Stacking and moving IBC totes

Reading the stacking load

The plate lists the maximum load a tote can bear when stacked. A tote rated for a certain mass will bear the weight of the tote above it only when both are sound and on a flat surface. Rated stacking assumes fully intact cages and bottles, so never stack a damaged tote.

• Empty totes can usually stack more than full ones.
• Stack on a flat surface, indoors if possible.
• Never stack outdoors in a storm season.
• Align cages edge to edge.
• Do not stack on a wood base that has cracked.

Forklifts and jacks

1. Check the tines will go fully under the pallet base.
2. Approach straight on, not at an angle.
3. Lift only a few inches for travel.
4. Drive at walking speed, forks low.
5. Set down flat and level.

A pallet jack should be rated for the load and used on smooth floor. A full tote on a jack is a heavy push.

Strapping for transport

Ratchet straps over the top of the tote and through the cage to anchor points keep it from shifting. A full tote can slosh and push on the straps; check them again after a few miles. Do not let the tote lean on the tailgate.

In a storm yard

In hurricane season, do not stack empties outdoors. Lay them down or move them inside. See securing totes for storms.

In South Florida

Warehouse yards in Doral and Medley see heavy afternoon storms most summer days. A stack of totes that is stable at noon can shift when the ground turns soft. Stack only on paved, level, well-drained surfaces, keep the height low, and unstack before a named storm. Water flowing across a lot can undermine the base of a stack within minutes.

A short checklist before lifting

Look at the tote before the forks go in. Is the cage straight, is the base sound, is the cap closed, is the valve capped? Check the ground for dips and soft spots, and look up for wires and low beams. Test-lift an inch and watch for sway. If the forks are not long enough to reach through the base, find longer ones. Do not lift a tote by the cage bars alone. Keep people out of the swing zone and never ride the load. Write down the weight on a tag, because the next operator may not know what is inside, and a dummy load is not funny in a yard with a tote of syrup on the forks.

Training and signage

Post the stack height limit on a sign at the dock. Mark floor lines for stacking zones. Train every operator once a year and after any near-miss. A stack that falls is almost always a stack that was built without a rule.