Mountains Belong Outside – A Pallet Stacking Plan Ensures a Safer Inside
Empty Pallet Mountains are Unsafe – It’s Better to Have A Plan
While we love our mountains in Colorado, but it’s best to avoid recreating the vista with empty pallets inside or around your facility. A pallet stacking plan will help ensure the safety of your team, create a more efficient process, and maximize your workspace. It’s a make-sense must-have, and here are some tips to help put you over the top.
Guidelines for Handling Empty Pallets
- Always start with a flat surface
- Only stack same-sized pallets together
- Pallets must stack together evenly
- Lay pallets flat, not vertically
- Do not include damaged pallets
- Set a safe stack height and stick to it –See below
- Keep stacks clear of lighting, electrical panels, and ventilation units
- Group stacks in 4’s with access space between
- Improve safety and stability with stacking frames or racking
Pallet Stacking Plan — Height Guidelines
Let’s look at what the authorities say about empty pallet stacking.
OSHA guidelines – Secure storage 1910.176(b) cites “Storage of material shall not create a hazard. Bags, containers, bundles, etc., stored in tiers shall be stacked, blocked, interlocked, and limited in height so that they are stable and secure against sliding or collapse.”
National Fire Prevention Agency (NFPA) – Idle pallet stacks should not exceed 15’ high or be greater than 400 sq. ft. Additionally, any obstruction that interrupts the full deployment pattern of a sprinkler’s water stream presents a problem and should be avoided.
Insurance company – these restrictions will vary by company but generally deal with fire prevention due to the wood combustibility.
A wood pallet stacking plan incorporating these guidelines should satisfy all the regulating bodies:
- Floor stacking – do not exceed 6’ high and include at least 8’ of space between groups of 4 stacks. An automatic fire sprinkler system should protect stacks taller than 6’.
- Rack stacking – repurpose under-utilized pallet racking for empty pallets and improve vehicle safety while opening up valuable floor space to improve traffic flow. However, the rack must have an Early Suppression Fast Response (ESFR) sprinkler system to ensure safety.
- Hand stacking – equip workers with proper PPE such as gloves and boots to protect against injuries. They should work in teams of two and follow OSHA lift guidelines.
Note: Workers should NEVER attempt to climb on the stacks of pallets.
Safety enforcement is always crucial to safety compliance, so be sure to train your team on the rules, include signs where appropriate as a reminder, and retrain anyone who is found out of compliance.
Stack Up Great Results with the Apex Team
Create your empty pallet stacking plan using these guidelines… or call in the Apex PROs to assist you with an overall safety and rack system inspection. Our team will inspect your racking for damage and ensure it’s used safely. We will also review your flow to pinpoint areas where warehouse safety may be compromised. You will receive a comprehensive report and plan for moving forward with any necessary repairs and or safety adjustments, including pallet stacking recommendations if desired.
The Apex PROs also offer group forklift training and certification if your team needs a refresher to stay OSHA compliant (three-year recertification for Class 1-5 vehicles, five years for Class 7).
Apex is a full-service pallet racking and material handling equipment provider. For all your warehousing needs, just call Apex –One call does it all.
