Pallet storage: height and weight limits
Every rack level has a load limit and it must be shown on a plate.
Rack levels do not carry unlimited load. An overloaded beam first bends, and in the worst case the whole rack collapses, which is a disaster for people and goods alike. The cause is often simple: nobody read what was written on the plate. When storing pallets, always keep three things under control: permitted load, height and the condition of the pallet.
The load plate
The manufacturer issues a table of permitted loads for each rack bay. It is usually fixed as a plate in a visible place at the start of the rack. The plate shows two limits: the load on one level (a pair of beams) and the total load on the whole bay. Both must be respected.
For example, the plate shows 2,000 kg for one level, and two pallets stand on it. If one weighs 1,200 kg and the other 1,000 kg, the total is 2,200 kg, which is over the limit. Each pallet on its own does not look "that heavy".
Another important point: the permitted load depends on the spacing between beams. If you move a beam higher or lower, the limit may change, so after changing the height the plate is updated. If the plate is missing or unreadable, contact the manufacturer; do not work by the rule "it will probably hold about this much".
Height and clearance
The top level must match the forklift's lifting height. In addition, leave clearance to the building's ceiling, trusses, light fittings and fire-suppression pipes. The requirements for these are set out in the building design and fire rules, so set the height with them in mind.
There must also be a gap between the pallet and the beam above it: about ten centimetres for putting the pallet in and taking it out safely, with the exact figure given in the rack manufacturer's recommendations. A tall, narrow load tends to topple, so wrap it in film and protect the corners. The lightest loads go on the upper levels.
Pallet and packaging condition
The pallet itself must be sound. A pallet with a cracked board, a protruding nail or a broken edge must not go on an upper level; it must be replaced. The load must not overhang the pallet: a load that does not rest fully on the beams gradually shifts. Common sizes are 1200x800 and 1200x1000 millimetres, and the rack must be designed for the very pallet you use.
If cartons are laid in an interlocking pattern, the stack is more stable. Wet or softened cardboard cannot take the weight of the load, so in damp premises use coated packaging.
Distributing weight correctly
Heavy goods are stored low and light goods high: this is necessary for the stability of the rack and the safety of the forklift. Record the actual weight of each pallet in the system, especially mixed pallets. At receiving, weigh pallets on a sampling basis: the weight on the document often differs from the real one. Do not forget to add the weight of the pallet itself to the calculation; a wooden one usually weighs around twenty kilograms. On a mixed pallet put the heaviest cartons at the bottom and the fragile, light ones on top, and write the total weight on the pallet label: then the picker and the forklift driver know it before lifting.
Regular inspection
Once a week look over the rack: a hit upright, a bent beam, a loose bolt, the anchors in the floor. Mark the result with a simple colour system: green is normal, amber is under observation, red means unload immediately and repair.
Write down every occasion when a forklift touched the rack, even a "minor" one. If such hits keep repeating, the problem may not be the rack but the aisle width or driver training. From time to time, for example once a year, have the rack looked at by an independent specialist.
Conclusion
Three rules of pallet storage: do not exceed the load on the plate, keep height and clearance, and inspect racks and pallets regularly. During a warehouse audit, SkladKontrol checks storage locations and helps identify shortcomings in load plates, layout and order.