all pallets presented to the Postal Service for acceptance, whether the
pallets are provided by the Postal Service or the mailer, must meet the
basic standards in the DMM pertaining to pallet labels, physical
[[Page 66144]]
pallet dimensions, pallet load integrity, stacking, and minimum/maximum
loads and heights. The Postal Service will consider individual
shipments that are presented for acceptance under the plant-verified
drop shipment (PVDS) program at a destination entry postal facility to
be bedloaded if the load integrity of the pallets or the safety of
postal employees is compromised. Such loads might require driver
unloading or may be refused by the destination facility. If a shipment
is refused, the mailer or mailer's agent who is presenting the mail for
acceptance at the destination entry facility has the option to rework
the mail off-site to match its original preparation as verified, then
resubmit it with the appropriate documentation when the entry facility
can reschedule the shipment.
The Postal Service will monitor load integrity of customers'
pallets at mailers plants when mail is verified by on-site postal
personnel and at postal facilities where mailings are entered, whether
at business mail entry units under local verification and acceptance or
a destination entry facilities where mailings are drop shipped under
programs such as PVDS. The Postal Service may initially notify the
transportation company presenting mail to the Postal Service for
acceptance or the mail preparer, or both, when pallet load integrity
problems are identified. The failure of pallet loads to maintain their
integrity might be caused by poor preparation methods of the mailer
(for example, the load exceeds maximum weight or height limits or the
load is not secured to the pallet) or the improper loading and security
of pallets onto the transportation used to move pallet loads to postal
facilities for acceptance (for example, pallets are not secured with
shoring equipment in vehicles to prevent pallets from toppling in
transit, or heavier pallets are stacked onto lighter pallets and crush
the mail on the bottom).
After a mailer is notified of recurring pallet load integrity
problems and allowed to make changes to improve load integrity, if the
mailer's methods still do not work, the mailer will be considered
nonconforming and required to meet the specifications developed by
Postal Service Engineering for securing pallets, pallet box
construction and dimensions, stacking of pallets, maximum height/layers
of trays, and use of top caps. These specifications are included in the
DMM language at the end of this discussion of comments. Mailers whose
pallets continue to fail to meet minimum load integrity levels will be
suspended from the pallet program.
Three comments were received from two commenters concerning load
integrity. One commenter wanted to know how damaged loads will be
handled, who will be notified, whether the mailer/agent will be allowed
to rework the mail, and how presentation of damaged loads will affect
drop shipment appointments. This commenter also noted that ``in our
business, it is common to refuse loads that have not maintained their
integrity. At that point, it is the shipper's or carrier's
responsibility to see that the load is taken to an alternative site for
reworking.'' This same commenter wanted clarification about who will
determine whether pallets are properly prepared to meet load integrity
standards, at what point a mailer will be considered nonconforming, and
whether the mailer will have an option to pay a penalty or fine at
destination to have nonconforming pallets accepted for time-sensitive
mailings. The commenter also expressed concern about possible
inconsistencies in the determinations by different facilities about
whether a pallet load meets the load integrity standards. The second
commenter wanted feedback from the Postal Service about pallet load
integrity problems, starting with the mail preparer and proceeding to
the owner. The Postal Service will initially contact the mailer or
mailer agent (such as a transportation company) when load integrity
problems are identified.
Training materials will be distributed to postal facilities that
accept pallets from mailers to ensure consistent understanding and
application of pallet load integrity guidelines and the procedures that
apply when problems are identified. The Drop Shipment Appointment
System (DSAS) will be used, where possible, to identify and track the
mailers or their agents presenting problem pallet loads. The DSAS will
also help to establish contact to ensure that corrective actions are
taken to improve future load integrity. The Postal Service will also
work with mailers to ensure that corrective actions are taken to
prevent recurrence of problems and to provide training and other
necessary tools that will communicate the responsibilities of all
mailers or their agents who create or handle mail on pallets.
Over the next few months, the Postal Service will formulate clear,
objective criteria to identify pallet load integrity problems and to
establish consistent feedback mechanisms for notifying mailers or their
agents when problems are identified. Until those details are developed,
load integrity will be monitored at origin and destination postal
facilities as it is today, feedback will be provided to mailers, and
mailers will be allowed to improve preparation methods for identified
problems. However, during that interim, mailers will not be determined
as nonconforming or suspended from the pallet program. Accordingly, the
rules relating to nonconforming mailers and suspension will not take
effect until July 1, 1996.
