Purpose

To establish a proper stacking and storage system for workplace safety, operational efficiency, and compliance with legal regulations. Improper stacking can lead to injuries and equipment damage.

Scope

This SOP applies to all employees stacking materials or equipment in the workplace.

Definitions

• Safe Stacking: Arranging materials, good and equipment in a stable organised manner that prevents collapse, movement or injury to people and property, while ensuring proper housekeeping, clear passageways, and segregation of hazards.
• Storage: Involves keeping items in a designated area, to prevent loss, damage, unauthorised access, or accidental harm, ensuring they remain in a good quality state until needed.

Responsibilities

• Supervisors/Managers:
  • Assist with safety audits.
  • Ensure compliance.
  • Provide procedures, instructions, and training to employees.

• Staff:
  • Ensure you follow the safety procedures.
  • Immediately report any incident to First Aiders, Health and Safety Reps and Human Resources.
  • Participate in training.

• Safety Officer:
  • Conduct monthly inspections to identify potential risks and implement corrective actions.
  • Conduct risk assessments.
  • Address staff about workplace hazards.
  • Maintain incident records.

Pre-Start Checks

• Ensure that you have a sturdy base for stacking.
• Ensure that you have the correct equipment to move the load to the designated area e.g. platform trolley and that you have the right equipment to reach the shelves e.g. step ladder.
• Ensure that he equipment you are going to use is not damaged in anyway.
• Ensure that when stacking boxes, they are all a consistent box size for stable stacking and that none of the boxes are damaged.
• Ensure that you can pick up the load that you intend to stack, and if in doubt ask for assistance.
• Ensure that the path is clear of all obstructions and personnel.

 Safe Operating Procedure 

• When stacking boxes or cartons, stack with interlocking patterns to prevent shifting. When stacking pallets, inspect for damage before use, stack evenly and not more that 4 high unless otherwise specified.
• Create a sturdy base, use flat level surfaces for stacks, wooden pallets can prevent water damage when stacked on floors. Avoid using damaged or weak pallets as they can compromise stack stability.
• Stacking items of the same size reduces the likelihood of toppling and ensures structural stability. Grouping similar items also makes retrieving materials safer and more efficient.
• Arrange materials in a wall pattern rather than a column to evenly distribute weight and enhance stability. This method reduces the chances of a single item compromising the entire stack.
• Ensure that pallets, trolleys, and forklifts that you need to use are in good condition to prevent accidents. If something is not working report to maintenance, office management and health and safety rep.
• Adhere to height restrictions based on the type of material and stack stability. Avoid stacking items beyond safe limits to reduce the risk of toppling.
• Make sure that stacks do not overhang, also ensure that the base supports the weight of the stack.
• Report Insufficient or faulty lighting in the storage areas, this will eliminate the risk of accidents during stacking or retrieval.
• Ensure that all aisles are clear from debris and marked clearly.
• Post signage for load limits and safety instructions.

Emergency Responses

• If load has collapsed, do not attempt to fix alone, alert your supervisor immediately for assistance.
• Evacuate the area if there is a risk of further collapse or hazardous exposure.
• Secure the area, prevent others from entering until it is safe to do so.
• Call emergency services if there is any injuries or hazardous material involved.

While Waiting for Help:

• Stay calm, panic can only lead to further accidents.
• Alert your first aiders for assistance and if it is safe to do so.
• Communicate using radios or phones to update emergency responders.
• Assist other where possible, help coworkers to evacuate if necessary.
• Document all incidents, take photos and notes to assist you with reporting it later.

Incident Reporting & Investigation

• Regular inspections need to be done to help identify potential risks, such as unstable stacks or faulty equipment, and ensure compliance with safety guidelines.
• Training employees is equally crucial. A trained workforce can assist in identifying hazards, operate equipment safely, and follow stacking and storage procedures.
• Report all incidents or near misses and complete an incident report form within 24 hours by reporting it to your Health and Safety Reps, Human Resources, and your manager.
• Supervisor to conduct a preliminary investigation.
• Document all findings and update any relevant risk assessments or SOPs.
• Conduct annual risk assessments.
• Identifying and address workplace hazards
• Perform safety inspections and implementing corrective actions.

Post-Operation Procedure

• After completing any tasks, return all equipment (trolleys, lifting aids, step ladders) to designated storage areas.
• Check equipment for any signs of damage or wear.
• Report any faults or maintenance needs.
• Access yourself for any signs of strains, discomfort, or injury.
• Report any symptoms to your supervisor immediately.
• Note any difficulties or hazards encountered during the task.

Training & Review

• All staff must receive safe stacking and storage training annually.
• Review this SOP every 12 months or following any incident.
• Refresher training provided after incidents or procedural changes.
• Keep training records and attendance logs for auditing and compliance.