Safe Stacking & Unstacking

Welcome back, let's Build Smart & Build Safe! We’ve covered lifting materials, both manually and with mechanical aids. Today, we're focusing on the other half of the material handling equation: safe stacking and storage.

A poorly stacked pile of materials is a ticking time bomb. It can collapse without warning, creating a deadly "struck-by" hazard for anyone in the area. A little bit of planning and a few simple rules can prevent a catastrophe.

Three Rules for a Stable Stack

1. Start with a Stable Foundation: All materials must be stacked on a level and solid surface. Stacking on uneven ground, loose soil, or an unstable pallet is a recipe for disaster.

2. Cross-Stack for Stability: When stacking bags, boxes, or other uniform materials, use a cross-stacking pattern. This creates a "tied" pile where each layer locks the one below it in place, preventing the stack from toppling over.

3. Know the Ratio: Do not stack materials too high. A general rule of thumb is to keep the pile no more than three times as tall as the width of its base. For example, if a pallet is 4 feet wide, the stack should be no more than 12 feet high.

The Most Important Rule of All: Unstacking

Unstacking a pile can be even more dangerous than stacking it. Never pull a piece from the middle or bottom of a stack.

• The Rule: Always unstack a pile from the top down, one piece at a time.

• The Reason: Pulling a piece from the middle of a stack can shift the entire load, causing a domino effect that results in the collapse of the entire pile.

By respecting these rules, you can ensure that your stored materials don't become a deadly hazard.

Tomorrow, we'll talk about securing loads on racks and pallets.

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-The Safety Man