At a Glance:
- Store wooden pallets on level, dry surfaces, stack them evenly within height limits, and rotate the stock to maintain their structural integrity.
- Conduct regular inspections to identify damage, contamination, or pest activity early and take corrective action.
- Keep pallets away from heat, moisture, and outdoor exposure to prevent warping, splitting, or infestation.
- Avoid unsafe practices such as blocking safety routes, overloading stacks, or mixing damaged pallets with usable ones.
Wooden pallets are very important in any facility that relies on the steady movement of goods. Their durability, versatility, and ease of handling make them an industry standard. However, their performance depends on how they’re used and stored.
Well-managed storage practices can significantly extend pallet life and protect both people and products, whereas improper storage can lead to unnecessary damage and operational risks.
This article covers the essential do’s and don’ts of wooden pallet storage every handler should know.
Do’s: Storage Practices That Protect Your Wooden Pallets
The right storage measures can extend pallet life and reduce the need for frequent repairs and maintenance.
Below are the best practices for storing wooden pallets properly.
Keep Pallets Level and Dry
Start by choosing the correct storage location. The area should be level and dry, as a stable, flat base forms the foundation of safe pallet storage. If the pallets are placed on uneven surfaces, weight distribution becomes uneven, increasing the risk of stacks leaning or toppling.
Prolonged exposure to moisture is equally damaging. For instance, direct contact with water can cause swelling, rot, and fungal growth, all of which weaken the pallet’s structure and load capacity. So, store pallets on racking systems, concrete floors, or treated timber platforms to keep them elevated from any ground-level dampness.
Build Stable, Balanced Stacks
Proper alignment within a stack ensures even weight distribution and reduces strain on the pallet components, such as boards and stringers. To achieve this, pallets should be positioned flush on all sides, with no overhangs that can weaken edges. For long-term storage or transport, apply strapping or stretch wrap to prevent pallets from shifting within the stack.
Follow Maximum Stack Heights Guidelines
Wooden pallets come with specific height limits and guidelines to maintain workplace safety and protect their integrity. These limits vary depending on pallet design, working conditions, and the type of load being supported.
Overstacking increases the risk of collapse, particularly if the lower pallets are weakened or damaged. To prevent such hazards, handlers should regularly check that stacks are within approved height limits and ensure the bottom units are strong enough to bear the weight above.
Use the FIFO Approach for Pallet Use
The First-In, First-Out (FIFO) method keeps pallet rotation systematic and efficient. Pallets stored for long periods without movement can develop hidden weaknesses from moisture absorption or pest activity. As a result, using older pallets first ensures wear is evenly distributed and helps identify units needing repair or replacement before they deteriorate further.
Make Routine Inspections
A routine inspection can help identify and address any pallet-related issues before they get worse. So, businesses should inspect stored pallets for hygiene and structural matters. Look for cracks, splinters, loose boards, missing nails, and contamination from oil, chemicals, or debris.
In addition, identifying and repairing damage early extends pallet lifespan, protects goods, and reduces injury risks for staff handling them.
Maintain a Safe Distance from Heat
Heat sources such as machinery exhaust, welding stations, or industrial heaters can dry out pallet timber, making it brittle and flammable. Continuous heat exposure can damage the pallet structure, increasing the risk of collapse during operation. So, always keep wooden pallets away from a heat source to prolong their life significantly.
Don’ts: Wooden Pallets Storage Habits That Create Problems
Even small mistakes or a lack of awareness can create significant issues when storing wooden pallets. Space constraints, rushed operations, or lack of oversight can quickly turn a well-organised pallet area into a safety hazard.
Recognising these common mistakes is the first step toward preventing pallet damage, avoiding compliance violations, and protecting workplace efficiency.
Here are some practices you should avoid:
Leaving Pallets Unprotected Outdoors
Direct sunlight can dry out and split timber, while rain and humidity accelerate decay and promote mould growth. Outdoor storage also exposes pallets to pests, compromising both the quality and hygiene standards of the pallets.
If outside storage is unavoidable, place pallets under a covered shelter or use breathable, waterproof covers to minimise exposure.
Piling Beyond Safe Limits
Overstacking may seem cost-efficient, especially in facilities with limited storage space. However, it leads to uneven, damaged or overloaded stacks, leading to instability.
Always follow weight ratings and stack height limits, considering both the pallet’s design capacity and the condition of each unit. Even one compromised pallet at the base of a stack can trigger a collapse under pressure.
Overlooking Pest Prevention
Termites, wood-boring beetles, and rodents can weaken pallets and spread to other stored timber or goods. A proactive pest control program is essential to avoid heavy costs and operational disruptions.
A comprehensive pest control program, including regular inspections, baiting systems, and targeted treatments, is essential for safe storage. Moreover, you should also opt for ISPM 15-compliant pallets to reduce pest-related damage. To ensure treated pallets stay pest-free, export pallets must be kept segregated from untreated, domestic-use pallets.
Mixing Damaged and Usable Pallets
Storing damaged pallets with usable ones in a stack can compromise the load-bearing capacity of the entire pile. Even a small number of damaged pallets can pose a serious risk to your inventory and staff. So, it is very important to separate these immediately for repair, recycling, or disposal, and avoid returning them to circulation until they meet safety standards.
The bottom line is that safe pallet storage is a continuous process that must adapt to various workplace regulations, material handling technologies, and environmental standards.
Consider integrating pallet storage checks into regular safety audits, training staff on handling and inspection procedures, and tracking pallet condition in your inventory management system.
If you are looking for durable, compliant, and ready-to-use wooden pallets for your facility, partner with a reliable wooden pallet supplier.