Pallet Safety: Best Practices

Pallets are the unsung heroes of logistics, but improper handling can lead to injuries. Every year, thousands of workplace injuries involve pallets. Following proper safety procedures protects your team and your products.

The Scope of Pallet-Related Injuries

Pallet injuries are among the most common in warehouse and logistics environments. The most frequent types include puncture wounds from protruding nails, splinter injuries from rough or damaged wood, back and muscle strains from improper lifting, crush injuries from falling pallet stacks, and foot injuries from dropped pallets. OSHA does not specifically regulate pallets, but general workplace safety standards apply, and employers have a duty to protect workers from recognizable hazards.

Inspection Before Use

Always inspect pallets before putting them into service:

• Check for broken, cracked, or missing boards
• Look for protruding nails or fasteners
• Verify structural integrity by checking stringers and blocks
• Inspect for contamination (chemicals, mold, pest damage)
• Ensure the pallet is appropriate for the load weight
• Check for warping, twisting, or excessive moisture
• Verify the pallet grade matches your application needs

Personal Protective Equipment

Anyone who handles pallets regularly should wear appropriate PPE:

• Heavy-duty work gloves to protect against splinters, nails, and rough surfaces
• Steel-toed or composite-toed safety footwear to protect against dropped pallets
• Long pants and long sleeves to minimize skin exposure to rough wood
• Safety glasses when dismantling or repairing pallets
• Back support belts for workers who manually move pallets frequently

Proper Handling Techniques

• Never manually lift a pallet alone — they weigh 30-70 lbs
• Wear gloves to protect against splinters and sharp edges
• Use proper lifting mechanics (bend at the knees, not the waist)
• Never stand on pallets — they are not designed as platforms
• Keep walkways clear of loose or stacked pallets
• Use a two-person team for moving pallets manually
• Avoid dragging pallets across the floor — this causes splinters and damage

Stacking Guidelines

• Stack empty pallets no higher than 6 feet
• Stack only on flat, level surfaces
• Never lean pallet stacks against walls
• Keep stacks uniform — do not mix sizes
• Secure tall stacks with strapping when necessary
• Leave adequate aisle space between stacks for safe passage
• Keep stacks away from emergency exits, fire equipment, and electrical panels

Forklift Operations

• Center the forks fully under the pallet before lifting
• Lift smoothly — avoid sudden movements
• Do not push pallets with fork tips
• Ensure the load is balanced and stable before moving
• Follow all facility speed limits and traffic patterns
• Check that forks are the correct width for the pallet being handled
• Lower the load as close to the ground as practical during transport
• Never carry unbalanced loads — reposition before lifting

Storage Best Practices

Proper pallet storage reduces both safety risks and pallet damage:

• Store pallets in a designated area, not scattered around the facility
• Keep stored pallets dry — moisture weakens wood and promotes mold growth
• Store pallets away from heat sources and direct sunlight to prevent warping
• Separate pallets by size and grade for easy identification
• Dispose of severely damaged pallets promptly — do not let them accumulate
• Keep the pallet storage area clean and free of debris

Creating a Pallet Safety Program

Every facility that handles pallets should have a documented safety program that includes:

• Written pallet handling procedures posted in visible areas
• New employee orientation covering pallet safety basics
• Regular refresher training for all pallet-handling staff
• Designated pallet inspection areas and rejection criteria
• Incident reporting procedures for pallet-related injuries
• Regular audits of pallet handling practices and storage conditions
• A relationship with a pallet supplier that provides pre-inspected, quality pallets