When operating electric forklifts to transport unstable stacked cargo such as loosely bundled light goods, irregularly stacked cartons or unfastened soft packages, the reasonable setting of load-back-rest dimension parameters is a core factor that directly affects operation stability and on-site safety. Many warehouse operation teams tend to focus on load capacity and lifting height of electric forklifts, while ignoring the matching degree between load-back-rest dimensions and the characteristics of unstable stacked cargo, which may lead to unexpected cargo slipping or tipping risks in the moving or lifting process.

The first key dimension parameter refers to the vertical height of the load back rest, which should be higher than the top surface of the highest point of the normally stacked unstable cargo by a reasonable safety margin. If the height of the load back rest is too low, it cannot provide sufficient blocking force for the upper part of the stacked cargo when the forklift brakes suddenly or drives on a slightly uneven road surface, while excessive redundant height will increase the obstruction of the operator’s rear view and interfere with daily normal operation. For general unstable stacked cargo with stacking height within 1.6 meters, the vertical height of the load back rest can be set between 1.8 and 2 meters according to actual operation scenarios.

The second core dimension parameter is the horizontal width of the load back rest, which needs to match the maximum cargo bearing width of the fork carriage. The width parameter should not be narrower than 90% of the maximum effective extension width of the two forks, so that the side parts of the wide unstable stacked cargo can also get effective lateral support when the cargo shifts sideways during turning. It is not recommended to blindly expand the width of the load back rest beyond the outer contour of the forklift body, to avoid collision with surrounding shelves, passing personnel or other operating equipment in narrow aisle working conditions.

Apart from the two basic dimension parameters, the installation flatness and the gap between the bottom of the load back rest and the fork surface are also non-negligible reference indicators. The excess gap at the bottom should not exceed 15 centimeters, to prevent small-sized stacked cargo from slipping out from the gap and causing hidden safety hazards. Operation teams can adjust corresponding dimension parameters according to the actual types of frequently transported unstable stacked cargo in their own scenarios, conduct small-scale test runs before formal large-scale operation, and verify the rationality of parameters through multiple steering, braking and lifting tests, so as to form a targeted safe operation specification suitable for their own warehouse material handling scenes.