Forklift damage accounts for an estimated 70% of all pallet failures. The good news: most of this damage is preventable with proper operator technique and awareness. Here are seven proven ways to reduce forklift-related pallet damage.
#1: Center the forks. Forks should be spaced symmetrically and centered in the pallet openings. Off-center engagement puts uneven stress on stringers and can crack or split them. Most forklifts have adjustable fork spacing — use it.
#2: Fully insert the forks. Forks should extend all the way through the pallet to the opposite side. Partial insertion means the load weight is concentrated on a small area of the stringer, increasing the risk of failure. This is especially critical for heavy loads.
#3: Slow down on approach. High-speed pallet engagement is the leading cause of board breakage. The forks should contact the pallet at minimal speed. Train operators to approach at crawl speed and lift smoothly.
#4: Never drag pallets. Dragging a pallet across the floor instead of lifting it cleanly destroys the bottom deck boards and weakens the overall structure. If a pallet is stuck or hard to reach, reposition the forklift rather than forcing it.
#5: Stack evenly. When stacking pallets, ensure each pallet is centered on the one below it. Offset stacking creates point loads that crack boards and collapse stringers. Use visual alignment guides if necessary.
#6: Inspect before engaging. A 2-second visual check before engaging a pallet can prevent damage. Look for: cracked stringers, loose boards, protruding nails, and wet or visibly weakened wood. Report damaged pallets instead of using them.
#7: Regular training. Quarterly refresher training on pallet handling techniques has been shown to reduce pallet damage by 30-40%. Include damage cost awareness — when operators understand that each broken pallet costs $3-15, behavior changes.