In fast-paced working environments, from warehouses to retail stockrooms, knowing how to stack pallets safely is essential – not just for maximising space, but for maintaining a safe workplace for everyone. Poorly stacked pallets can lead to serious incidents, including injuries from falling loads, damaged stock, and costly disruptions (both in terms of money and time!). Given that handling and lifting injuries account for around 17% of all non-fatal workplace injuries in the UK, your pallet stacking procedure isn’t one to overlook.
Enter this guide. We’ll walk through safe stacking techniques, common patterns to use, key equipment recommendations, and how to avoid common mistakes. So, whether you’re managing a small stockroom or a large distribution centre, stick with us for some valuable advice.
Here’s what’s coming up:
- Why proper pallet stacking matters
- Key safety principles
- Common stacking patterns
- Recommended equipment
- Stacking pallets safely: step-by-step
- Common mistakes to avoid
- Conclusion
Why Proper Pallet Stacking Matters
Stacking pallets might seem straightforward but doing it carelessly can cause real problems. When stacked incorrectly, pallets become unstable, which increases the risk of injuries, stock damage, and operational delays. Plus, collapsed loads can also block walkways and damage expensive handling equipment, putting a spanner in the works beyond just the initial incident.
From a business perspective, poor pallet stacking wastes valuable storage space and slows down productivity. It can also lead to failed inspections or enforcement action if standards aren’t met, resulting in consequences ranging from minor inconveniences to hefty fines.
Ultimately, knowing how to stack pallets safely, and implementing this knowledge into your daily practice, supports smoother workflows and makes it easier for teams to do their jobs free of unnecessary manual handling hazards.
Key Safety Principles To Keep In Mind
Before stacking pallets, it’s important to understand the broader safety considerations that underpin day-to-day handling. These aren’t just best practices: they’re often required by workplace regulations and supported by HSE guidance, including the PM15 code of practice on pallet safety.
Know Your Limits
Stack height should always be kept within safe working limits – generally no more than 1.5 to 1.8 metres – unless racking or appropriate restraints are in place. Overstacking significantly increases the risk of collapse and makes it much harder to manoeuvre pallets safely. A good rule of thumb is not to stack higher than the length of the base of the pallet. So, if your load looks like a cube, you’re at your upper limit.
Also, ensure loads do not exceed the rated capacity of your equipment, be they pallet trucks or stackers. Overloading can cause tipping, brake failure, and excessive wear.
Accounting For The Handling Method
How a pallet is going to be moved should influence how it’s stacked. For instance, a pallet intended for use with a manual pallet truck should have a relatively stable, low centre of gravity, as these tend to be harder to stabilise once moving. If pallets are being stored at height or lifted frequently, powered stackers or mobile elevating work platforms (MEWPs) may be safer alternatives.
Keep Visibility And Access In Mind
Ensure that stacked pallets don’t block any walkways, fire exits, or reduce visibility around corners. Poor layout planning will contribute to collisions and injuries, so if it’s necessary to use areas with reduced visibility, implementing signage can be a good move to keep people alert when stacked pallets may not be immediately obvious. Stacks should also be positioned with enough clearance for safe loading, unloading, and inspection.
Train And Supervise Appropriately
Even with good equipment and strong policies in place, pallet stacking errors often come down to a lack of training or oversight. All relevant staff should be trained in proper stacking techniques, equipment handling, and hazard awareness. Supervision is also key to make sure that guidelines are followed consistently, especially in operations with high volumes or a high turnover.
Common Pallet Stacking Patterns
When it comes to how to stack pallets safely, choosing the right stacking pattern for within the pallet can make a big difference to both load stability and space efficiency. The right method will depend on your product type, how the load will be moved, and whether it’s being stored for an extended period of time or shipped quite quickly.
Firstly: Column Or Interlock Stacking?
Before looking at specific patterns, it’s important to understand the two main stacking approaches to guide your decisions:
- Column stacking refers to placing each item directly on top of the one below, in neat vertical lines. It maximises vertical strength and works well for lighter items in rigid, uniform packaging. However, it offers less side-to-side stability and may require extra strapping to stay secure.
- Interlock stacking staggers each layer, helping to “lock” the stack together, like a brick wall. This improves stability, especially for heavier loads or during transport, but can reduce vertical strength, potentially leading to load leaning or shifting, especially if pallets are not fully filled or rigid.
Types Of Pattern
Each stacking pattern below is a variation of one of the above techniques, designed to suit different load types and situational needs:
Block Stacking
This is the most space-efficient method. Items are stacked directly on top of each other in a cube-like formation, typically using column stacking. It works well for strong, evenly sized loads, but care must be taken to ensure that each row can bear the weight of the one above.
Brick (Or Cross-Tiered) Stacking
Each layer is offset, much like laying bricks. This interlocking method helps to prevent shifting during movement and is particularly useful when stacking on less stable surfaces.
Pinwheel Stacking
A more complex interlocking pattern where each corner of the stack alternates direction, forming a pinwheel-like layout. This is commonly used for mixed or irregular loads as it distributes weight more evenly. It’s stable but can make it harder to access those stacks in the centre and is less space-efficient.
Row Stacking
Pallets are arranged in rows, typically length-ways and then width-ways, without interlocking. It’s a simple method best used for uniform loads and works well when combined with shrink wrap or straps for added security.
