Maintaining the Correct Amount of Pallet Overhang

Proper pallet positioning is essential for maintaining a safe and efficient warehouse environment. While many assume that pallets should sit flush with the face of the racking system, this is actually a common misconception. In reality, pallets should extend slightly beyond the front edge of the pallet rack to ensure better load support and safer handling. At Commander Warehouse, we understand how correct pallet placement can help reduce wear on your racking, improve accessibility, and enhance overall efficiency. That is why we have outlined some important considerations for maintaining the correct amount of pallet overhang.

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How Can You Determine the Right Amount of Pallet Overhang?

Even though the idea of overhanging pallets might seem unsafe, a small amount of overhang (just a few inches) is actually the industry standard. This design allows the pallet’s bottom deck boards to rest securely on both the front and rear beams of the racking system, keeping the load stable and evenly supported. Here are a few important points to keep in mind when determining the right pallet position for your setup:

Why a Slight Overhang is Recommended

When pallets are positioned with a small overhang, they are easier for forklifts to handle, especially when loading or unloading. This setup helps distribute the pallet’s weight evenly, reducing stress on the racking beams and minimizing the risk of pallet slippage. Sitting completely flush with the rack can cause the pallet’s edges (not the boards) to bear the load, which may lead to rack damage or unsafe storage conditions over time. Maintaining that slight overhang helps create a balance between safety, accessibility, and stability.

Risks of Having Too Much Overhang

While a few inches of overhang is ideal, excessive overhang can cause several problems. Pallets that extend too far may block aisles, limit visibility, or interfere with nearby equipment. This can lead to operational slowdowns and increased safety risks for workers. Whether you are using standard racks or a roll out pallet system, the key is to find the right balance, allowing just enough overhang for proper support without creating obstructions or instability.

How Racking Design Impacts Pallet Positioning

The type and depth of your racking system play a big role in achieving proper pallet positioning. Selecting racking that complements the size and style of your pallets will make it easier to maintain a consistent and safe setup. Accessories, such as pallet stops or back guards, can also help prevent pallets from being pushed too far back, protecting both the racking and stored materials from potential damage.

Improve Safety and Efficiency with the Right Setup

Correct pallet placement may seem like a small detail, but it has a significant impact on warehouse safety, performance, and workflow. By allowing a slight overhang instead of placing pallets flush with the rack, you can help maintain load stability and prolong the life of your racking system.

At Commander Warehouse, we offer a variety of pallet racking systems, safety accessories, and storage solutions to help you optimize your warehouse layout. Visit our website today to learn more about setting up your racking for maximum safety and efficiency.

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