Load Stability & Stacking Practices: Keeping Stock Secure on Your Pallet Racking

Pallet racking safety doesn’t stop at the steel. One of the most common causes of racking damage, product loss, and workplace incidents is how stock is placed on the racking, not the racking itself.

Even a fully compliant, well-maintained racking system can become unsafe if loads are unstable, uneven, or poorly stacked. During inspections, we regularly find issues that stem from everyday storage practices rather than structural failure.

This blog looks at load stability and stacking practices, why they matter, and how simple improvements can dramatically reduce risk.

Why Load Stability Matters

Pallet racking systems are engineered and load-rated based on assumptions about how loads are stored. These include:

• Even weight distribution

• Correct pallet positioning

• Suitable pallet condition

• Loads staying within rated limits

When these assumptions aren’t met, forces are transferred into the beams and frames in ways they were never designed to handle. Over time, this leads to:

• Excessive beam deflection

• Frame distortion

• Increased forklift impact risk

• Collapsed or dislodged stock

From a safety perspective, unstable loads present a serious risk to workers operating forklifts or walking through aisles and pedestrian zones.

Uneven and Unbalanced Loads

One of the most common issues we see during inspections is unevenly distributed loads.

Examples include:

• Heavy items stacked on one side of a pallet

• Mixed loads with different weights not evenly spread

• Pallets loaded higher on one side than the other

Uneven loads cause beams to twist and deflect unevenly, which:

• Accelerates fatigue in the steel

• Places additional stress on beam connectors

• Increases the likelihood of pallets slipping or tipping

Even if the total pallet weight is within the rated capacity, uneven distribution can still make the load unsafe.

Pallet Condition and Quality

Not all pallets are equal, and damaged pallets are a major contributor to unsafe racking conditions.

Common pallet issues include:

• Broken or missing deck boards

• Cracked or split bearers

• Warped or twisted pallets

• Poor-quality or non-standard pallets

Damaged pallets can:

• Fail under load

• Sit unevenly on beams

• Shift unexpectedly during placement or retrieval

As part of good warehouse practice, pallets should be regularly inspected and removed from service if damaged. Using pallets that are unsuitable for racking significantly increases the risk of both product damage and racking failure.

Correct Pallet Positioning on Beams

Pallets should always be centred correctly on the beams and positioned in accordance with the racking system design.

Common positioning problems include:

• Pallets overhanging beams excessively

• Pallets not fully supported by both beams

• Pallets placed too far forward or backward

Incorrect positioning can:

• Reduce the effective load capacity of the beam

• Cause point loading rather than even load transfer

• Increase the risk of pallets falling from the racking

Where timber decking or mesh decks are required, they must be designed for the load and correctly supported. Improvised solutions, such as loose boards or unsecured timber, are not acceptable.

Overloading and Load Creep

Overloading isn’t always obvious. In many warehouses, loads slowly increase over time without anyone realising the racking is now carrying more weight than it was designed for.

This can happen when:

• Product changes but load signage is not updated

• Heavier pallets replace lighter ones

• Additional items are stacked onto existing pallets

• Beam levels are repurposed for different stock

Load signage exists for a reason. If the stock stored on the racking no longer matches the sign, the system is effectively out of compliance, even if no damage is visible.

Poor Load Containment

Loads that are poorly wrapped, strapped, or secured are a major hazard.

Issues include:

• Shrink wrap that is loose or torn

• Unstable stacking of cartons

• Items protruding beyond pallet edges

• Loads stacked too high

Uncontained loads are far more likely to:

• Shift during forklift movement

• Fall from the back of racking

• Strike beams, frames, or guards

In areas with walkways or traffic zones behind racking, fall prevention mesh should be installed. Even then, loads must be stable — mesh is a preventative measure, not a load-bearing solution.

Inconsistent Stacking Practices

When stacking practices vary between operators or shifts, risk increases.

Common causes include:

• Lack of training

• No clear stacking procedures

• Pressure to maximise space

• Poor communication between teams

Consistency is key. Clear rules around pallet condition, load height, positioning, and weight help ensure racking performs as intended.

What Inspectors Look For

During a pallet racking inspection, we don’t just look at steel condition — we also observe how the system is being used.

This includes:

• Load placement and alignment

• Signs of beam overloading or excessive deflection

• Pallet condition and suitability

• Evidence of falling or displaced stock

• Compatibility between stored loads and load signage

Unsafe stacking practices are often early warning signs that structural damage may follow if not addressed.

Simple Ways to Improve Load Safety

Some practical steps that make a big difference include:

• Regularly inspecting pallet condition

• Training forklift operators on correct placement

• Reviewing load signage when stock changes

• Using appropriate decking or support bars where required

• Keeping loads within height and weight limits

• Installing fall prevention mesh in high-risk areas

These measures not only improve safety but also extend the life of your racking system.

Final Thoughts

Pallet racking is only as safe as the way it is used. Even the best-designed, fully compliant system can become dangerous if everyday stacking practices are overlooked.

Regular inspections, combined with good load management and consistent warehouse practices, are the most effective way to prevent damage, reduce risk, and protect both people and product.

If you’re unsure whether your current storage practices are putting unnecessary stress on your racking, a professional inspection can identify issues early — before they turn into serious safety concerns.