EdApp by SafetyCulture

Pallets, Racks and Stacking Safety

By EdApp
5 Lessons
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About this course

In the warehouse, safety is of utmost importance. Take this course to learn how to productively stack, rack and handle pallets with precaution.

Pallets, Racks and Stacking Safety Lessons

Click through the microlessons below to preview this course. Each lesson is designed to deliver engaging and effective learning to your team in only minutes.

  1. Pallet Safety Guidelines
  2. Internal Inspections
  3. Pallet Load Limits
  4. Stacking Materials
  5. Empty Pallets

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Pallets, Racks and Stacking Safety course excerpts

Pallet Safety Guidelines

Pallets, Racks and Stacking Safety Course - Lesson Excerpt

Pallets, Racks and Stacking Safety

Pallet racking is extremely important in our business. Issues with things like installation and repair can have dire consequences in the warehouse.

We have to pay attention to these guidelines, as not adhering to them could result in injury of our co-workers. As always if you see something that looks hazardous, or could potentially be dangerous, please tell management immediately.

What can we do to preserve the integrity of the racks? Select the TWO that apply.

How do we stay safe? We have an inspection period built into our schedules for a reason. Though it may feel like it hinders our production time, it doesn't. It's one of the most important tasks we have. We should keep an eye on our pallets and make notes of damage. Any suspicion of a pallet or rack not working up to par should not be used. All damaged equipment should be removed from the floor. We have to pay attention to loading limits as well as distribution. This course will help us do that.

Internal Inspections

Pallets, Racks and Stacking Safety Course - Lesson Excerpt

Internal Inspections

Broken or damaged pallets can result in horrible accidents. To protect our co-workers, let's take our time and do thorough inspections.

Next, it's time to check the beams. First, make sure if there are any connectors missing. Then make sure no beams have popped out of the upright.

After that it's time to check the floor anchors. Make sure they aren't damaged and don't need replacing.

Some other tips: Look for overloaded or unevenly loaded pallets. This should be fixed immediately for everyone's safety. Pallets should be level and not exceed 15 feet (or 4.5 meters). Make sure the warehouse stays clean. Excess debris can be dangerous!

Pallet Load Limits

Pallets, Racks and Stacking Safety Course - Lesson Excerpt

Pallet Load Limits

Pallets are meant to hold a tremendous amount of weight when racked properly. However, let's not test its limits. That's how racking disasters happen.

But really, there are three types of weight limits: Static load capacity - the weight supported when a pallet is still **Dynamic load capacity **- the weight supported when a pallet is being moved Racking load capacity - the weight a pallet can hold when in a racking system (this is where it gets complicated)

A dynamic load is going to have less capacity than a static one. It's important to know these distinctions, but mainly, follow the listed load capacities, and we should be fine.

Reconditioned pallets Over time, pallets will have less weight capacity. This is why we should remain under the maximum load limit listed. If you have any questions about load limits, you can consult signage or management for a clear answer.

Stacking Materials

Pallets, Racks and Stacking Safety Course - Lesson Excerpt

Stacking Pallets Safely

When using a powered industrial truck: Center the load on the forks to evenly distribute the weight. Also make sure the weight is close to the mast. Do not overload. Do not try to add a counterweight on the back to carry a heavier load. Always keep the load on the lowest position possible when moving. Follow the particular vehicle's operating requirements.

Be aware of the material you're storing. It's important to know how and where to store materials safely. Not only the height and weight is important, but the nature of the materials should inform where it's placed.

ALWAYS follow these safety guidelines when storing materials, as load collapse and falling materials has the potential to crush or fatally pin your co-workers.

Other tips: Do not store paper or rags closer than 18 inches (45 cm) to a wall. This is a fire hazard.

When storing kegs or barrels make sure to block the bottom tiers to prevent rolling.

When storing kegs or barrels place either plywood, pallets or planks between them to create a firm stack.

Empty Pallets

Pallets, Racks and Stacking Safety Course - Lesson Excerpt

Stacking Empty Pallets Safely

If pallets are manually stacked: At least two people should be stacking them. This is not a one-person job. Use PPE like gloves and work boots to avoid splinters and crushed toes. As you probably know, lift with your LEGS not with your BACK. This is an ergonomic principle to use in all areas of your life. Empty pallets shouldn't be manually stacked over approximately 6 feet (or 2 meters). If you need to stack higher, then a forklift should be used.

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Pallets, Racks and Stacking Safety


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