Load and lift
Safe stacking and unloading in racking
Stacking and unstacking without falling goods
Stacking at height is where both capacity and stability are most at stake: capacity falls with lift height, and above 2 metres there is a particular risk of falling goods. Here is the safe procedure for putting a pallet in place in racking and taking it down again.
Check the capacity at full lift height
Read the load chart at the lift height the rack location requires — not at travel height. Capacity drops markedly with height: in the Toyota example, a truck drops from 1,600 kg at 3,000 mm to 750 kg at 7,000 mm at the same load centre. If the location is too high for the load, the lift must not be carried out.
Example1,600 kg → 750 kg (3→7 m)Check headroom and racking space
Measure/check that there is headroom above the top of the load to the ceiling, beams, pipes and sprinkler system, and that the rack location is clear and intact. Look for damaged rack uprights — a rack that has been hit is a collapse risk.
Clear the area under and in front of the lift
When the forks are raised above 2 metres, there is a particular risk of falling goods. Make sure nobody is under or in front of the mast. The truck should have an automatic red warning light that is activated when the forks pass 2 m.
Particular riskforks above 2 mDrive forward, stop and lift steadily — with the mast vertical
Drive up to the rack with the load low, stop completely and apply the parking brake if necessary. Bring the mast upright before you lift — never lift with the mast tilted forward, as the load's centre of gravity then moves far forward. Lift steadily to the correct height.
Drive in over the rack and set down gently
Drive forward carefully until the load is over the rack location, and lower it gently into place. If necessary, tilt the mast slightly forward to free the forks — but only with the load supported by the rack. Avoid jerks that can topple neighbouring loads.
Pull the forks clear and lower to travel height
Reverse calmly until the forks are completely clear of the pallet, and lower them immediately to travel height (approx. 15–30 cm) with the mast tilted slightly back before driving on. Never drive around with raised, empty forks at shoulder height — it is a collision risk.
Travel heightapprox. 15–30 cm above floorWhen retrieving: lift clear, tilt back, lower, reverse
When retrieving: drive the forks in under the pallet with the mast vertical, lift the load a few centimetres clear of the racking, tilt the mast slightly back, and reverse carefully until the load is clear. Then lower to travel height. The sequence — clear, back, lower, reverse — keeps the load stable all the way.
Source
Based on BFA Industri »Trucks« (Oct. 2023), p. 7 (speed, falling goods above 2 m); Toyota Material Handling DK, »Faktiske kapacitet« (capacity vs. lift height).