Best Practices for Pallet Stability

Written By Alexandra Benson

Why pallet stability matters

Unstable unit loads drive injuries, product loss, and transportation violations. In the United States, OSHA requires stored materials to be “stacked, blocked, interlocked and limited in height so that they are stable and secure against sliding or collapse” (29 CFR 1910.176). OSHA During transport, FMCSA rules require cargo to be “firmly immobilized or secured” using structures of adequate strength, dunnage, shoring bars, or tiedowns (49 CFR 393 Subpart I). eCFR+1

The standards map (what to design and test against)

Designing, wrapping, and verifying stable pallets typically draws from several complementary sources.

1) Choose a pallet that supports the load and environment

  • Match pallet design to duty. Use rated designs and test methods from ISO 8611 for static, dynamic, and racking loads. This ensures deflection and strength are appropriate for your mass, footprint, and handling path. ITEH Standards

  • Follow recognized construction standards. The NWPCA Uniform Standard for Wood Pallets and ANSI MH1 define dimensions, components, and quality for consistent performance. YMAWSANSI Webstore

  • Account for racking. When pallets sit in selective or drive-in racks, use rack-compatible pallets and maintain RMI-recommended clearances to prevent contact with uprights and loads in adjacent bays. studylib.nets354933259.onlinehome.us

  • Inspect condition. Remove cracked stringers, broken deckboards, and protruding fasteners that can initiate load lean or film cuts. OSHA’s general material-handling rule applies here. OSHA

2) Build a stable load before you wrap it

  • Eliminate overhang. Box overhang reduces effective box compression strength and can initiate tilt. Peer-reviewed work shows significant BCT losses with overhang, with magnitude dependent on geometry. Wiley Online LibraryVTechWorkssparrow.up.poznan.pl

  • Prefer column stacking for compression strength. Industry data compiled by the Fibre Box Association shows columnar stacking retains much more compression strength than interlocked patterns, where losses of roughly 40 to 60 percent have been reported for interlocked stacks. Use interlock only when stability benefits outweigh compression loss. Fibre Box Associaton

  • Use tier sheets, slip sheets, and corner posts where needed. These increase interlayer friction and help transmit vertical loads along box corners, which improves stability through the stack. This practice aligns with ISO 2234 static stacking philosophy and common unit-load design. Environmental Chambers

  • Mind environmental effects. Corrugated compression strength drops with humidity and temperature cycling. Factor this into allowed stack height and storage duration. MDPI

3) Unitize appropriately, then verify containment

  • Stretch film. Select film type, pre-stretch, wrap count, and application per ASTM D4649. The standard explicitly frames selection as application- and test-dependent, which means there is no one “correct” containment force value for all loads. Validate on your product. ASTM International | ASTM

  • Strapping. Where needed, specify to ASTM D3950 for nonmetallic strapping or ASTM D3953 for steel strapping, then match to load mass and handling stresses. Antpedia+1

  • Stretch hooding. For challenging profiles or weather exposure, stretch hoods can provide high stability and environmental protection. They are widely used in Europe and described in neutral technical resources as a compressive hooding method applied without heat. Validate with the same test methods below. sicurezzadelcarico.it

  • Corner protection. Corner boards help transmit vertical loads and prevent film damage, especially with fragile primaries. This practice is consistent with the goal of preserving column strength and preventing cut-through during handling. I cannot confirm a single universal standard mandating corner boards, so validate usage through testing.

4) Test stability in the lab and the field

  • Static stacking. Use ISO 2234 to establish safe compression margins for your unit load and storage duration. This helps set maximum stack heights and storage periods. Environmental Chambers

  • Distribution simulation. Use ASTM D4169 for a representative sequence of compression, vibration, and shock tailored to your distribution cycle. For full truckload unit loads, ISTA 3E is a common option. ASTM International | ASTMista.org

  • Dynamic load rigidity. Use EUMOS 40509 acceleration testing to evaluate whether the unit load resists typical horizontal inertial forces. Guidance commonly used with this method calls for withstanding about 0.8 g forward and 0.5 g lateral and rearward for a defined duration, which reflects braking and cornering dynamics. Verify acceptance levels within your test protocol. lansmont.comWienerberger

  • On-vehicle securement. Inside trailers, combine unitization with blocking, bracing, dunnage bags, or load locks as required by FMCSA 49 CFR 393 Subpart I. eCFRLegal Information Institute

5) Operate with clear limits, training, and audits

  • SOPs tied to standards. Write pallet-build SOPs that cite your chosen standards and tests (for example, “wrap recipe per ASTM D4649, verified by ISO 2234 and EUMOS 40509”). ASTM International | ASTMEnvironmental Chamberslansmont.com

