How to Stack Pallets Safely and Efficiently

warehouse pallets stacked

The use of pallets in any storage context is the subject of a range of statutory and industry processes and procedures.

This includes health and safety legislation, risk management assessments, and maintenance and inspection regimes. A pallet is even defined legally.

But it is for sound reasons that this storage tool is the focus of attention from government and industry.

Millions of pallets are handled by thousands of businesses every day, keeping goods and products moving around the country.

The risks of injury and damage if pallets were to be used incorrectly, loaded badly or stacked poorly are all too real.

Such actions may have a financial cost or cause damage to stock and equipment and even harm business reputation. Above all, there is a clear risk to the health and safety of staff.

Guidance on Pallet Loading and Stacking

At Quickline, we have the expertise and experience to help you when it comes to pallet loading and stacking so here is our guide on best practice, starting with the pallet itself.


    • Ensure you have the right pallet for the job you want it to do.

    • Consider size, strength and material (wood, metal, plastic) the pallets are made from.

    • When stacking, make sure you do not mix pallet types.

    • Follow all manufacturer guidance on usage and carry out regular pallet inspections.

    • Never use a damaged pallet.


    • Load pallets gradually and distribute stock evenly, using the maximum amount of space available and avoid creating a pyramid shape.

    • In general, the height of the load should not be more than the length of the longest side of a pallet.

    • Strap and wrap stock loaded on the pallet to increase safety and minimise movement.

    • Load the heaviest items first, both on individual pallets and as you put pallets into racking.

    • Plan ahead and ensure you know in advance the size and volume of stock you will be loading


    • Include pallet placement and retrieval methods when deciding on the appropriate stacking pattern and system.

    • Check location and accessibility for pallet handling, assessing space, routes, corners, doors, pillars, floors and gradient changes.

    • Provide operational training to staff in order to optimise safety.

    • Ensure a regular care and maintenance regime is in place.

More information on pallet safety and stacking is available from the Health and Safety Executive and the Storage Equipment Manufacturers’ Association (SEMA) which sets the industry standards for building storage systems.

At Quickline, we design, supply and install a range of warehouse pallet racking that is designed to meet your specific business requirements.

We also carry out racking inspections and maintenance once the system is up and running and all our teams are qualified to SEMA standards.

We can provide you with end-to-end support if you are launching a warehousing construction project or you are planning to update your existing stacking facilities.

Let us know how we can help by getting in touch.