IV. Sleeving and Strapping of Trays
No comments were received about the proposal to require mailers to
sleeve and strap trays of letter mail placed onto BMC, ASF, SDC, and
mixed BMC pallets; the proposed standards are adopted in the final
rule. These standards provide an incentive to prepare pallets to finer
levels of sortation, allowing for greater cross-dock opportunities at
the BMCs and significant relief for BMC operations heavily affected by
unstrapped trays. In addition, this rule adopts the proposal to extend
the current requirement to sleeve all trays that contain letter-size
automation rate mail and that may be processed at a BMC/ASF or AMF/AMC
(that is, mail that does not originate and destinate in the delivery
area of the same SCF) to include trays containing nonautomation rate
letter-size mail.
V. Maximum Pallet Load
One commenter requested clarification of how the proposed 2,200-
pound maximum for pallets applies to stacked pallets. The proposal to
set 2,200 pounds as the maximum weight for any single pallet and as the
maximum total weight for stacked pallets presented to the Postal
Service is adopted in the final rule. When the weight of a single
pallet or a stack of pallets is calculated, the weight of the mail and
any tare placed on the bottom pallet are included in the calculation.
The proposed maximum load for trays on pallets of 12 layers, not to
exceed 2,200 pounds, is also adopted in the final rule.
VI. Minimum Pallet Load
For packages, parcels, and sacks on pallets, the final rule
requires mailers who prepare mail on pallets to prepare a required
level of pallet sortation when there are 500 pounds of mail for that
destination (for example, for a 5-digit ZIP Code or an SCF). At their
option, mailers may prepare pallets for any required or optional level
of sortation when they prepare at least 250 pounds of mail for a
destination.
Palletization of trays of letter-size mail is based on the number
of layers. Mailers may prepare a pallet when they
[[Page 66145]]
have from three to five layers of 1- or 2-foot managed mail (MM) or
extended managed mail (EMM) trays. Preparation of pallets to required
levels of sortation is mandatory with six layers of trays to that
destination (for example, SCF pallets).
For improved service, the processing and distribution manager of
the facility where a mailing is entered may issue a written
authorization to the mailer, allowing preparation of 5-digit or 3-digit
pallets containing less than the minimum volume (250 pounds of
packages, parcels, or sacks or three layers of trays) if the mail on
those pallets destinates in the service area of that facility.
At the mailer's option, the minimum volume used to determine when a
pallet is prepared may vary within a mailing, provided that pallets are
prepared to required levels of sortation when there are at least 500
pounds or six layers of mail to the destination.
Mailers are reminded that under the Postal Service's Guidelines for
the Plant-Verified Drop Shipment (PVDS) Program, the driver must unload
mail entered at delivery units. In some instances, the driver must
break down palletized loads because of the physical limitations of a
delivery unit (for example, a small or congested office that cannot
accommodate large or stacked pallets).
VII. Stacking Pallets
A. Double- and Triple--Stacking
Several commenters responded favorably to the proposal to allow a
mailer to double- or triple-stack pallets up to the maximum allowable
height and weight (84 inches/2,200 pounds total for the stacked
pallets); this proposal is adopted in the final rule. Such pallets must
be presented for acceptance at the mailer's plant or a postal facility
in a manner that ensures safe and efficient unloading, handling, and
transporting. Triple-stacking allows a mailer to make better use of
transportation for drop shipments when low-weight pallets are prepared.
When stacking pallets, the mailer must place the heaviest pallet on
the bottom and the lightest pallet on the top to prevent crushing or
other damage to mail on the bottom. If part of the load is crushed, the
entire load is likely to collapse.
B. Securing Stacked Pallets Together
The proposed rule required that all stacked pallets be secured
together with at least two straps at least \1/2\ inch wide. Several
commenters were opposed to this requirement. Two commenters stated that
they stretchwrap stacked pallets together and that the stacked loads
maintain their integrity throughout transportation and processing.
These commenters indicated that stretchwrapping stacked pallets is
consistent with the stretchwrapping operation in their plants for
single pallets and that a requirement to strap or band stacked pallets
would add an unnecessary cost to their operations.
