Improper Stacking
Improper stacking of products is a common but preventable hazard in workplaces that handle pallets and materials.
When products are not stacked correctly, the most common hazard is that they can create unstable loads that can shift, slide, or collapse, posing significant risks to workers.
- Hazards: Products stacked unevenly or without consideration for weight distribution can lead to unstable stacks. Overloaded pallets can break or collapse under excessive weight, causing injuries to workers or damage to products.
- Related Standards: OSHA’s 29 CFR 1910.176(b)requires materials to be stacked securely to prevent sliding or collapsing. OSHA Standard 1926.250(a)(1) requires that all materials stored in tiers shall be stacked, racked, blocked, interlocked, or otherwise secured to prevent sliding, falling or collapse.
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Examples:
- A warehouse stacks boxes of varying sizes on a single pallet without interlocking or securing them, causing the stack to lean and eventually collapse.
- A pallet loaded with heavy machinery parts exceeds the manufacturer’s weight limit, causing the pallet to crack while being lifted by a forklift.
- An employer receives a citation after a worker is struck by falling materials from an improperly stacked pallet in a warehouse.
Real-life Scenario
Lack of training and other failures led to forklift operator fatality
An OSHA investigation revealed that proper workplace safety training and correct storage of pallets taller than 16 feet could have prevented the fatal injuries suffered by a forklift operator at a tire distribution center.
The OSHA inspectors found widespread safety failures that exposed dozens of employees to potentially serious and deadly injuries.
OSHA inspectors learned the forklift operator was struck by a falling pallet of industrial truck tires after the pallet’s three-tier rack storage system failed. The system’s vertical supports were damaged and the horizontal beam locks were missing. The company was cited for 12 violations, including failing to properly train forklift drivers and improperly storing unbanded pallets higher than 16-feet.
The employer faces $288,299 in proposed penalties for 1 willful and 11 serious violations.
Knowledge Check Choose the best answer for the question.
1-2. What is the most common risk when pallets are stacked improperly?
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