A metal pallet (10) has a deck (12), a base (14) and a plurality of beams (16) therebetween. The deck (12), the base (14) and the beams (16) may be formed from lightweight sheet metal. The metal sheets are folded into the desired shape to respectively form the beams (16), and panels (18, 22) and slats (20, 32) for the deck (12) and the base (14). The panels (18, 22) and the slats (20, 32) are corrugated and the opposed side edges thereof may be folded upon themselves to provide for robust multi-ply edge constructions. Different types of corrugations may be provided over the panels (18, 22) and the slats (20, 32) to locally reinforce the pallet (10). The bottom portion of the beams (16) may be plastically deformed to create arched opening (58) to permit side entry of pallet handling equipment. The plastically deformed regions (60) of the beams (16) may be configured to improve the mechanical properties of the beam while providing maximal clearance for pallet handling equipment.