The Postal Service proposed that mailers be required to secure
stacked pallets with banding or strapping because this material is
easier to remove than stretchwrap. Only one cut per band is required on
no more than two sides of a banded pallet, whereas a stretchwrapped
pallet must be cut around all four sides of the stacked pallets to
separate the pallets and to insert a forklift or pallet jack. If
pallets are triple-stacked, the stretchwrap must be cut on all four
sides (two times between the bottom and middle pallets and between the
middle and top pallets). Not only is this method time-consuming, it can
be difficult to move around a tall pallet load in a full vehicle in
order to cut the stretchwrap and remove the top pallet(s). The
requirement to strap stacked pallets together is adopted in the final
rule. The mandatory compliance date is July 1, 1996, to allow mailers
who currently use other means of securing stacked pallets together to
change their preparation methods.
C. Use of Top Caps
Three commenters raised issues about top caps. Under the proposed
rule, mailers would have been required to top-cap the lower pallets
when pallets were stacked. Top caps have been found to be one of the
key elements in ensuring the stability of stacked pallets. However, as
one commenter noted, the characteristics of certain mail can provide a
flat, stable, and protective surface on which to place a pallet (for
example, cartons of books placed on a pallet), making top caps
unnecessary. The Postal Service agrees. Therefore, the final rule is
modified to make top caps optional on stacked pallets when the top
surface of the pallet load provides a sturdy, flat surface parallel to
the pallet base, that allows for safe and efficient stacking and for
preventing damage to mail or crushing of the load from pallets placed
on top. The Postal Service will monitor the preparation of all stacked
pallets, particularly those that are triple-stacked, to ensure that the
pallets can be handled safely and without damage to the mail.
One commenter asked whether the Postal Service will provide top
caps. Although the Postal Service does have a limited supply of top
caps, it has no plans, at this time, to provide them to mailers on a
general basis. By limiting the circumstances under which top caps are
required, the Postal Service expects mailers to continue providing
their own top caps to ensure the integrity of stacked mail loads.
Two commenters indicated that top-capping pallets can create
problems for consolidators who combine pallets and move them closer to
destinating postal facilities. Because consolidators are not
manufacturing plants, they do not have scrap material to sue for top-
capping stacked pallets. Mailers who prepare lightweight pallets that
are likely to be stacked by consolidators for drop shipment must work
out arrangements with their transportation agents about whose
responsibility it is to top-cap those pallets. Regardless of the
arrangements, stacked pallets must be top-capped when required to
maintain load integrity.
D. Top Cap Construction
Mailers may determine the best material for ensuring pallet
integrity and may use manufacturing materials that come into their
plants as top-capping material. Mailers must not use flimsy paper
obtained from the ends of paper rolls or similar material for top caps
because this material, used alone, can cause stack failure.
VIII. Securing Single Pallet Loads
Depending on the characteristics of a mail load, strapping might
not be the most effective method of ensuring load integrity of a single
pallet throughout transportation and mail handling. Loads can compress
during storage in a mailer's plant or while in transit, causing
strapping to become loose. In those instances, stretchwrap can be more
effective in securing loads on a single pallet. Therefore, in the final
rule, the proposal allowing mailers to choose the most appropriate
method of securing a single pallet load is adopted. Acceptable methods
include strapping or wrapping with stretchable or shrinkable plastic
wrap.
IX. Pallet Sortation Levels
This final rule does not adopt any of the proposed changes related
to levels of pallet sortation, including the proposed allowance for
working pallets or the elimination of the ``courtesy pallet,'' by
requiring that all mailings placed onto any pallet be sorted to the
finest level of presort. Modified proposed standards will be included
in the Federal Register notice containing proposed DMM
[[Page 66146]]
language to implement the pending classification reform filing.
The following revisions are made to the Domestic Mail Manual,
incorporated by reference in the Code of Federal Regulations, See 39
CFR part 111.
List of Subjects in 39 CFR Part 111
Postal Service.
PART 111--[AMENDED]
1. The authority citation for 39 CFR part 111 continues to read as
follows:
Authority: 5 U.S.C. 552(a); 39 U.S.C. 101, 401, 403, 404, 3001-
3201-3219, 3403-3406, 3621, 3626, 5001.
