Pallets are the backbone of logistics, warehousing, and industrial operations, but if not stored properly, they can also pose a major fire risk.

With thousands of wooden and plastic pallets stacked across UK warehouses every day, understanding how to store them safely isn’t just good housekeeping; it’s a compliance and safety essential.

In this guide, we break down how to store pallets safely, including spacing rules, stacking recommendations, and the role of fireproof covers in reducing risk.

Why Pallet Storage Is a Fire Risk

At first glance, pallets seem low-risk. But in reality, they’re often highly combustible, especially when dry and untreated, and stacked tightly in large quantities, creating a fire load.

Pallets can often end up being stored near ignition sources, like charging stations or lighting, and are often used in facilities holding flammable stock, compounding the fire risk.

When a fire starts in or near a poorly stored pallet stack, it spreads rapidly. Flames can move from pallet to pallet fast, potentially reaching ceiling height within seconds. Add in the use of shrink wrap or plastic pallet covers, and the fire becomes harder to control.

In the UK, the HSE, fire brigades, and insurers have all issued guidance on improving pallet storage as part of overall fire risk mitigation.

Safe Pallet Storage: Key Distance Guidelines

One of the most critical principles of safe pallet storage is separation.

Here are some key best practices for spacing:

Minimum clearance from walls

Leave at least 1 metre between pallet stacks and any walls. This allows fire detection and suppression systems (such as smoke detectors or sprinklers) to operate effectively, and provides access for emergency responders.

Separation between stacks

Create clear aisles with a width of 2.4 metres or more between large stacks of pallets. This prevents a fire from jumping directly between stacks and provides safe access for forklifts and personnel.

Height restrictions

Follow the height limits set by your fire risk assessment. Generally speaking, this is likely to be 3 metres at maximum in unsprinklered areas, or up to 4.5 metres in sprinklered facilities (with fire officer approval)

Make sure stacks are stable and not leaning, because leaning stacks are not only a fire hazard but a collapse risk.

Keep clear of ignition sources

Store pallets well away from battery charging stations, electrical panels, machinery that may emit sparks or heat and smoking areas or open flames

Safe Stacking: Stability First

Correct stacking isn't just about saving space; it’s also about preventing collapse and maintaining escape routes in the event of a fire.

Follow these tips to make sure pallets are stacked in a stable way:

• Stack pallets squarely, aligning edges to avoid overhang
• Never stack broken or damaged pallets
• Limit height to avoid instability (especially with lighter-weight plastic pallets)
• Avoid mixing different types (wood/plastic) in the same stack
• Store stacks flat, and not on their edge or tilted

Should You Use Fireproof Pallet Covers?

Absolutely, especially in high-risk environments.

Standard pallet wraps (like shrink film or tarpaulin) are flammable and can actually accelerate fire spread. In contrast, fireproof pallet covers are designed to slow down ignition and flame spread, protect the contents from sparks or radiant heat and allow critical time for staff to evacuate or suppress the fire

Fireproof covers are particularly important when storing high-risk items, such as those listed below:

• Lithium-ion batteries or EV products
• Flammable aerosols or chemicals
• Pallets are stored near machinery or charging areas
• Waste materials or returns awaiting disposal

Fireproof covers should be tested to standards such as EN 13501-1.

Other Safety Measures to Consider

In addition to spacing and covers, taking these measures will enhance pallet safety:

• Install smoke detection above pallet storage zones
• Use flame-retardant treatments for wooden pallets (if viable)
• Regularly inspect pallet conditions and remove any that are cracked, splintered, or soiled with oil
• Ensure sprinklers are tested and unobstructed
• Train staff on hot work precautions and reporting damage to pallets
• Keep escape routes free of stacked pallets at all times

Indoors vs Outdoors: A Quick Note

Pallets stored outside still present a fire risk, particularly to the building itself.

If storing pallets outdoors, make sure you keep them 10 metres away from buildings (if possible). Also, don’t stack pallets against walls or under overhangs and avoid placing them under roof vents or near air intakes.

Note: For high-risk businesses, your insurer may have additional spacing requirements, so always be sure to check your policy terms.

In addition to our Pallet Covers, the Firechief® range of fire safety products also includes extinguisher stands, suppression systems, signage and fire safety products for all types of fires. For information, call us on +44 (0)330 999 0019 or email sales@firechiefglobal.com.

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Disclaimer

The information contained within this blog is provided solely for general informational and educational purposes and is not intended as a substitute for professional advice. Before taking any actions based upon this information, we advise the reader to consult all relevant statutory or regulatory guidance and, where necessary, to consult a qualified fire or industry regulation professional. The use or reliance on any information contained herein is solely at the reader's risk.