Pallets are so common in warehouses that it is easy to take them for granted. But improper handling of pallets causes thousands of workplace injuries every year, including back injuries from lifting, puncture wounds from protruding nails, crushing injuries from collapsed stacks, and slips and falls from pallets left in walkways. OSHA estimates that pallet-related injuries cost American businesses over $2 billion annually in workers compensation, medical costs, and lost productivity. Follow these comprehensive tips to keep your team safe.
Inspection Tips
The most important safety practice is inspecting every pallet before use. A 30-second visual inspection can prevent serious injuries and product damage. Make pallet inspection part of your standard operating procedure, not an afterthought.
- Always inspect pallets before use — look for broken boards, protruding nails, cracks, rot, and signs of pest infestation
- Never use a pallet that is visibly damaged, unstable, or missing boards — it is not worth the risk
- Check for contamination (oil, chemicals, mold, unusual odors) before loading food products or sensitive materials
- Verify the pallet size matches your racking system — using wrong-size pallets on racks is a leading cause of collapses
- Look for water damage and soft spots that could indicate reduced load capacity
- Check that the ISPM-15 stamp is present if the pallet will be used for international shipping
When to Reject a Pallet
- More than 2 broken or missing deck boards
- Any cracked or broken stringer (these are structural — never use a pallet with a broken stringer)
- Protruding nails that cannot be hammered flush
- Visible mold growth (especially on food-contact pallets)
- Chemical stains or strong odors from unknown substances
- Excessive warping that prevents the pallet from sitting flat
Handling Tips
Safe pallet handling requires awareness, proper technique, and the right equipment. Even empty pallets weigh 30-70 lbs, which is enough to cause injury with improper lifting technique.
- Wear heavy leather or cut-resistant gloves to avoid splinters and nail punctures when handling wood pallets
- Never stand on pallets — they are designed for goods, not people, and can break or shift unexpectedly
- Use proper lifting technique (bend at knees, keep back straight) if moving pallets manually
- Ensure forklift forks are fully inserted and centered before lifting — partial insertion causes tipping
- Never walk on pallets to reach items or cross gaps in staging areas
- Keep hands and fingers clear of the edges when sliding pallets together
- Use a pallet jack or forklift for any distance over 20 feet — do not carry pallets by hand
Storage Tips
How you store empty pallets matters just as much as how you handle them. Improperly stored pallet stacks are a significant safety hazard.
- Do not stack empty pallets more than 6 feet high (OSHA recommendation) — taller stacks become unstable
- Store pallets on flat, stable, level surfaces to prevent leaning and toppling
- Keep pallet storage areas clean, organized, and away from foot traffic and emergency exits
- Remove damaged pallets from circulation immediately — do not return them to the usable stack
- Store pallets away from heat sources, open flames, and electrical panels (dry wood is a fire hazard)
- Ensure adequate aisle space around pallet stacks for safe forklift access
- Mark pallet storage areas clearly with floor markings or signage
- Never lean pallets against walls or equipment — they can slide and fall
Forklift Safety with Pallets
Forklifts and pallets go hand in hand, but this combination is also where many serious injuries occur. Forklift operators should receive specific training on safe pallet handling practices.
- Approach pallet stacks squarely — never at an angle
- Tilt mast back slightly after engaging the pallet for stability during transport
- Travel with forks as low as possible (4-6 inches from ground)
- Never drive over loose pallets or pallet debris — it can cause tire damage and tip-overs
- Sound horn when approaching blind corners in pallet storage areas
- Set the parking brake and lower forks completely before leaving the forklift unattended
Creating a Pallet Safety Program
The most effective way to prevent pallet-related injuries is to implement a formal safety program. This should include written procedures for pallet inspection, handling, and storage; regular training sessions for all warehouse personnel; a clear process for removing damaged pallets from service; and designated pallet storage areas with appropriate signage and floor markings.
A safe warehouse is a productive warehouse. Investing a few minutes in pallet inspection and proper handling can prevent injuries, product damage, workers compensation claims, and costly downtime. The return on investment for pallet safety training is immediate and substantial.