2. Revise the following sections of the Domestic Mail Manual as set
forth below:
E Eligibility
* * * * *
E300 Third-Class Mail
* * * * *
E333 Carrier Route Presort
* * * * *
3.0 PRESORT
3.1 Qualifying Mail
* * * * *
[Add the following at the end of the current section:]
c. Correctly presorted carrier route packages that meet the package
preparation standards in M043 and are sorted to the appropriate pallet
level.
* * * * *
E350 Destination Entry Discounts
* * * * *
3.0 DEPOSIT
* * * * *
3.8 Unloading Vehicles
The mailer is responsible for the unloading of vehicles, subject to
these conditions:
[Add new 3.8a and redesignate current 3.8a through 3.8c as 3.8b
through 3.8d, respectively. Amend redesignated 3.8b.]
a. Postal employees unload palletized and containerized loads at
MBMCs/FSFs/SCFs, except that the USPS does not unload or permit the
mailer (or mailer agent) to unload palletized or containerized loads
that are unstable or severely leaning or that have otherwise not
maintained their integrity in transit.
b. [Remove the second sentence.]
* * * * *
E400 Fourth-Class Mail
* * * * *
E416 Special Fourth-Class Rates
* * * * *
2.0 SPECIAL FOURTH-CLASS PRESORT
* * * * *
2.6 Level A
[Revise the introductory text as follows:]
To qualify for the special fourth-class presort level A rate, a
piece must be in a mailing of at least 500 pieces receiving identical
service, properly prepared and presorted under M404 in full 5-digit
sacks or under M044 on 5-digit pallets. These conditions also apply:
* * * * *
2.7 Level B
[Revise the introductory text as follows:]
To qualify for the special fourth-class presort level B rate, a
piece must be in a mailing of at least 500 pieces receiving identical
service, properly prepared and presorted under M404 in full or
substantially full bulk mail center (BMC) sacks or under M044 on
destination BMC pallets. These conditions also apply:
* * * * *
E450 Destination BMC/ASF Discount
* * * * *
3.0 DEPOSIT
* * * * *
3.8 Unloading Vehicles
* * * * *
a. [Revise the second sentence as follows:]
* * * The USPS does not unload or permit the mailer (or mailer
agent) to unload palletized or containerized loads that are unstable or
severely leaning or that have otherwise not maintained their integrity
in transit.
* * * * *
M Mail Preparation and Sortation
M000 General Preparation Standards
* * * * *
M030 Container Preparation
* * * * *
M033 Sacks and Trays
1.0 BASIC STANDARDS
* * * * *
[Add new 1.4 and 1.5 as follows:]
1.4 Sleeving and Strapping of Trays
Except under 1.5, each letter mail tray must be sleeved. All
nonpalletized trays of letter mail that are transported from the
mailer's plant to a BMC/ASF or AMF/AMC on USPS or mailer transportation
and all trays placed on BMC/SDC or mixed BMC/SDC pallets must also be
secured with a plastic strap placed tightly around the length of the
tray. The strap must not crush the tray or sleeve. Strapping is not
required on trays placed on pallets prepared to finer levels of
sortation.
1.5 Sleeving Exception
When all pieces in a mailing originate and destinate in the
delivery area of the same SCF and the trays containing those pieces are
not to be processed at a BMC or an AMF, the processing and distribution
manager may (on request) issue a written authorization to the mailer to
submit the mailing in trays without sleeves.
* * * * *
3.0 BASIC STANDARDS FOR TRAYS--AUTOMATION RATES
* * * * *
[Remove current 3.6 and 3.7.]
M040 Palletization
M041 General Pallet Standards
[Revise 1.0 through 3.0 as follows:]
1.0 PHYSICAL CHARACTERISTICS
1.1 Standards
All pallets presented to the USPS, whether USPS- or mailer-
provided, must meet the standards in 1.2 through 1.4. Mail on such
pallets must meet the standards applicable to the class and rate
claimed.
1.2 Construction
Pallets must be made of high-quality material that can hold loads
equal to a gross weight of 2,200 pounds. Pallets must measure 48 by 40
inches and allow for four-way entry by fork trucks and two-way entry by
pallet jacks.
1.3 Securing
Except for pallet boxes under 4.3, loaded pallets of mail must be
wrapped with stretchable or shrinkable plastic strong enough to retain
the integrity of the pallets during transportation and handling.
