Predicting the effect of pallet overhang on the box compression strength

A corrugated box's compression strength can easily be affected by how the box is used, including pallet overhang which reduces a box's effective compression strength (BCT). The specific impact of a given amount of overhang on BCT remains poorly defined. In the current study, a range of box sizes and constructions were examined in over a dozen single‐side overhang configurations and five adjacent‐side overhang scenarios to identify key factors contributing to loss of strength, producing an average reduction in BCT of up to 40%. These results indicated that common safety factors fit well with adjacent overhang scenarios but overestimate single‐side overhang scenarios. We developed a range of multiple linear and nonlinear regression models, estimating the change in a box's compression strength due to overhang compared with a no‐overhang scenario. The impact of overhang on the short and long sides, whether overhang exists on a single side or adjacent side, box size, and board type were all statistically significant. This work also indicates the need for further research refining the first‐order model and extending it to other materials, box sizes, and box aspect ratios.