Ensuring that everyone who uses them knows how to stack a pallet rack can be crucial to ensuring efficiency, productivity and safety in a warehouse or distribution center.
Pallet racking is, in many ways, the backbone of storage facilities, as it takes up a significant amount of floor space and is used to store goods, materials and other items until they are used or shipped to other locations.
Racking comes in many forms: some are basically heavy-duty racking systems, while others can be complex equipment with electrical elements. Proper training of workers on how to stack pallet racking will depend in part on the types of racking you have installed.
SEE ALSO: 6 Warehouse Racking Options to Improve Efficiency
But to keep workers safe, it is not enough to teach them how to stack pallet racking. Because the condition of those racks is also an important consideration, with regular inspection of the warehouse racks being necessary.
It will also be essential to ensure that all staff members use the appropriate safety equipment and hold the relevant certifications to perform their duties.
If you need pallet racks, supplied, installed or inspected in Brazil, Mexico or the United States, please contact us, contact us at.
How to stack a pallet rack: 6 important tips
Although this procedure may vary from warehouse to warehouse depending on the type of goods and merchandise stored, as well as the type of racking used, the following shares some general tips on how to stack a pallet rack that should be useful in most cases .
1. Inspect your pallet
Before wondering how to stack a pallet rack, confirm that the pallets are in good condition and do not have cracks, are broken or have any structural damage.
Pallets are the base of the structure where goods and materials will be stacked, so it is necessary to check them before placing any boxes on them. Remember that it is vital that your storage structures are in excellent condition through periodic inspections.
2. Plan your stacking pattern
Planning is essential to optimize resources and make warehouse operations more efficient. To know how to stack a pallet rack, for example, it is necessary to know in advance which products will be stored and which pallets will be used.
It will depend on the type of goods and materials to choose the right pallets, but the most common patterns for stacking boxes are:
- Column stacking. This is the most common stacking pattern. It is mainly used when the boxes are the same size, have low density and contain soft or fragile products. Unfortunately, columns can fall over if not stacked correctly, so this solution is only sometimes recommended.
- Stacking by interlocking. This is the best stacking method when the boxes are of different sizes and weights or are all the same size but very dense. Although this solution is not the most practical due to the rotation method used to place the boxes and the uneven weight distribution, it provides excellent stability to the entire load.
3. Distribute the weight
Regardless of the stacking pattern you choose, as a general rule, heavier items should always be placed at the bottom to support and stabilize the entire stack.Knowing how to properly stack a pallet rack involves taking into account weights and structural integrity.
This practice will not only prevent lighter packages from being crushed and damaged, but will also create a lower center of gravity, resulting in a more robust structure that can support heavier weights without fear of collapse.
4. Align the boxes
When you start stacking the products, make sure that the first layer is as close to the edges of the pallet as possible, but does not overhang or overhang the aisles. Next, each layer should line up with the first, and so on.
A well aligned first layer, with barcodes facing out for quick identification, will facilitate this whole process of how to stack a pallet rack and prevent possible damage during shipping and handling of goods. It is crucial for efficiency in operation.
5. Fasten the merchandise
Once the items are lined up and stacked according to their dimensions and the stacking pattern you have chosen, tie them together with straps. This will keep the boxes attached to the pallet and reduce the likelihood of them falling off.
The straps should be made of very strong materials, such as polypropylene, polyester or steel. You will need at least two, one to secure the load vertically and one horizontally. Protectors will also be required between the boxes and the straps to prevent damage to the items.
6. Wrapping the merchandise properly
Now that the boxes are stacked and aligned with the pallet edges, with the barcodes visible and securely fastened, you can give the entire load more stability by covering it with stretch film.
This is the last step of how to stack a pallet rack. This process can be done manually or with a shrink wrap machine. In addition, an alternative is prefabricated pallet decks which, although less affordable and take up more space, can be reused.
Additional tips on stacking pallet racking
Do not use damaged pallets or racking. It may seem obvious, but it bears repeating: employee safety comes first in any warehouse. So check pallets before stacking products on them, especially for loose boards, protruding nails or splinters, to avoid damaging boxes or causing them to fall.
Be aware of size and weight restrictions. In order to know how to stack a pallet rack, you need to be aware of height and weight limits. Stacked boxes should never exceed 15 feet in height or 400 square feet in area, but this will be determined by the type of products to be stored and distributed, as well as the dimensions of the warehouse.
The maximum weight of the load will be determined by the type of pallet used, as well as its condition. The standard size of a pallet is 123 x 102 centimeters (48 x 40 inches), with each board 0.8 centimeters (3 ½ inches) wide and 0.8 centimeters (five-sixteenths of an inch) thick, and can carry up to 2,086 kilograms (4,600 pounds). If you opt for plastic pallets, it is possible to increase the load capacity.
Use appropriate lifting equipment. To prevent warehouse employees from lifting heavy loads and injuring themselves, use lifting equipment to perform this work quickly and safely. The most common are forklifts, with a bifurcated platform that raises or lowers as pallets are loaded. There are also pallet trucks, electric and manual, with wheeled carts and a lever or crank to lift and move pallets to load materials.
Serviap Logistics supplies, installs and inspects shelving and racks
At Serviap Logistics we supply, install and inspect warehouse racking in Brazil, Mexico and the United States. We also supply and install other elements, such as warehouse signage, floor markings and collision protection.
In addition, we offer comprehensive project management services to oversee the installation, remodeling or relocation of a warehouse from start to finish.
We count some of the world’s largest companies among our satisfied customers and partners, covering a wide range of industries such as automotive, e-commerce, wholesale and others.
We are known among our customers for being dedicated to maintaining the highest safety standards wherever we work, including OSHA certification in the United States.
Contact us at for more information on how we can help you with a warehouse configuration checklist.
If you were interested in this article on how to stack a pallet rack, check out the rest of our coverage.