1.4 Nonconforming Mailers
The USPS informs mailers or their agents who present palletized
mailings, including plant-verified drop shipment (PVDS), when their
pallets fail to meet basic pallet integrity and safety standards. After
July 1, 1996, once a mailer is notified and allowed to make changes to
improve load integrity, if the mailer's methods, or those of the
mailer's agent presenting PVDS mailings, do not work, the mailer is
considered nonconforming. A nonconforming mailer must meet the
[[Page 66147]]
specifications for nonconforming mailers for use of top caps, stacking
of pallets, pallet box construction, and maximum height/layers of trays
in 2.0 through 4.0. After July 1, 1996, mailers will be suspended from
the pallet program if their pallets continue to fail to meeting the
minimum standards for load integrity levels.
2.0 TOP CAPS
2.1 Use
Top caps are used as follows:
a. Except under 2.1b and 2.1c, all pallets of sacks, letter mail
trays, parcels, packages or bundles of mail, or pallet boxes must be
top-capped if the pallets are double- or triple-stacked when presented
to the USPS for acceptance.
b. The top pallet need not be top-capped if the strapping or
banding securing the stacked pallets together neither damages the mail
on the top pallet nor allows the stack to shift.
c. Lower pallet(s) containing either parcels or packages or bundles
of mail need not be top-capped if the top surface of each pallet load
provides a sturdy, flat surface, parallel to the pallet base, that
provides safe and efficient stacking of pallets placed on top and
prevents sliding of the top pallet(s), damage to the loaded mail, or
crushing of the load.
2.2 Construction
Any material may be used as a top cap if it provides a flat, level
surface horizontal to the base pallet, protects the integrity of the
mail below while supporting a loaded pallet above, and allows easy
entry of a forklift to remove the upper pallet(s). Flimsy paper or
fiberboard (e.g., the ends of paper rolls) or similar material is
inadequate and may not be used as a top cap.
2.3 Securing
A top cap must be secured to the pallet horizontal to the plane of
the base pallet, with either stretchwrap or at least two crossed straps
or bands, so that the top cap stays in place to protect the mail and
maintain the integrity of the pallet load.
2.4 Nonconforming Mailers
Nonconforming mailers (see 1.4) must use top caps on all pallets of
sacks, letter mail trays, parcels, or packages or bundles of mail,
regardless of weight, or on pallets containing pallet boxes 60 inches
high or less. Top caps must be approximately 48 by 40 inches and meet
one of these construction standards:
a. Five-wood boards, with uniform edges and nine-leg pallet contact
for stacking.
b. Fiberboard box-end style, with a minimum 3-inch side and wall
material of at least double-wall corrugated fiberboard C and/or B
flute.
c. Fiberboard honeycomb covered on both sides, with heavy
linerboard at least \1/2\ inch thick.
d. Corrugated fiberboard C flute sheet covering the entire top of
the load, with standard pallet solid fiberboard corner edge protectors.
3.0 STACKING PALLETS
3.1 Double- or Triple-Stacking
Pallets may be double- or triple-stacked if:
a. The combined gross weight of the stacked pallets (pallets, top
caps, and mail) does not exceed 2,200 pounds.
b. The heaviest pallet is on the bottom and the lightest is on the
top.
c. The pallets are secured together with at least two straps or
bands of appropriate material to maintain pallet integrity during
transportation and handling. Stretchable or shrinkable plastic wrap be
used to secure stacked pallets together until July 1, 1996.
d. Pallets are top-capped under the standards in 2.0.
e. The combined height of the stacked pallets and their loads does
not exceed 84 inches.
3.2 Nonconforming Mailers
Nonconforming mailers (see 1.4) who stack pallets are subject to
the conditions in 3.1, except that triple-stacking is allowed only for
pallets of parcels and the combined height of stacked pallets may not
exceed 77 inches.
4.0 PALLET BOXES
[Renumber current 4.0 through 6.0 as 5.0 through 7.0; add new 4.0 as
follows:]
4.1 Use
Mailers may use pallet boxes constructed of single-, double-, or
triple-wall corrugated fiberboard placed on pallets to hold sacks or
parcels prepared under M042, M043, or M044. Single-wall corrugated
fiberboard may be used only for light loads (such as lightweight
parcels) that do not require transportation by the Postal Service
beyond the entry office. The boxes must protect the mail and maintain
the integrity of the pallet loads throughout transportation, handling,
and processing. The base of the boxes must measure approximately 40 by
48 inches.
