Pallet Safety: Best Practices for Warehouse Operations

According to the Bureau of Labor Statistics, pallet-related injuries account for roughly 30,000 workplace incidents in the United States each year. Most of these are preventable with proper training and procedures. Here's what every warehouse operation should know.

Inspection before use is the foundation of pallet safety. Before loading any pallet, check for cracked or missing boards, protruding nails, broken stringers, and signs of contamination (chemicals, mold, pest damage). A compromised pallet under load is an accident waiting to happen.

Proper stacking matters. Stack pallets on level, firm surfaces. Never exceed the manufacturer's rated capacity. Stack pallets no more than 60 inches high for wooden pallets on the floor — higher stacking requires racking. When stacking empty pallets, keep stacks to 15 or fewer to prevent toppling.

Forklift operation around pallets requires specific training. Operators should approach pallets squarely, insert forks fully before lifting, and never use a single fork to drag or push a pallet. Forks should be spread as wide as the pallet allows for maximum stability during transport.

Manual handling of pallets is where many injuries occur. Empty pallets still weigh 30-50 lbs, and awkward gripping positions lead to strains and pinch injuries. Workers should wear gloves when handling pallets, use team lifts for heavy or awkward pallets, and never throw pallets off trucks or stacks.

Nail and splinter hazards are the most common pallet injuries. Protruding nails can cause puncture wounds, and rough-sawn wood can cause splinters. Any pallet with protruding nails should be repaired or rejected immediately. Workers should wear puncture-resistant footwear and gloves.

Storage of empty pallets should be organized and stable. Leaning pallets against walls or stacking them haphazardly creates falling hazards. Designate specific areas for empty pallet storage, use upright storage racks if available, and keep walking and driving paths clear.

At Bakersfield Pallet Co., every pallet we ship has been inspected for safety hazards. We remove or re-set protruding nails, replace cracked boards, and reject pallets with structural defects. But even with quality pallets, safe handling practices are essential. If you'd like a pallet safety assessment of your warehouse operations, contact us — we offer free consultations.