According to the Bureau of Labor Statistics, pallet-related injuries account for over 30,000 workplace incidents annually in the United States. Most of these are preventable with proper training, inspection, and handling procedures.
The most common pallet-related injuries include foot punctures from protruding nails, back injuries from improper lifting, hand lacerations from splinters and sharp edges, and crushing injuries from falling pallet stacks. Forklift-related incidents involving pallets are also a significant concern.
OSHA doesn't have pallet-specific regulations, but several general standards apply. OSHA 1910.176 covers material handling and storage, requiring that stored materials be stacked, blocked, or limited in height to prevent sliding or collapse. Pallet stacks must be stable and shouldn't exceed the structural capacity of the floor.
Best practice: inspect every pallet before use. A 10-second visual check can prevent serious injuries. Look for broken or missing boards, protruding nails or staples, structural cracks in stringers, and excessive moisture or contamination. Reject any pallet that fails inspection.
Stacking standards: empty pallets should never be stacked more than 6 feet high (approximately 15 pallets). Stacks must be on level surfaces, aligned vertically, and away from high-traffic areas. Never climb on pallet stacks — this is one of the most common causes of serious fall injuries.
Forklift operations: ensure forks are fully engaged under the pallet before lifting. Approach loads squarely, not at an angle. Never push loads along the floor on damaged pallets. And always verify load weight doesn't exceed pallet capacity before moving.
Personal protective equipment (PPE) is essential. Workers handling pallets should wear steel-toed boots, cut-resistant gloves, and safety glasses at minimum. In areas with overhead pallet storage, hard hats are recommended.
At Riverside Pallet Co., safety is built into our products. Every pallet we sell has been inspected for protruding nails, structural integrity, and safety hazards. We also provide safety guidelines with bulk orders and offer workplace safety consultations for our managed accounts.