Safe Storage Practices for Materials on Pallets
The Problem
Pallets are essential for storing and organising materials, but they are more than just timber or plastic platforms—they are load-bearing tools that, if misused, can result in serious injury, property damage, or even fire hazards. Damaged pallets or poorly stacked goods can collapse without warning. Today, we’ll focus on safe pallet storage practices to help prevent injuries and maintain a safe, efficient worksite.
Identify the Hazards
- Collapsed Loads: Overloaded or damaged pallets failing under weight.
- Falling Objects: Unbalanced or overhanging items increasing the risk of falling.
- Blocked Exits: Pallets stored in front of doors or evacuation routes.
- Fire Hazards: Inadequate clearance around sprinkler heads or emergency access areas.
Safety Practices and Preventative Measures
Inspect Pallets Before Use
- Action: Check for cracked boards, splinters, protruding nails or signs of damage.
- Why: Damaged pallets are more likely to break under load.
- Solution: Tag and remove damaged pallets from service immediately.
Use the Right Pallet
- Action: Select pallets appropriate for the size and weight of the load.
- Why: Wrong-sized pallets can make loads unstable.
- Solution: Check the load rating and ensure it matches your task.
Stack Materials Evenly
- Action: Spread weight evenly across the pallet.
- Why: Prevents tipping and makes loads safer to move.
Interlock Bagged Items
- Action: Cross-stack or alternate every 10 bags high.
- Why: Helps prevent bagged materials from sliding or toppling.
Avoid Overhang
- Action: Ensure goods stay within the pallet's dimensions.
- Why: Overhanging loads shift easily and reduce stability.
Secure Loads
- Action: Use shrink wrap, banding, or straps.
- Why: Secures the load for transport and storage.
Store on Level Surfaces
- Action: Only place pallets on flat, stable ground.
- Why: Uneven surfaces can lead to leaning stacks or collapse.
Keep Aisles and Exits Clear
- Action: Never stack pallets in walkways or emergency exits.
- Why: Blocks emergency egress and creates trip hazards.
Observe Load and Height Limits
- Action: Do not exceed racking or floor load ratings.
- Why: Overloaded shelving can collapse.
Maintain Sprinkler Clearance
- Action: Keep 450mm of space between top of load and sprinkler heads.
- Why: Ensures sprinklers can operate properly during a fire.
Real-Life Case or Scenario
At a warehouse in Auckland, a partially broken pallet collapsed due to uneven stacking. Several items fell onto a worker’s foot, resulting in a lost-time injury. The cause was a mix of pallet damage and poor load balance—both preventable through a proper pre-use inspection and careful stacking.
Employee Responsibilities
- Inspect pallets before use and report damaged ones.
- Stack items evenly and securely.
- Keep aisles and exits clear.
- Respect all weight and height limits.
Employer Responsibilities
- Provide pallet safety training and guidelines.
- Inspect storage areas routinely.
- Replace damaged pallets and enforce proper storage methods.
Discussion & Questions
- "Have you come across an unsafe pallet or load recently?"
- "What could we do better to ensure pallets are stored safely?"
Encourage team members to share feedback and suggestions.
Commitment/Action Plan
Let’s agree to inspect pallets before each use and report damage immediately. Make sure all loads are stable and stored correctly to keep our site safe and organised.
Wrap-Up
Safe pallet storage helps prevent injuries, improve workflow, and reduce fire risks. Let’s make smart choices with every load and support each other in maintaining a safe site.
Standards Overview
WorkSafe New Zealand requires all workplaces to manage risks associated with storage and material handling under the Health and Safety at Work Act 2015. This includes proper use, inspection, and maintenance of storage systems such as pallets.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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