How to Properly Store Wooden Pallets: Safety and Technical Tips

Wooden pallets are essential in warehouses for moving, stacking, and storing goods, but improper storage can lead to serious safety risks. If mishandled, pallets can become fire hazards, cause injuries, and lead to costly fines. Here’s a detailed guide on how to store wooden pallets safely and avoid common hazards.

1. Store Idle Pallets Safely

Idle pallets can pose significant risks if not stored properly. Here’s how to avoid those hazards:

Don’t Stand Pallets Upright: A common mistake is to stand pallets on end when they’re not in use. This is dangerous because they can easily tip over, injuring anyone nearby. According to OSHA, pallets must be stored to prevent sliding and collapsing (OSHA Standard 1917.14).
Lay Flat and Stable: Store pallets flat and stacked evenly. Make sure they’re not placed in areas where workers need to step over them, as this can cause trips, falls, and twisted ankles.
Inspect for Protruding Nails: Regularly check for nails, splinters, or damaged boards that could cut or injure workers. Remove or repair any pallets that are unsafe to handle.

2. Fire Hazard Prevention in Pallet Storage

Wooden pallets are highly flammable, and if not stored correctly, they can significantly increase the risk of a warehouse fire. Here’s how to minimize fire risks:

Keep Pallets Away from the Main Facility: The NFPA recommends storing pallets away from the main facility whenever possible, as they can pose a fire hazard beyond what many sprinkler systems can handle. Refer to the National Fire Protection Association (NFPA) guidelines for more details.
Install Proper Sprinkler Systems: If pallets must be stored indoors, ensure that the area is equipped with a suitable automatic sprinkler system that meets NFPA guidelines for pallet storage.
Mind the Height and Clearance: Follow NFPA recommendations for stacking height and keeping adequate clearance from other combustibles. It’s important to maintain proper distances between stacks to prevent fire from spreading.
Outdoor Storage: If you store pallets outside, keep them at a safe distance from the building and other flammable materials. Use covers to protect them from rain and snow, which can cause rot and weaken the pallets over time.

3. Avoid Blocking Exits and Keep Aisles Clear

Pallets should never obstruct exits or emergency pathways. Improper storage can lead to fines and safety hazards:

Keep Exits Free: OSHA regulations require exit routes to be clear of any obstructions. Pallets blocking exits are a serious violation (OSHA Standard 1910.37).
Clear Aisles: Make sure that aisles are wide enough and free of pallet stacks to allow the safe movement of equipment and employees. This ensures that forklifts can navigate the area without risking collisions or injuries.
Avoid Blocking Emergency Equipment: Keep pallets away from fire extinguishers, emergency exits, and electrical panels to ensure they are easily accessible in an emergency.

4. Stack Pallets Properly to Ensure Stability

Proper stacking is crucial for preventing pallet-related accidents:

Stack Uniformly: Ensure that pallets are stacked uniformly to prevent them from leaning or collapsing. Avoid stacking them at odd angles, which can create instability.
Limit Stack Height: Don’t stack pallets too high. Keep stacks between 6 to 8 feet, depending on the weight and size of the pallets. Taller stacks are more likely to tip over.
Use Safety Cages: In high-risk areas, consider using safety cages or barriers around pallet stacks. These provide an extra layer of protection to keep pallets contained in case of a bump or shift.

5. Maintain Proper Aisle and Storage Space for Safety

Organizing your pallet storage area can prevent accidents and improve efficiency:

Leave Enough Aisle Space: Ensure there’s adequate space between pallet stacks to allow for safe movement of forklifts and other equipment. Aisles should be kept clear and wide enough for easy navigation.
Fire Safety Spacing: According to the NFPA, there should be a minimum of 8 feet between stacks to prevent fire from spreading. Pallets should also be at least 25 feet below the ceiling if stacked high.
Separate Damaged Pallets: Use a designated area for damaged or defective pallets. These should be removed from circulation quickly to prevent them from causing injuries or structural failures.

6. Monitor Pallet Condition to Reduce Hazards

Regular inspection and maintenance of pallets are key to a safe warehouse:

Inspect for Damage: Regularly inspect pallets for damage, including cracks, broken boards, and protruding nails. Damaged pallets should be repaired or discarded to prevent injuries.
Check for Rot: Wooden pallets exposed to moisture can develop mold or rot, making them weaker. Replace any that show signs of deterioration.
Implement a Rotation System: Use a first-in, first-out (FIFO) method to keep the pallets in use fresh and to prevent older, weaker pallets from remaining in the stack for too long.

7. Fire Safety Equipment and Training

Equipping your facility with the right fire safety gear and training your team can reduce the risk of pallet-related fires:

Install Fire Extinguishers and Sprinklers: Make sure fire extinguishers are readily available near pallet storage areas and that sprinklers are installed according to NFPA standards.
Conduct Regular Fire Drills: Train employees on emergency procedures, including how to handle a fire in a pallet storage area. Fire drills should be conducted regularly so staff are familiar with exit routes and safety procedures.
Use Flame-Retardant Pallets: Consider investing in flame-retardant pallets if your operation requires large amounts of pallet storage. These pallets are designed to reduce the risk of fire spread.

8. Plan for Proper Pallet Storage Layout

A well-organized pallet storage layout can improve safety and efficiency:

Use Vertical Space Wisely: Use pallet racks to store pallets vertically, freeing up floor space. Make sure racks are securely fastened and inspected regularly.
Place Heavier Loads on the Bottom: Store heavier pallets on the bottom of stacks to create a more stable base. Lighter pallets should go on top.
Utilize Corners and Walls: For added stability, place pallet stacks against walls or in corners. This minimizes the risk of tipping and provides additional support.

9. Stay Compliant with OSHA and NFPA Regulations

Compliance with OSHA and NFPA standards is not just about avoiding fines; it’s about keeping your team safe:

Follow OSHA Guidelines: Ensure that pallet storage areas comply with OSHA regulations for access, egress, and fire safety. Penalties for violations can range from hundreds to thousands of dollars, especially for repeat offenses. Refer to OSHA’s guidelines on access and egress and fire safety.
Regular Safety Audits: Conduct safety audits to identify potential hazards related to pallet storage. This proactive approach can help catch problems before they result in accidents or fines.
Reduce Unnecessary Pallets: Evaluate whether all pallets in the facility are necessary. Reducing the number of idle pallets can minimize risks and improve safety.

Conclusion

Proper wooden pallet storage is about more than just stacking them neatly. It’s about ensuring safety, maximizing storage space, and keeping operations running smoothly. By following these guidelines—choosing the right location, stacking safely, preventing fire hazards, and following OSHA and NFPA guidelines—you can avoid costly accidents and create a more efficient working environment.

A little attention to detail goes a long way in preventing accidents, reducing fire risks, and avoiding costly fines. With the right practices in place, wooden pallets will remain a reliable tool for transporting and storing goods in any facility. This can also save you money by avoided fines and keeping pallets in good condition for resale/recycling.