Ultimately, choosing the right stacking pattern helps you to get the most out of each pallet, making loads much safer to handle and less likely to shift or collapse.
Recommended Equipment For Manoeuvring And Stacking Safety
Utilising the appropriate equipment is essential for ensuring safe and efficient pallet stacking. Here are three products which will (literally) take the load off you.
Pallet Trucks
When it comes to safely transporting pallets, for example, across a warehouse floor, there’s nothing better than a pallet truck. They come in various types depending on your needs:
- Manual pallet trucks: ideal for general use and reliable daily performance.
- Electric pallet trucks: provide powered movement to reduce manual effort and increase overall efficiency.
- Scissor lift pallet trucks: enable lifting pallets to slightly higher levels, facilitating stacking and retrieval.
Pallet Stackers
Pallet stackers are designed to lift and stack pallets to greater heights safely. They are especially useful in those environments with limited space or where manual stacking is impractical.
- Manual pallet stackers: offer a cost-effective solution.
- Electric pallet stackers: provide powered lifting to reduce physical strain and to better handle more demanding loads.
Forklift Attachments And MEWPs
For operations involving any type of forklift truck, various attachments can enhance functionality and safety, such as fork extensions that increase the length of the fork, allowing for safe handling of larger pallets, or lifting hooks which enable the lifting of items that cannot be handled by standard forks.
For stacking tasks that involve working at height, MEWPs are essential, providing a stable platform that is compliant with working at height legislation.
How To Stack Pallets Safely: Step-By-Step
So, we’ve covered general safety considerations, stacking patterns, and suggested equipment. With this wealth of information in mind, here’s a step-by-step method to ensure you’ve got how to stack pallets safely down.
1. Inspect Your Pallets
Before stacking, always check pallets for damage or wear – such as cracks, broken boards, or twisted bases. Defective pallets can lead to instability and increase the risk of collapse. Under PUWER 1998, this should be done regularly anyway, but the HSE also recommends checking pallets after each delivery or load cycle to ensure they remain safe enough to use.
2. Select The Right Stacking Pattern
Choose a stacking method suited to your load. For stable, uniform goods, block stacking works best. If loads are irregular or heavy, consider brick stacking. Whichever you choose, the stacking pattern should help to distribute weight evenly and maintain balance, especially if loads are to be moved frequently.
3. Stack By Weight And Size
Always place heavier and larger loads at the bottom of the stack. This lowers the centre of gravity and prevents lighter loads from being crushed or damaged. Where possible, avoid mixing pallet types or sizes in the same stack unless they are all rated to handle the weight above.
4. Align Loads Securely
Each pallet should sit squarely on the one below, with no overhang. Misaligned pallets increase the risk of tipping and make it much harder for forklifts or pallet stackers to lift safely. This is especially important when stacking numerous layers, as small deviations can get much bigger and riskier with height.
5. Follow Height And Weight Guidelines
As already mentioned briefly, always stay within your site’s stack height limits. As a general guide:
- Loaded pallets should not be stacked more than 2-3 high, depending on load stability, weight, and handling method.
- Never exceed the pallet’s rated capacity, or the limits of the stacking surface and/or equipment.
- In line with HSE PM15, assess each stack based on risk, considering the pallet type, load uniformity, and method of retrieval.
6. Fasten And Secure
If the stack is being stored for any length of time or will be moved, secure it with wrapping, strapping, or corner boards. This will reduce the risk of shifting, especially if loads are unstable or partially filled. Plus, in outdoor or low-security contexts, it also prevents theft or tampering with the load. Just be sure that securing methods don’t add excessive pressure, as this can deform the lower levels.
Common Stacking Mistakes To Avoid
Before we round off this post, here are just a few common mistakes that even the most experienced of manual handling teams should watch out for:
Overlooking Pallet Racking
Pallet racking systems are only as safe as their condition. Damage, poor layout, or overloading can all lead to serious incidents. According to HSE guidance, racking should be inspected regularly by staff and at least once every 12 months by a technically competent individual.
Not Stacking Like With Like
Mixing different pallet types, sizes, or loads in one stack risks creating imbalance and weakening the stack’s structure. Where possible, always prioritise stacking pallets with similar weights and loads to maintain even distribution.
Leaning Pallets On Their Sides
Leaning pallets upright against a wall or racking is a common shortcut, and a major hazard. They can fall easily without warning, especially when knocked, exposed to vibrations, or even simply from weather conditions if stored outside. Always store pallets flat and be sure to stack them according to approved procedures.
Stacking Pallets On Uneven Ground
Even a slight slope or uneven surface can compromise the stability of a pallet stack, increasing the risk of tipping or collapse, especially when it comes to heavier loads. Always check that the ground is level, dry, and free of debris before stacking. It can help to use designated pallet zones or floor markings to guide safe placement.
Final Thoughts
By now, we hope to have given you more of an idea on how to stack pallets safely: it’s not just about saving space. By following best practices, using the right equipment, and staying in line with HSE guidance, businesses can reduce the risk of accidents, protect stock, and improve day-to-day operations.
Ultimately, safe pallet stacking starts with good habits and the right equipment. To get a head start, explore our full range of manual handling equipment to support safer, smoother operations.