Drive-In Pallet Rack Forklift Loading Steps | Apex Safety Spotlight

Essential Forklift Operator Loading Procedures for Drive-In Pallet Racking

Drive-in pallet racking is a popular dense storage solution due to its high load capacity within a condensed footprint. The design requires forklift operators to drive into the pallet storage lane, which can be several pallets deep and levels high. After positioning the pallet load, the driver backs out of the lane, turns in the aisle, and drives away from the system. Each step in that forklift operation is fraught with potential risk, more so than with most other pallet storage rack systems. Drive-in rack forklift operators must be highly skilled and thoughtfully trained. 

Before focusing on drive-in pallet rack training, ensure that your forklift operators are OSHA trained and certified for the equipment they will be driving.

 

 

Drive-In Pallet Loading Procedures

Begin loading from the floor positions and up. You must start with the furthest pallet position and at the floor level. Then work up one level at a time from lowest to highest. Place subsequent pallets in the same fashion working back towards the lane opening.

NEVER load upper pallet positions first. This action can alter the system’s structural integrity and cause a system failure.

 

Drive-In Loading Steps:

1. Square the forklift with the opening of the drive-in lane.
2. Always load a Drive-In lane working from the FLOOR-Up starting with the last (or furthest) location.
3. The first pallet will likely be placed on the floor and potentially stacked two high.
4. To place a pallet on the rails, lift the pallet 3” to 4” above rail level.
5. Slowly drive to the last open pallet position, carefully lower the pallet onto the rails, and slowly back out of the system.
6. Lower the forklift mast. Never drive with the mast extended.
7. Ensure forks are clear of the rack before turning in the aisle.
8. Continue to load pallets – floor up/ and from BACK to FRONT until the lane is full. 

 

Important Drive-In Pallet Loading Cautions:

 

 

Misaligned Pallets – If the pallet is misaligned (not centered squarely on the rails), the driver MUST re-enter the rack and re-secure the pallet onto the forklift. Once the driver has the pallet secured on the forklift, it can be centered within the lane and lowered back onto the rails.

It is NEVER acceptable to push or pull the pallet along the rails hoping that it will “fall into place.” Unfortunately, that is a common and dangerous pallet loading error. This action stresses the system and could cause the pallet to shift and fall through the rails resulting in product and component damage and worker injury.

 

Drive-In Unloading Steps:

1. Enter the drive-in lane with the truck’s forks elevated to the height of the pallet to be removed.
2. Secure the pallet on the forks and raise it approximately 3” to 4” above the rails.
3. Slowly back out of the lane.
4. Lower the forklift mast. Never drive with mast extended.
5. Ensure forks are clear of the rack before turning in the aisle.

 

Other Safety Considerations for Drive-In Pallet Racking

• All pallets must be the same size.
• Damaged and weak pallets should not be placed in drive-in racking.
• Pallet load weights must comply with rated system capacity.

 

Where to Go for Full-Service Drive-In Pallet Racking Resources

The Apex team offers full-service support for warehousing and manufacturing operations. Our systems engineers and design teams will create the system that meets your inventory storage needs ensuring load capacity and safety features. Additionally, our expert forklift operator trainers conduct on-site team training and certification. Our on-site courses use your equipment for system-specific instruction. 

The purpose of our Apex Safety Spotlights is to prevent warehouse dangers and accidents; however, if you need rack inspection, the Apex Rack Repair App is the tool to use.

The Apex Rack Repair App helps users inspect pallet racking for damage. The app prompts users to take pictures and enter system specs to create a custom repair kit if the damage is structurally threatening.

We call this the Do It Yourself approach. Simply download the free Apex Rack Repair app onto your mobile device and conduct your pallet rack inspection. Once concluded, upload your results for a thorough review by the Apex PROs. You’ll receive a prompt, independent report and cost-effective repair solution if needed.

Another option is to call the Apex PROs to conduct your inspection and repair if needed. It’s up to you. Call our PROs for all your warehousing inspection and repair needs.

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