Pallet Safety in the Workplace: Essential Guidelines for Ontario Warehouses

Pallets are involved in thousands of workplace injuries across Canada every year — most of which are entirely preventable. Here is what every warehouse supervisor and logistics manager in Ontario should know about safe pallet practices.

Understanding Pallet-Related Hazards

The most common pallet-related injuries include: cuts and punctures from protruding nails or splinters, crush injuries from falling stacked pallets, strains from improper manual lifting, and forklift incidents caused by unexpected pallet failure. Most of these risks are eliminated through proper pallet selection, inspection, and storage protocols.

Inspect Before Every Use

Never put a pallet into service without a quick visual inspection. Look for: broken or missing deckboards, cracked or split stringers, protruding nails or fasteners, signs of rot or water damage, and pest evidence such as tunneling or feces. A damaged pallet that fails under load can injure workers, damage equipment, and destroy product. Remove any suspect pallet from service immediately.

Safe Stacking Practices

Empty pallets should be stacked flat in stable columns no higher than 5 feet (approximately 8 pallets) when stored manually without racking. Mixed-size pallets should never be stacked together as they create unstable configurations. Always store pallets away from high-traffic forklift lanes and emergency exit routes. Use dedicated pallet storage areas with appropriate signage.

Forklift and Pallet Jack Safety

Never exceed the rated load capacity of a pallet. Centre loads as evenly as possible on the pallet surface. Ensure forks are fully inserted before lifting. Travel with loads lowered as close to the floor as safely possible. Avoid sudden turns or acceleration with loaded pallets. Train all forklift operators on pallet load limits and condition inspection.

When to Retire a Pallet

Any pallet with a broken stringer, multiple damaged deckboards, or structural compromise should be removed from service immediately. In high-throughput environments, establish a regular pallet audit schedule — weekly at minimum — to identify and replace damaged units before they cause an incident. Serv-U-Pallets Inc. supplies replacement pallets across the GTA with same-day delivery to keep your operation moving safely.