  • Inspection points. Define reject criteria for pallets and packaging, acceptable overhang (preferably 0 mm), required corner and tier sheets, and minimum wrap pattern. Reference OSHA language about stable storage. OSHA

  • Feedback loop. Track toppling or leaning incidents, trailer reworks, and stretch-film or strap failures, then re-test using ASTM D4169 or EUMOS 40509 when problems recur. ASTM International | ASTMlansmont.com

Quick checklist you can implement today

  1. Use MH1-compliant pallets in good condition, rated per ISO 8611 for your load path. ANSI WebstoreITEH Standards

  2. Eliminate box overhang and prefer column stacking when compression strength is critical. Wiley Online LibraryFibre Box Associaton

  3. Specify film or straps to ASTM standards and document the application recipe. ASTM International | ASTMAntpedia+1

  4. Validate with ISO 2234 static stacking, ASTM D4169 or ISTA 3E distribution tests, and EUMOS 40509 acceleration testing where applicable. Environmental ChambersASTM International | ASTMista.orglansmont.com

  5. Train teams on OSHA storage rules and FMCSA securement expectations. OSHAeCFR

References

ANSI. (2016). MH1, Pallets, slip sheets, and other bases for unit loads. American National Standards Institute. https://webstore.ansi.org/preview-pages/MHIA/preview_ANSI%2BMH1-2016.pdf ANSI Webstore

ANSI. (2021). MH16.1, Design, testing, and utilization of industrial steel storage racks. Rack Manufacturers Institute. https://studylib.net/doc/27529950/ansi-mh16.1-2021-design--testing--and-utilization-of-indu... studylib.net

ASTM International. (2025). ASTM D4649-20, Standard guide for use of stretch films and wrapping application (latest update noted Aug 14, 2025). https://www.astm.org/d4649-20.html ASTM International | ASTM

ASTM International. (2023). ASTM D3950-23, Standard specification for strapping, nonmetallic (and joining methods). https://img.antpedia.com/standard/files/pdfs_ora/20231024/ASTM/D%203950%20-%2023.pdf Antpedia

ASTM International. (2022). ASTM D3953-15(2022), Standard specification for strapping, flat steel and seals. https://img.antpedia.com/standard/files/pdfs_ora/20221211/astm/ASTM%20D3953-15%20%282022%29.pdf Antpedia

ASTM International. (2022). ASTM D4169-22, Standard practice for performance testing of shipping containers and systems. https://img.antpedia.com/standard/files/pdfs_ora/20221122/ASTM%20D4169-22.pdf Antpedia

EUMOS. (2020). EUMOS 40509, Test method for load unit rigidity (rev. of 2012). https://eumos.eu/services/standards/ eumos.eu

Fibre Box Association. (2021, July). The Tech Box: Compression loss with stacking patterns. https://www.fibrebox.org/news/the-tech-box-july-2021 Fibre Box Associaton

Federal Motor Carrier Safety Administration. (n.d.). 49 CFR Part 393, Subpart I: Protection against shifting and falling cargo. https://www.ecfr.gov/current/title-49/subtitle-B/chapter-III/subchapter-B/part-393/subpart-I eCFR

International Organization for Standardization. (2000). ISO 2234: Packaging, complete, filled transport packages and unit loads, stacking tests using a static load. https://wewontech.com/testing-standards/190424008.pdf Environmental Chambers

ISO. (2011). ISO 8611-2: Pallets for materials handling, performance requirements and selection of tests. https://cdn.standards.iteh.ai/samples/50115/202bea00f78f49239539ff6aecfd432b/ISO-8611-2-2011.pdf ITEH Standards

Lansmont. (n.d.). EUMOS 40509 overview and equipment for acceleration testing. https://www.lansmont.com/standards/eumos-40509 lansmont.com

Occupational Safety and Health Administration. (n.d.). 29 CFR 1910.176, Handling materials, general. https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.176 OSHA

Virginia Tech, Center for Packaging and Unit Load Design. (2024). Predicting the effect of pallet overhang on box compression strength [open repository item]. https://vtechworks.lib.vt.edu/items/a44b58f5-f8a2-4e60-b709-23a013411d58 VTechWorks

Wienerberger. (2021). Acceleration test values for unit load stability certificate [technical note]. https://www.wienerberger.be/.../124010_500X140X224.pdf Wienerberger

Zawieja, T., & Garbowski, T. (2024). Estimation of compressive strength of cardboard boxes including pallet overhang. Applied Sciences, 14(2), 819. https://www.mdpi.com/2076-3417/14/2/819

Alexandra Benson
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