4.2 Maximum Height
The combined height of the pallet, pallet box, and mail may not
exceed 77 inches, except that until July 1, 1996, the combined height
may be up to 84 inches. The contents of the box must not extend above
the top rim of the box.
4.3 Securing
Pallet boxes must be secured to pallets with strapping, banding,
stretchable plastic, shrinkwrap, or other material that ensures that
the pallets can be safely unloaded from vehicles, transported, and
processed as single units to the point where the contents are
distributed with the load intact if:
a. The pallet and its contents are transported by the USPS from the
office where the mail is accepted to another postal facility where the
contents are distributed.
b. The weight of the mail in the box is not sufficient to hold the
box in place on the pallet during transportation and processing, a
pallet box must be secured to the pallet base.
4.4 Nonconforming Mailers
Nonconforming mailers (see 1.4) may use pallet boxes only if the
boxes are constructed of triple-wall corrugated fiberboard (C and/or B
flute material) with a maximum height of 77 inches.
5.0 PALLET PREPARATION
[Renumber 5.3 as 5.8; add new 5.3 through 5.7; revise renumbered 5.0 as
follows:]
5.1 Presort
[Delete the ``s'' at the end of ``Pallets'' in the first sentence.]
5.2 Minimum Load
In a single mailing, the minimum load per pallet is 250 pounds of
second-class, third-class, or fourth-class packages and bundles of
mail, parcels, or sacks (or three layers of letter trays of second-
class or third-class mail), except that the processing and distribution
manager of the facility where a mailing is entered may issue a written
authorization to the mailer allowing preparation of 5-digit or 3-digit
pallets containing less volume if the mail on those pallets is for the
service area of that facility.
5.3 Required Preparation
A pallet must be prepared to a required level of sortation when
there are 500 pounds of second-, third-, or fourth-class packages,
bundles, sacks, or parcels (or six layers of letter trays of second-
class or third-class mail).
5.4 Maximum Weight
The maximum weight (mail and pallet) is 2,200 pounds for a single
pallet.
[[Page 66148]]
5.5 Maximum Height
The combined height of a single pallet and its load may not exceed
these limits:
a. A maximum of 77 inches for packages, bundles, parcels, sacks, or
fiberboard pallet boxes and their contents (sacks or parcels) on
pallets, except that until July 1, 1996, the maximum for pallet boxes
is 84 inches.
b. A maximum of 12 layers of second-class or third-class letter
trays.
5.6 Nonconforming Mailers
For nonconforming mailers (see 1.4) of letter-size mail in trays,
the combined height of a pallet and its load may not exceed six layers
of MM or EMM trays.
5.7 Mail on Pallets
Mailpieces in trays, packages, bundles, and sacks must be prepared
under the standards applicable to the class of mail and rate claimed.
* * * * *
M042 Second-Class Mail
* * * * *
4.0 PREPARING PALLETS OF PACKAGES OR BUNDLES
[Remove current 4.1; renumber 4.2 through 4.5 as 4.1 through 4.4. Amend
renumbered 4.4 as follows:]
* * * * *
4.4 Sacking
[In the first sentence, change ``4.3'' to ``4.2.'']
5.0 PREPARING PALLETS OF COPALLETIZED FLAT-SIZE PUBLICATIONS
[Remove current 5.3; renumber 5.4 through 5.10 as 5.3 through 5.9.
Amend renumbered 5.5 and 5.8 as follows:]
* * * * *
5.5 Sacking
[In the first sentence, change ``under 5.4'' to ``under 5.3.'']
* * * * *
5.8 Documentation
* * * * *
d. [Remove ``/650.'']
* * * * *
[Revise the heading of 6.0 as follows:]
6.0 PREPARING PALLETS OF SACKS OR TRAYS
[Remove current 6.1; renumber 6.2 through 6.4 as 6.1 through 6.3. Amend
renumbered 6.2 and 6.3 as follows:]
* * * * *
6.2 Presort and Labeling
Presort sequence and labeling:
a. 5-digit (required for sacks, optional for trays); use
destination of packages for Line 1.
b. Multicoded city (optional); use L001 for Line 1.
c. 3-digit (required for sacks, optional for trays); use L002,
Column A, for Line 1.
d. SCF (required); use L002, Column B, for Line 1.
e. SDC (optional); use L201 for Line 1.
f. Transfer hub (optional).
