Top Hazards of Unsafe Pallet Stacking: How To Prevent Accidents in the Workplace

Studies have shown that nearly 2 billion pallets are in use throughout the world at any given moment. Most of them are the large wooden pallets that have been used for about a century, though some are also made from more modern materials, each with unique advantages. Our plastic pallets by ORBIS are a great example of wood alternatives. 

If your company regularly uses pallets, encourage your employees to take the necessary steps to prevent workplace accidents related to them. Unsafe pallet stacking, in particular, has become a big problem for many companies when it comes to employee safety. Attention to this issue is just as important as the quality and materials of the pallets you decide to include in your day-to-day operations. 

Would you like to learn about simple steps your employees can take to reduce the risks of stacking pallets? Find out about them below and put them to good use as you provide workers with the proper pallet stacking training. 

Pay Close Attention to Pallet Stacking Height

Many companies have been hoarding warehouse space in recent years and forcing competitors to use warehouses that are smaller than they might like. Because of this, it isn’t uncommon for certain companies to get into the habit of stacking pallets much higher than they should to make the most of their space. 

Generally speaking, your employees should stick to a six-foot height when creating stacks of pallets. If they attempt to stack pallets any higher than that, it could cause load distribution issues and, potentially, a pallet stack to fall over and injure workers. 

Avoiding unsafe pallet stacking starts with limiting how high your employees stack pallets to begin with. Keeping them at the six-foot mark can reduce the chances of pallets falling off stacks. 

Steer Clear of Overloading Pallets Before Stacking Them

Overloading pallets is another common mistake some companies make. They try to put too many items onto a single pallet, and when they stack that pallet on top of others, it can cause work injury risks. 

Overloading pallets can also lead to heavy pallets crushing lighter pallets that sit beneath them. This could destroy the products on these pallets and cost your company money. Always have your employees perform last-minute pallet inspections to ensure they haven’t overloaded them and set the scene for a workplace accident. 

Place Heavier Pallets at the Bottom of Pallet Stacks

Even if your employees don’t overload pallets, some pallets will no doubt weigh significantly more than others. If your employees routinely put these pallets at the top of stacks, it can throw off their load distribution and cause them to topple over. 

Your employees will need to plan carefully, but they should figure out how to strategically stack pallets so the heaviest ones are on the bottom while the lighter ones sit on top. This will keep these pallet stacks safe and make it easier to move pallets around when the time comes. 

Use the Correct Handling Techniques With Pallets

Hopefully, your employees can access the right equipment to practice proper pallet handling techniques. This equipment should include some combination of the following: 

• Forklifts 

• Jacks 

• Pallet jacks 

Make sure your warehouse employees are trained to use these pieces of equipment to move pallets. This alone can minimize unsafe pallet stacking incidents. 

Your employees may also find themselves in situations where they have to manually pick up pallets and move them. If they absolutely need to do this, ask them to lift pallets with their legs and keep them level to prevent them from tipping over. 

Consider Upgrading to Plastic Pallets

If your employees notice any pallets that aren’t in the best condition, they should notify you about it, and you should work to have these pallets removed from regular rotation. Pallet condition is one more thing that’s important to preventing accidents involving pallets in the workplace. 

Your company could even consider upgrading your current pallets to durable and lightweight plastic pallets from ORBIS. They’re easier to maneuver, simpler to stack, and much safer than their traditional counterparts. 

At the same time, when stacked correctly, these plastic pallets are tough enough to withstand whatever your employees might throw at them without falling over. 

Want To Put an End to Unsafe Pallet Stacking? Let Us Help!

Unsafe pallet stacking can lead to avoidable accidents taking place among your employees. You can prevent these unfortunate incidents from occurring by learning the right weight limit for pallets and putting the other tips found in this article to the test. 

ORBIS carries a large selection of high-quality plastic pallets along with other bulk containers that can come in handy for your company. Give us a call to place an order or to request a free quote.