How To Safely Stack 10 Empty Pallets

How To Safely Stack 10 Empty Pallets

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How To Safely Stack 10 Empty Pallets

Pallet Management for Safe Pallet Stacking

Most businesses receive pallets in with their goods and products but then don't know what to do with the empty pallets. Empty pallets can be a liability to a business or an expense to dispose of properly. If a correct pallet management plan is in place empty pallets can become an asset for the company. Many companies buy and sell empty pallets at Repalletize. Pallet prices may be higher depending on your location.

Incorrect Pallet Stacking Can Put Employees At Risk

Incorrect Pallet Stacking Incorrectly stored pallets can be a safety hazard for employees. Pallets are bulky and can take up a lot of space on your dock, in your warehouse, behind your building or other places you store them. Pallets after much usage can begin to break and expose sharp pieces of pallet wood, nails and splinters that could injure an employee.

Correct Pallet Safety Can Reduce Employee Injuries

Correct Pallet Stacking We tend to see companies that do not have pallet management programs have more workplace injuries and more expenses in pallet removal. Employees who are not trained properly on who to stack pallets tend to set the pallets in uneven piles. Pallets typically are facing different ways, stacked on the sides, or are upside down. These piles of pallets are not safe and take up more space than correctly stacked pallets. In addition, it takes a lot of labor to clean these up and remove. Because stacking pallets can be unsafe OSHA inspectors can cite companies under housekeeping rules.

Guide to Safely Stacking Pallets

Pallets should never be place in a pile where they face different direction, are leaning up against something or upside down. Another problem is stacking pallets to high. Some companies institute 10 pallet high maximums and some others don?t stack above 18 high. Each pallet can weigh between 40 and 60 pounds so a stack that is too high can be very heavy.

To Stack Pallets Correctly:

Sort pallets by size.

Sort pallets by type

Sort pallets by condition

Do not stack damaged pallets

Employees Safety While Stacking Pallets

Workers that have to handle empty pallets are at risk for injury if the pallets are not correctly stacked. Moving pallets puts stress on your back, shoulders, wrists and forearms. Employees can also trip over pallets and hurt their feet or get hurt falling.

Pallet Equipment for Stacking Pallets

There are many types of tools and equipment that can make pallet handling safer. A simple piece of equipment to operate is a pallet jack. With a pallet jack employees can manually move pallets without much strain. With a forklift, employees can easily move pallets around and stack them. There are also pallet stackers that can help with pallet stacking.

Checklist for Stacking Pallets


When inspecting pallets you should first look at the condition. The condition should be good. If possible determine the Grade of the pallet , such as A Grade Pallets or B Grade Pallets. If the condition is bad you should separate them. Bad condition pallets that need repair have nails sticking out, splinters, broken boards, cracked boards or other defects. If the pallet is unsafe send it in for repair.

Sort by Pallet Size:

Pallets need to be sorted by size to be stacked correctly. The most common size pallet is a 48 x 40 inch pallet . However, there are many other pallet sizes and dimensions. Make sure you measure each pallet and stack each size in a different stack.

Sort by Pallet Type:

6 Pallet Sizes In addition to sorting pallets by size you should sort them by type. The most popular types of pallets are block pallets and stringer pallets. You also have plastic and corrugated pallets. All of these types should be stacked by size and type of pallet.

Damaged Pallets:

Be cautious when stacking damaged pallets. There are many things to look out for like nails, splinters, and loose boards. Get damaged pallets to the repair and recycling area as quickly as possible. If the pallets are to damaged for repair send them to be ground up into mulch.

Additional Tips for Stacking Pallets

Keep the area clean

Only stack pallets in approved areas

Use protective equipment on hands and feet

Safely lift pallets with correct tools and equipment

Don't stack pallets on their side

Don't stack to pallets to high.

Stack pallets 10 in high traffic areas and 18 high in no traffic areas.

Don't stack uneven