Key Takeaways:
- Idle pallets can present safety hazards if left unattended or unaccounted for.
- Idle wooden pallets can fray and become fire hazards. For these reasons, they must be properly stored.
- Recommendations for proper idle pallet storage (outdoors) include stable stacking, keeping pallets in good condition, and separated storage from other storage areas for safety reasons.
- Guidelines for proper idle pallet storage (indoors) include not exceeding height limitation for pallet stacks, ensuring areas are equipped with sprinkler systems, and keeping pallet stacks separated properly.
- All the potential hazards of indoor and outdoor idle pallet storage can be eliminated by pallet pooling.
- With pallet pooling, idle pallets are kept to a minimum and eliminate potential hazards. Pallet pooling is safer, more manageable, and more cost-effective.
Regardless of whether they are part of your company’s internal pool or simply awaiting disposal, towering stacks of pallets are likely a common sight at most warehouses and fulfillment centers. In many cases, workers pile these pallets wherever they can find empty space, creating potential hazards. But idle pallets aren’t merely an inconvenience and business headache; they can also potentially topple over and catch fire, presenting a threat to facilities, equipment, and most worryingly, people.
In the case of wood pallets, frequent contact with packaging and equipment makes wood fibers susceptible to fraying and potentially becoming more combustible. Fire prevention is perhaps the most important reason that idle pallets must be properly and safely stored.

Outdoor Idle Pallet Storage Guidelines
A supply chain manager planning their outdoor idle pallet storage might be tempted to consult with government regulations for guidance. But the Occupational Safety and Health Administration doesn’t have as much to say about pallet stacking and fire prevention as it does about warehouse raking safety guidelines (link to previous blog).
Comprehensive pallet storage guidance is typically provided by the insurers that safeguard these facilities against losses. The typical recommendations given by these organizations include:
- Stable Stacking: Stacks of pallets should be arranged in stable piles with the broad horizontal side placed against the ground; pallets should never rest on their edges.
- Good Repair: Pallets that are damaged should quickly be identified, removed from the general pallet population, and either repaired, disposed of, or recycled.
- Separated Storage: Stacks of pallets should be housed well away from other storage areas. This reduces the possibility of a fire spreading from pallets to other work areas. Most insurers do not give an exact distance. Storage well away from propane and compressed gas storage areas is also essential.
It is important to note that these guidelines are not the only best practices that may apply in a given situation. Enterprises as well as local municipalities sometimes set their own rules for how pallets can be stored; a local fire department is often a smart resource for consultation.
While storing pallets in outdoor settings may seem like a safe way to reduce fire hazards, this can introduce other potential issues. Pallets that are stored outdoors are more exposed not only to insects and wildlife but also to the elements, which can introduce moisture, mold, mildew, and bacterial contamination. Enterprises that store and ship sensitive and perishable products like food and pharmaceuticals, which require careful environmental monitoring and safety considerations, are better off storing their idle pallets indoors.
Indoor Idle Pallet Storage: Keeping Your Facility Safe
For indoor pallet storage, the governing guidance is set by the National Fire Protection Association (NFPA) within the agency’s standards for the installation of sprinkler and fire suppression systems. The NFPA states that the preferred indoor storage location for idle pallets is in adjacent rooms or buildings that are separated from primary storage areas, ideally by protected entryways and non-combustible walls. This can include, for example, a concrete or masonry wall with a steel door. Steel columns in these storage areas should be protected by one-hour fire-rated coverings and the walls themselves should have a three-hour fire-resistance rating.
Idle pallet storage areas should be protected by NFPA 13-standard sprinkler systems; for rooms with pallet stacks that exceed certain height limitations, an ESFR sprinkler system may be needed. If idle pallet storage must be within the primary area of the main facility, the NFPA has issued the following guidelines:
- Stack Limitations: Pallets stacks on the floor should not be greater than six feet high for wood pallets and ten feet high for plastic pallets.
- Sprinkler Requirements: For pallet storage with stacks greater than six feet in height for wood pallets and ten feet high for plastic pallets, the storage area must be equipped with an Early Suppression Fast Response (ESFR) sprinkler system.
- Separation: Stacks of wood pallets, in groups of four, should be separated from other stacks by at least eight feet. If this is not possible, then the idle pallet storage area must be separated from commodities by a minimum of 24 feet.
One of the many benefits of pallet pooling, such as the solutions provided by iGPS Logistics, is that special storage for idle pallets and the storage of idle, unused pallets within a facility is kept to a minimum, eliminating most of these hazards.
Pallet storage takes up a considerable footprint inside and outside of a facility, and pallet storage also requires time and effort by workers, especially when pallets must be tidied up and rearranged. Creating separate storage areas and cutoff rooms that are safe and in compliance with fire codes also requires significant investments of time and resources.
Pallet pooling, or rental, programs provide manufacturers and distribution centers with only the pallets they need, when they are needed, which is nearly always a must more efficient and cost-efficient strategy (link to iGPS site). Pallet pooling eliminates the headaches associated with idle storage transportation, repair, storage, and disposal. This makes pallet pooling not only a safer and more efficient choice than managing an internal pallet pool, but also a more cost-effective one.
That being said, not all pallet pooling providers are the same. Look into the benefits of iGPS plastic pooling and learn why our pallets are the safer and more sustainable choice.
Frequently Asked Questions:
What are the requirements for idle pallet storage indoors?
Idle pallet storage indoors requires a designated area that is clean, dry, and well-ventilated to prevent moisture buildup and deterioration. Additionally, the storage area should have proper signage and clear pathways to ensure safety and accessibility for workers.
What are the standards for idle pallet storage?
The standards for idle pallet storage typically include adherence to guidelines set by organizations such as the Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI). These standards often dictate proper stacking methods, weight limits, and the need for safety measures such as fire prevention systems.
How high may idle pallets be stacked?
Idle pallets should generally not be stacked higher than 6 to 10 feet to ensure stability and minimize the risk of falling. However, specific height limits can vary depending on the type and material of pallets used and the recommendations of the pallet manufacturer.
What types of pallets should be used?
The types of pallets that should be used for storage include wood, plastic, and metal pallets, depending on the nature of the stored goods. Each material has its advantages; for example, plastic pallets are lighter, less resistant to moisture, and more durable.
The iGPS pallet pool is the ideal alternative to idle pallet storage. iGPS plastic pallet pooling eliminates the headaches of transporting, storing, and disposing of idle pallets. To switch or learn more, give our team a call at 800-884-0225, email a specialist at switch@igps.net, or visit our contact page.
Pallet pooling does away with the need to arrange special transportation solely for pallets and keeps the idle pallets in your warehouse to a minimum.