09 Feb Stacking Materials Safely – Avoid a Pile of Trouble

Stacking Materials Safely – Avoid a Pile of Trouble

Safe stacking of materials is essential whenever boxes, bags, pallets, or other supplies are stored or moved. Poorly stacked materials can shift, collapse, or fall, causing struck-by injuries, property damage, and forklift or material-handling incidents.

Guide for Discussion

Start With a Stable Foundation

Every safe stack begins with a solid base.

• Stack materials only on firm, level surfaces.
• Inspect pallets before loading them.
• Do not use pallets that are cracked, broken, missing boards, or otherwise damaged.
• Make sure the floor or storage surface can support the intended load.
• Keep the area around stored materials clear and accessible.
• Correct uneven or unstable conditions before beginning the stack.

Never try to compensate for a damaged pallet or uneven surface by rearranging the load.

Build a Stable Stack

The way materials are arranged determines how stable the finished stack will be.

• Place heavier and larger items at the bottom.
• Place lighter materials toward the top.
• Distribute weight evenly.
• Keep the stack as straight and vertical as possible.
• Interlock boxes or containers when their design permits.
• Keep materials within the edges of the pallet whenever possible.
• Follow manufacturer limitations regarding maximum stacking height or number of containers.
• Do not stack materials so high that the stack becomes unstable.
• Never allow materials to lean or extend into aisles or travel paths.

If a stack appears unstable, correct it before leaving the area.

Boxes and Containers

Packaging can lose strength when excessive weight is placed on it.

• Follow stacking instructions printed on cartons or containers.
• Do not place excessive weight on crushable packaging.
• Inspect boxes for water damage, crushing, tears, or deterioration.
• Do not place damaged containers at the bottom of a stack.
• Keep the load balanced from side to side.
• Secure loads when necessary to prevent movement.

A crushed carton at the bottom can compromise the stability of the entire stack.

Bagged Materials

Bagged products require special attention because their contents can shift.

• Distribute the contents of each bag as evenly as practical.
• Lay bags flat to provide a stable surface for the next layer.
• Use an interlocking or appropriate stacking pattern.
• Do not allow bags to overhang excessively.
• Repair or remove damaged bags that could leak or destabilize the stack.
• Secure tall or potentially unstable stacks when necessary.

Secure Unstable Loads

Some materials cannot be stacked securely through arrangement alone.

When necessary:

• Stretch-wrap or otherwise secure palletized loads.
• Use banding or other approved restraints appropriate for the material.
• Use racks, bins, blocking, or other storage systems when appropriate.
• Protect materials from accidental contact with vehicles and mobile equipment.
• Restack materials that have shifted during transportation or handling.

Do not rely on plastic wrap or banding to compensate for an improperly constructed stack.

Forklift and Pallet Jack Operations

Materials that appear stable while stationary may shift when moved.

Before transporting a load:

• Verify that it is stable and properly secured.
• Make sure the pallet is in good condition.
• Know the approximate weight of the load.
• Confirm that the load is within the rated capacity of the forklift, pallet jack, or other handling equipment.
• Center and balance the load appropriately.
• Travel carefully to minimize sudden movement.
• Avoid abrupt starts, stops, and turns.
• Keep employees away from areas where materials could fall.

Never attempt to catch or manually stabilize a falling load.

Storage Racks and Floors

The supporting structure must be capable of handling the stored material.

• Know and observe rack and shelving capacities.
• Never exceed posted load limits.
• Report damaged racks, shelves, or structural components.
• Protect storage racks from forklift impacts where required.
• Distribute loads appropriately rather than concentrating excessive weight in one location.
• Do not climb racks or material stacks to retrieve items.
• Use appropriate ladders, platforms, or material-handling equipment to reach elevated materials.

Inspect Stored Materials

A stack that was safe when constructed may become unstable later.

Periodically look for:

• Leaning or shifting materials.
• Crushed or deteriorating boxes.
• Broken pallets.
• Loose wrapping or banding.
• Leaking containers or bags.
• Damaged storage racks.
• Materials protruding into aisles.
• Evidence that a forklift or other equipment has struck the stack.

Correct unsafe conditions promptly and keep personnel away from unstable materials until they can be safely restacked.

Remember

A stack is only as strong as its foundation and weakest component. Build loads on stable surfaces, place heavier materials at the bottom, stay within equipment and storage capacities, and secure materials that could shift or fall.