Idle pallets are common in agribusiness, food and beverage facilities, fuel and propane operations, warehouses, and farms. Many operations rely on pallets for daily work, so it’s easy for unused pallets to build up over time. But when pallets are stacked or stored improperly, they can quickly become a serious fire hazard. Knowing how to store pallets safely is critical for reducing pallet storage fire risk and meeting NFPA guidance.
Are pallets a fire hazard?
- Are dry and easy to catch fire
- Have gaps that let air flow through, helping fire spread quickly
- Can burn at very high temperatures (especially plastic pallets)
- Can block sprinkler water when stacked too tightly
- Can allow fire to spread to nearby buildings
Even small ignition sources – such as hot work (PDF), electrical problems, equipment, or smoking – can quickly lead to a fire.
What is the safest way to store pallets?
- Outdoors (preferred)
- In a separate (detached) structure away from other structures
- Inside a building with a properly designed sprinkler system
These options can help slow down fires and keep them from spreading.
General pallet storage best practices
- Stack pallets flat and in stable, neat piles
- Remove broken or damaged pallets right away
- Use designated storage areas away from other materials
- Keep pallets away from ignition sources, gas cylinders, and building supports
- Never allow pallets to block aisles or exits
Outdoor storage (preferred)
Key guidelines:
- Maximum height: 15 feet
- Maximum pile size: 400 square feet
- Maintain at least 8 feet between piles
- Store pallets on noncombustible surfaces (like gravel or pavement)
- Keep the area clean
- Prevent unauthorized access
Distance from buildings:
- Small piles (under 50 pallets) – about 20 feet away
- Medium piles (between 50 and 200 pallets)– about 30 feet away
- Large piles (greater than 200 pallets) – about 50 feet away
Buildings made of fire-resistant materials may allow for less separation (NFPA).
Indoor storage (higher risk)
If pallets must be stored inside:
- The building should have a professionally designed sprinkler system
- The sprinkler design depends on stack height, ceiling height, and water supply
- Do not store pallets in racks unless protected by an Early Suppression Fast Response (ESFR) sprinkler system, in accordance with NFPA 13, Standard for the Installation of Sprinkler Systems.
Extra precautions for plastic pallets
Guidelines:
- Stack no higher than 4 feet
- Limit pile size to 2 stacks
- Keep at least 8 feet between pallet piles (or 25 feet from other materials)
- Use sprinkler protection designed to handle higher fire risk (a minimum of an Ordinary Hazard 2 (OH2) design)
More dense storage may require more robust sprinkler coverage or the use of a cut-off or special storage room.
Where to start
- Remove extra or unused pallets
- Dispose of damaged pallets
- Move pallets farther away from buildings
- Organize and stabilize stacks
- Clean up debris around storage areas
Use the Pallet Storage Safety Checklist (PDF) to quickly identify risks and take action to improve your pallet storage setup.
Managing pallet storage
- Designated storage areas
- Limits on how many pallets can be stored
- Regular inspections
- Clear responsibility for cleanup and removal
Managing pallet storage the right way helps reduce fire risk and keeps your operation running safely.