In the world of warehouses and distribution centers, empty pallets often find themselves in a temporary limbo. They’ve fulfilled their cargo-carrying duties, but their next journey up the supply chain must wait until enough accumulates for transport. Amidst this logistical dance, how to stack empty pallets safely becomes a crucial consideration. While a haphazard pile might seem harmless, it can quickly transform into a toppling hazard, disrupting operations and potentially causing injuries. But by mastering safe pallet stacking techniques, we create order amidst the temporary chaos and ensure a secure and efficient workspace for everyone.
Those towering stacks of empty pallets might seem harmless, but they can be more than an eyesore; they’re a hidden safety risk in many warehouses and fulfillment facilities. Even when empty, the standard reusable wood block pallet weighs a hefty 65 – 75 pounds. Plastic pallets, typically lighter than their wooden counterparts, can still weigh over 50 pounds — enough to cause injury if they topple over. Even lightweight plastic, while less flammable than wood, can still melt or ignite in extreme heat, posing a fire hazard if stored improperly near ignition sources.
Therefore, proper pallet stacking practices are more than just a box to tick; they’re crucial for employee safety and preventing costly disruptions. Equipping your warehouse team with the knowledge and resources to safely handle and store empty pallets translates to a healthier, more productive work environment for everyone.
How to Stack Empty Pallets Safely
Safe pallet stacking starts with a simple rule: always begin on a flat, level surface. To prevent injuries, use lifting equipment when handling pallets. If manual lifting is necessary, ensure personnel safety by following proper procedures. These procedures include:
- Teamwork makes the (stacking) dream work: Always work in pairs for improved balance and safety when manually stacking pallets.
- Gear up for defense: Wearing gloves and proper Personal Protective Equipment (PPE) shields against splinters and lacerations. Ensure boots are worn to protect feet from crush injuries in case of a pallet fall or drop.
- Bend it like Beckham: Remember, your legs are powerhouses — use them (instead of your vulnerable back) to lift pallets. Grab an edge and slide it onto the stack, keeping the weight off your body and maximizing leverage.
- Stick to six feet: Skyscraper stacks might look impressive but keeping them shorter is safer. Use forklifts for anything higher than six feet.
Make sure pallets are on a flat surface and stacked evenly. Think of the game Jenga. Every block needs support, or the whole tower could come crashing down, a disaster for workers and products. Improperly stacked wooden pallets are even more dangerous, and pallets showing cracks or breakage in edge boards, stringers, or blocks are hazardous. They should be separated for repair or disposal rather than added to the stack.
The International Fire Code (IFC/ICC) and the National Fire Protection Association (NFPA) set strict guidelines to protect you and your property. These include:
- Clearance Zones: Keeping stacks away from buildings isn’t just about looking tidy; it’s about fire safety. These codes specify conditions for pallet storage, including regulations on stack height and distances from buildings and property lines. Codes also vary by state. To ensure legal and physical safety, align your insurance policy with these regulations and consider following any additional guidelines provided by your insurance company.
- Pallet Storage Regulations: These codes outline specific conditions for pallet storage, encompassing regulations regarding stack height and the distances maintained from buildings and property lines. It’s crucial to note that the applicable code may vary based on state regulations.
How High Is Too High to Stack Pallets?
According to NFPA standards, idle pallet stacks should not exceed 15 feet in height or cover an area over 400 square feet for outdoor pallet storage. Insurance standards offer clearer pallet storage guidelines, prompting many companies to refer to their policies for compliance. Guidelines from insurers like Nationwide Mutual Insurance Company and West Bend Mutual Insurance offer valuable insights. For idle pallet storage, common recommendations include limiting floor stacks to six feet in height, grouped in fours with at least eight feet between groups. Stacks above six feet inside the warehouse should be safeguarded by an automatic fire sprinkler system, following NFPA standard 13. Empty pallets stored in racks require protection through an Early Suppression Fast Response (ESFR) sprinkler system to optimize warehouse storage space.
Insurance companies prioritize fire risk in pallet stacking and storage. Wood poses a heightened ignition risk because it is combustible and prone to splintering as it dries. Idle stacks of used wood pallets in facilities become significant fire hazards. Insurance standards focus on fire prevention to safeguard personnel and prevent warehouse destruction. The potential danger to employees and the substantial costs associated with warehouse renovation or rebuilding underscore the importance of taking fire threats seriously.
Only You Can Prevent Pallet Fires
Many warehouse managers opt for alternative materials like high-quality plastic pallets in response to fire safety concerns. Independent certifications have confirmed that some plastic pallets exhibit fire performance on par with or exceeding that of wood. This improved fire resistance makes them a viable alternative for supply chain pallet needs.
Unlike wood pallets, plastic pallets lack dangerous nails and rough edges. Plastic pallets offer increased durability, resilience, and consistent sizing, facilitating more stable stacking. Their smooth construction and lightweight design improve employee safety, warehouse operations, and equipment.
Companies interested in lightweight, easy-to-stack pallets should consider using iGPS plastic pallets for all their shipping needs. Our lightweight, recyclable plastic pallets are easy to track and reduce carbon emissions, which lowers the Total Cost of Business. For more information, contact us at 1-800-884-0225, email a specialist at switch@igps.net, or visit our contact page.
Image 2: Flickr User Michael Coghlan
