Forklift Operator Training – Push-Back Pallet Rack

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Push-Back Pallet Rack - Apex Companies

Steps for Loading and Unloading Push-Back Rack 

Push-back pallet rack is a Last-In/First-Out (LIFO) dynamic storage system that stores multiple levels of 2-5 pallets deep per lane. Pallets sit on wheeled carts that glide up and down inclined rails. It is considered a high-density system for its compact design and high-volume storage capacity. 

Push-back is popular in all types of warehouse settings for its ease of use and low maintenance. However, it’s important to follow forklift operator training specific to this system design. Using the proper steps for loading and unloading will protect your rack and equipment from damage and improve overall warehouse safety.

 

Before starting forklift operator training, ensure these four things are in place:

  1. All operators must be certified to operate the forklift they will be using.
  2. Only use pallets that are the correct size for the system design.*
  3. Inspect pallets for broken or missing boards that can cause system hang-ups.
  4. Confirm load weights are within the system’s specified load capacity.

*Safety Note: Pallets sit on wheeled carts in a push-back rack system. The driver must push carts back to load new pallets in the lane; therefore, the size of the pallet must match the system specs. This ensures that the pallets will be secure on the cart.

 

Getting Started with Push-Back Forklift Training

Push-Back Video Thumb - Apex Companies

 

End - Apex Companies

Load End of Push-Back Lane

System Loading:

  1. Square the forklift with the lane opening.
  2. Lift the pallet load approximately 3”- 4” above the first cart, being sure to clear any pallet stops that might be in the system construction.
  3. Slowly enter the rack system and place the pallet centered on the top cart –slowly back out.
  4. Next, line up the bottom boards of the 2nd pallet with the bottom boards of the first, just above the cart.
  5. Gently push back the 1st pallet as you enter the rack –centering the 2nd pallet over the exposed cart.
  6. Place the pallet on the cart and again back out slowly.
  7. Repeat the process to fill the lane.
  8. The last pallet is placed directly on the push-back rails.

Safety Note: Ensure that pallets sit squarely on the carts. If a pallet is misaligned, it may cause subsequent pallets also to be misaligned. To fix, secure the pallet onto the forks, back out of the system and reload.

Misaligned pallet - Apex Companies

3-Deep Push-Back Rack

System Unloading:

  1. Center the forklift with the pallet at the pick aisle.
  2. Slowly enter the lane and secure the pallet onto the forks.
  3. Lift the pallet 3”-4” so that it clears any pallet stops or obstructions.
  4. Slowly back out of the system –Notice that the subsequent pallets will automatically glide forward to the aisle due to the system design.
  5. Unloading steps are repeated to clear the lane.
  6. If rear pallets do not automatically flow forward, the driver should put the front pallet back into place and gently push back about 2”-3” to dislodge the rear pallets. 
  7. Slowly back out of the system again and confirm that the rear pallets have begun to flow forward. This should take care of most flow issues. If pallets remain stuck, however, follow the instructions below.

Safety Note: Bumper plates help the carts come to a low-impact stop; however, the forklift operator is responsible for controlling the speed of the rear pallets by taking care to slowly back out of the system.

 

Pallet Stops - Apex Companies

Pallet Stops

Bumper Plate - Apex Companies

Bumper Plate

 

Push-Back Rack Maintenance & Clearing Stuck Pallets

Regular maintenance and pallet rack inspection helps prevent cumbersome and expensive repairs, and it’s as easy as 1, 2, 3.

  1. Visually inspect lanes to remove any debris that may obstruct carts from flowing, such as broken pallet boards, shrink wrap, cardboard, etc.
  2. Check all bolted connections –tighten any that have come loose over time.
  3. Lift each cart and inspect the wheels, particularly in moist environments or where subjected to liquids. Wheels should spin freely.

Safety Note: Before entering a push-back lane, remove all pallets in the lane and the adjacent lane. Workers should also wear a safety harness for inspections or when clearing a hang-up. 

Purging a Stuck Pallet

When a pallet holds up in the lane and pushing back with the forklift does not release it, you must enter the system to dislodge it. To do so, fill all open pallet positions with an empty pallet to create a solid “pallet floor.” Then enter the system in the adjacent lane –be sure a safety harness secures you. Try to safely access, and evaluate the stuck pallet and cart. If it can be quickly released, do so and then carefully exit the system. The forklift operator can then extract the empty pallets and the last remaining pallet.

Contact management to report the issue if neither purging nor the safety floor method works. Unloading all lanes within adjacent bays may be necessary to evaluate further and correct the problem. The Apex PROs can help you get unstuck and get your system up and running safely again. 

 

push back video CTA - Apex Companies

 

Pallet Rack Inspection & Damage Repair at Your Fingertips

System-specific forklift operator training is essential for warehouse safety. And, while the goal is always zero incidents, accidents can happen, so it’s best to prepare.

The Apex Rack Repair App is a free downloadable app that helps you quickly and accurately assess any pallet rack damage. In addition, as you inspect the damage, you can upload your exact rack specifications to trigger a fast replacement kit if damage warrants a repair.

You can also call the Apex PROs, and we’ll come out to you and complete a full warehouse safety audit. Our PROs are certified rack and safety inspectors that review for things such as:

Rack System Assessment

  • Damage to frames, bracing, anchors
  • Beam deflection
  • System use vs. design intention
  • Bolted/welded connections
  • Decking quality 
  • Pallet condition
  • Load capacity

 

With the Apex Rack Repair App, you can choose to Do It Yourself and inspect your rack systems, or you can call the Apex PROs for full-service support; either way, your warehouse safety is in good hands.

Download the Apex Rack Repair Mobile App – Available on the App Store.

Call the Apex team for more information or schedule your next warehouse safety inspection.