At a glance:
- Dragging, overloading, and forklift misuse are leading causes of pallet failure.
- Moisture exposure and poor stacking accelerate structural breakdown.
- Using damaged pallets increases the risk of product loss and injury.
- Clear protocols and training extend pallet life and reduce replacement costs.
Delays, damaged goods, and safety incidents often have one thing in common: a mishandled pallet. In the high-pressure world of logistics, even small errors in storage or movement can ripple through the supply chain. Knowing how to manage wooden pallets correctly is key to protecting cargo and keeping operations running smoothly.
Fortunately, most of these risks can be eliminated with consistent, correct handling. Adopting the right practices not only extends pallet life but also reduces costs and keeps operations free from avoidable disruptions.
This article outlines common handling mistakes that damage wooden pallets and offers practical ways to prevent them.
Dragging Instead of Lifting
Dragging pallets over concrete or other abrasive surfaces gradually grinds down the bottom boards, which can expose nails. What starts as light surface wear can, over time, weaken the pallet’s structure and reduce its load-bearing capacity, ultimately shortening its life span.
Handlers should lift the pallets properly by using a forklift or a jack with adequate clearance. Avoid dragging altogether, and keep walkways clear so pallets can be moved without resorting to damaging shortcuts.
Incorrect Forklift Entry
Misaligned forklift forks, whether set at uneven heights or positioned off-centre, can press against unintended areas of a pallet, cracking deckboards or splitting stringers. This weakens critical load-bearing points, especially when the pallet is stored in racks, and reduces its overall load capacity. Repeated misuse results in unstable pallets that may fail during handling or transit.
Align forks correctly and use marked entry points to avoid structural damage. Clear orientation markings and regular operator training further minimise forklift-related pallet damage.
Overloading Beyond Rated Capacity
Standard wooden pallets are designed to handle specific weight limits, whether in static storage, during movement, or when stored in racking. Exceeding these ratings can cause sagging, cracking, or complete structural failure. Overloading the pallet even by a small margin can lead to costly product loss, operator injuries, and equipment damage.
To avoid this, operators should understand each pallet’s load rating to prevent overloading the pallet. Clear signage and operator reminders help maintain safe load limits, while custom-made pallets are recommended for unusually heavy or specialised loads.
Poor Stacking & Inadequate Storage Conditions
Uneven stacking, unstable surfaces, or exceeding safe height limits can make pallet stacks unstable and prone to collapse. Wooden pallets are also susceptible to environmental factors. Prolonged exposure to moisture, heat, or rain accelerates wear, leading to warping, rot, mould growth, and a loss of load-bearing strength, all of which can result in product contamination.
These risks can be minimised by following consistent stacking practices, such as checking the ground surface and staying within height limits. Storing pallets under cover, off the ground, and in well-ventilated areas helps maintain their strength. Rotating stock and marking inspection dates can further extend usability.
Where moisture is a concern, pallet heat treatment can reduce mould risk, but proper dry storage is still essential for protection.
Using Damaged Pallets Without Repair
Using pallets with cracked boards, exposed nails, or loose fasteners increases the risk of collapse and injury. Operators should establish formal inspection routines to identify and remove compromised pallets before use.
Where viable, repair damaged pallets to maintain safety and lower replacement costs. Partnering with a supplier that offers refurbishment or pallet repair services can minimise downtime and ensure safe handling.
Lack of Staff Training and Handling Protocols
Untrained or time-pressured staff are a major cause of preventable pallet damage, often through fork strikes, overloading, or poor stacking. Such damage typically results from unclear, inconsistently enforced, or poorly communicated handling protocols.
Preventing it requires setting clear, practical procedures and ensuring every team member who handles wooden pallets is properly trained. Training programs should include correct lifting, storage, and inspection methods, as well as clear procedures for reporting damaged pallets.
Incorporating these practices into onboarding, toolbox talks, and visual reference guides helps maintain accountability and consistency across shifts.
Most pallet damage can be traced back to preventable handling mistakes. By investing in targeted training, maintaining correct storage practices, and carrying out regular inspections, businesses can extend the service life of their pallets and reduce unnecessary waste.
To reduce pallet damage and keep operations running smoothly, consult with the experienced team at Waterstone Pallets. They are a wooden pallet supplier with many years in the industry and we can provide you with a product that is a durable, fit-for-purpose wooden pallet, to help you get the most from every load.