[Revise the heading of 6.3 as follows:]
6.3 Sacks and Trays
[Revise the first sentence as follows:]
Mixed states sacks and residual trays may not be included in the
palletized portion of a mailing. * * *
M043 Third-Class Mail
* * * * *
4.0 PREPARING PALLETS OF PACKAGES OR BUNDLES
[Remove current 4.1; renumber 4.2 through 4.6 as 4.1 through 4.5. Amend
renumbered 4.5 as follows:]
* * * * *
4.5 Sacking
[In the first sentence, change ``4.3'' to ``4.2.'']
* * * * *
6.0 PREPARING PALLETS OF COPALLETIZED FLAT-SIZE MAILINGS
[Remove current 6.4; renumber 6.5 through 6.12 as 6.4 through 6.11.
Amend 6.1 and 6.10 as follows:]
6.1 Standards
[Change ``4.2 through 4.6'' to ``4.1 through 4.5.'']
* * * * *
6.10 Sacking
[In the first sentence, change ``4.3'' to ``4.2.'']
* * * * *
7.0 PALLETIZING MACHINABLE THIRD-CLASS PARCELS
[Remove current 7.1; renumber 7.2 through 7.5 as 7.1 through 7.4. In
renumbered 7.2 and 7.3, change all references from ``7.2'' to ``7.1.'']
* * * * *
8.0 PALLETIZING THIRD- AND FOURTH-CLASS MACHINABLE PARCELS
[Remove current 8.2; renumber 8.3 through 8.8 as 8.2 through 8.7. In
renumbered 8.3 and 8.4, change all references from ``8.3'' to ``8.2'';
revise 8.1 as follows:]
8.1 Standards
[Change ``4.2 through 4.6'' to ``4.1 through 4.5.'']
* * * * *
[Revise the heading of 9.0 as follows:]
9.0 PREPARING PALLETS OF SACKS OR TRAYS
[Remove current 9.1; renumber 9.2 through 9.4 as 9.1 through 9.3. Amend
renumbered 9.1 and 9.2 as follows:]
9.1 Presort and Labeling
Presort sequence and labeling:
a. 5-digit (required for sacks, optional for trays); use
destination of packages for Line 1.
b. Multicoded city (optional); use L001 for Line 1.
c. 3-digit (required for sacks, optional for trays); use L002,
Column A, for Line 1.
d. SCF (required); use L002, Column B, for Line 1.
e. BMC (optional); use L705 (or L708 for BMC/ASF if DBMC rate is
claimed) for Line 1.
9.2 Line 2
[Change ``9.2'' to ``9.1'' at the end of the section.]
9.3 Remaining Sacks and Trays
All sacks and trays remaining after all pallets are prepared may be
presented with the palletized mailing (on the same mailing statement),
if the sacks or trays are segregated from the palletized portion of the
mailing.
M044 Fourth-Class Mail
* * * * *
3.0 PREPARING PALLETS OF PACKAGES
[Remove current 3.1; renumber 3.2 through 3.5 as 3.1 through 3.4.]
* * * * *
4.0 PREPARING PALLETS OF MACHINABLE PARCELS
[Remove 4.1; renumber 4.2 through 4.6 as 4.1 through 4.5.]
* * * * *
4.2 Line 2
[Change ``4.2'' to ``4.1'' at the end of the section.]
* * * * *
5.0 PREPARING PALLETS OF SPECIAL FOURTH-CLASS PRESORT
[Remove 5.1; renumber 5.2 and 5.3 as 5.1 and 5.2.]
* * * * *
5.2 Line 2
[Change ``5.2'' to ``5.1'' at the end of the section.]
[[Page 66149]]
M048 Automation-Compatible Flats
* * * * *
2.0 PACKAGE PREPARATION
[Renumber 2.1 as 2.0 and remove the 2.1 section heading; remove 2.2.]
* * * * *
An appropriate amendment to 39 CFR 111.3 to reflect these changes
will be published.
Stanley F. Mires,
Chief Counsel, Legislative.
[FR Doc. 95-30989 Filed 12-20-95; 8:45 am]
BILLING CODE 7710-12-M
