Electric forklifts are widely adopted in modern warehouse, logistics and manufacturing storage scenarios for their zero local emission, low noise and easy operation features. Many front-line operators tend to judge the allowable stacking height only by the maximum lifting parameter of the forklift itself, ignoring the matching restriction from different rack configurations, which may lead to hidden risks such as cargo falling, rack deformation or even forklift tipping over.

For the most widely used selective pallet rack configuration in conventional warehouses, the safe stacking height limit should be determined by combining three core factors: the rated load mark of each layer of rack beams, the load center distance parameter of the loaded pallet, and the official load lifting curve of the matched electric forklift. Operators should never break through the height mark specified for the corresponding rack area, even if the forklift itself has the ability to reach a higher lifting position.

When working with double-deep rack configurations, the safe stacking height limit should be appropriately reduced on the basis of the selective rack standard with same load level. The extended forward working stroke will change the actual load center of the whole lifting system, and extra load will be applied to the fork arms and lifting gantry. Operators should strictly follow the pre-specified height limit of the double-deep rack zone, and do not attempt to stack at a higher position for the purpose of saving storage space.

In narrow aisle rack working scenarios, electric forklifts usually adopt special side shifting or rotating fork structure to adapt to the narrow channel space. The safe stacking height limit here needs to take the ground flatness of the operation area and the side load resistance of the rack into extra consideration. Any over-height stacking behavior may cause lateral instability of the forklift or unexpected extrusion deformation of the rack structure.

Before starting daily stacking work, operators are suggested to confirm the corresponding height limit mark of the target rack area first, and check if the forklift’s lifting limit alarm device keeps normal working state. Regular inspection on the deformation condition of rack beams will also help to maintain long-term safe operation of the whole storage system. Complying with the above specifications can effectively reduce the occurrence of safety accidents related to over-height stacking, and create a more reliable working environment for all on-site staff.