Palletised Storage- Block Stacking

Block stacking is a palletized storage that does not use any storage equipment. Loaded pallets are placed directly on the floor and built up in stacks on top of one another to a maximum stable height. Ware house safety is one of the primary concerns in warehousing. Therefore it is recommended to have a maximum stable height of stacks e.g. usually not more than six pallets. This aims in preventing accidents of toppling pallets. Bulk storage is done using block stacking. Block stacking can result in the minimum cost of storage since cube utilization is high and no storage medium is required. But in this storing material accessibility is low since only top of the front stack is accessible and loads at the bottom of the stack do not require support. Therefore, the goods is taken out Late In First Out (LIFO). Storage racks are used when support and/or material accessibility is required.

It requires pallets to be stackable, which means the container walls should be sturdy enough to bear the weight of several pallets. Block stacking is the most labour intensive method, because nothing moves unless a forklift truck moves it.


Since it's only stacking the loaded pallets onto one another, and no racking or equipment needed, its cost is very low and is easy to implement. Because of it low set up cost, it tends to be used when a warehouse is first starts up, even where it does not fit long term requirements.


Usefulness of topic in DCM:

-lower capital cost
-no stroage equipment needed
-utlization of space
-suitable for high throughputs


Constraints of topic in DCM:

-limit on stack height which can restrict the use of building height
- reduces storage capacity
-risk of damage of goods. Eg: fire risk