03 Jul Pallet Safety – Inspection, Loading, and Storage

Pallet Safety – Inspection, Loading, and Storage

Pallet safety is important whenever materials are stored, stacked, transported, or handled with forklifts and pallet jacks. Damaged pallets, unstable loads, improper stacking, and overloaded material-handling equipment can result in falling materials, damaged equipment, and serious injuries.

A pallet may look simple, but it supports significant weight and often receives considerable wear. Never assume a pallet is safe simply because it has been used before.

Inspect Pallets Before Use

Inspect each pallet before loading or handling it. Look for conditions such as:

• Broken, cracked, split, or missing boards.
• Damaged or missing blocks or stringers.
• Protruding nails, screws, staples, or sharp edges.
• Loose components or fasteners.
• Warped or badly deteriorated materials.
• Contamination from oil, chemicals, or other substances.
• Other damage that could affect the pallet’s ability to safely support the load.

Remove defective pallets from service. Do not place damaged pallets in a stack where someone may unknowingly use them later.

Never make unauthorized or makeshift pallet repairs.

Load Pallets Safely

A properly loaded pallet is less likely to shift, collapse, or fall during handling.

• Distribute the load evenly whenever possible.
• Center the load and maintain proper balance.
• Do not exceed the pallet’s rated or established capacity.
• Keep materials within the pallet footprint when practical.
• Secure loose or unstable materials with appropriate wrapping, strapping, banding, or other methods.
• Make sure containers and packages are strong enough to support stacking.
• Inspect the load before moving it.

Never attempt to move a visibly unstable load until it has been properly secured.

Stacking and Storage

Improperly stacked pallets and palletized materials can collapse without warning.

• Stack pallets and loads on firm, level surfaces.
• Keep stacks straight, stable, and properly aligned.
• Do not stack materials higher than can be safely supported.
• Do not use damaged pallets within a stack.
• Never climb or stand on stacked pallets or palletized materials.
• Keep stored materials away from aisles, exits, emergency equipment, and other required clearances.
• Periodically inspect stored loads for leaning, shifting, or damaged pallets.

Empty pallets should also be stacked securely in designated locations where they will not fall or obstruct travel routes.

Forklifts and Pallet Jacks

Only trained and authorized employees may operate powered industrial trucks.

Before moving a palletized load:

• Verify that the equipment has adequate capacity for the load.
• Make sure forks are properly positioned beneath the pallet.
• Check that the pallet is stable and capable of supporting the load.
• Keep the load stable and as low as practical while traveling.
• Maintain a clear view of the travel path.
• Keep pedestrians away from operating equipment and elevated loads.
• Never allow anyone to stand or pass beneath an elevated pallet or load.
• Never use pallets as personnel platforms unless an approved personnel-lifting system specifically designed for that purpose is being used.

Forklift overhead guards provide protection from certain falling-object hazards but do not make it safe to stand or travel beneath elevated loads.

Floor and Storage Capacities

Storage racks, mezzanines, elevated floors, and other supporting surfaces must be capable of handling the loads placed upon them.

• Know applicable load limits before storing heavy materials.
• Do not overload racks, shelving, floors, or elevated storage areas.
• Follow posted capacity limits.
• Report damaged racks, flooring, or storage structures immediately.

Handling Empty Pallets

Empty pallets can also cause strains, cuts, splinters, and crushing injuries.

• Wear appropriate gloves when handling rough wooden pallets.
• Use proper lifting techniques.
• Get assistance with heavy or awkward pallets.
• Do not throw or drop pallets.
• Keep hands and feet away from pinch and crush points.
• Remove loose nails, broken wood, and pallet debris from walking and working areas.

Remember

A damaged pallet should never become the “last resort.” Inspect pallets before use, load and secure materials properly, maintain stable stacks, and never exceed the capacity of pallets or material-handling equipment.

If a pallet is questionable, take it out of service before it becomes a failure.