When operating a forklift, safety and precision go hand in hand. One of the most overlooked yet critical questions is: how far should forks enter a pallet? The answer to this directly impacts load stability, operator safety, and overall warehouse efficiency. In this guide, we’ll unpack everything you need to know to handle pallets safely and correctly.
Why fork placement matters when handling pallets
Forklift operators often focus on lift capacity and speed, but proper fork entry is just as vital. The load can shift or fall if the forks don’t enter a pallet far enough. This puts staff at risk, damages products, and can lead to costly downtime.
Poor fork placement also impacts the load centre, which is crucial to maintaining forklift balance. When the load is unstable or not correctly supported, the forklift may tip forward, especially when lifting at height. For this reason, understanding fork placement is essential for safe operations.
Proper entry also ensures even weight distribution and minimises stress on the pallet boards. This reduces the chances of splintering, cracking, or breaking under pressure.
The ideal fork entry depth: How far should forks enter a pallet?
So, how far should forks enter a pallet? The short answer is: as far as possible—ideally, the full length of the pallet.
In most situations, the forks should enter the pallet at least 80% of its depth, though full entry is the safest option. This ensures the load is entirely supported by the forks, maintaining the correct load centre and reducing strain on the tips.
For example, if you’re lifting a standard Australian pallet (1165mm x 1165mm), your forks should ideally enter 900mm to 1165mm deep into the pallet. This helps avoid the pallet tilting backward or snapping under uneven pressure.
Failing to enter far enough can place all the weight on just the tips of the forks, dangerous for both the pallet and the person operating the forklift.
Forklift load centre
To fully understand why fork depth matters, you need to understand load centre. The load centre is the horizontal distance from the vertical face of the forks to the centre of gravity of the load. Most standard forklifts are rated based on a 600mm load centre.
If the forks don’t go far enough into the pallet, the load centre shifts further out, placing additional strain on the forklift and making it more likely to tip forward.
Picture lifting a box from the edge instead of sliding your arms underneath—it’s harder, less stable, and more likely to fall. The same principle applies to forklifts. When forks are fully inserted, the weight is balanced over the carriage and better supported.
Different pallet types and fork entry recommendations
Not all pallets are created equal. Depending on the type of pallet you’re handling, the ideal fork entry can vary slightly:
- Two-way pallets only allow fork entry from two sides, limiting angles and requiring precise alignment.
- Four-way pallets allow fork entry from all sides, offering more flexibility and safer access.
- Block pallets typically support entry from all directions, while stringer pallets may have notched openings that restrict fork movement.
In Australia, the most common pallet size is the 1165mm x 1165mm CHEP pallet. For this size, entering the forks fully or at least 900mm is recommended.
Regardless of pallet type, the goal remains the same: insert forks as deep as possible without damaging the backboard or structure.
Common mistakes
What happens if forks don’t enter far enough?
Cutting corners on fork placement might seem harmless in the moment, but it often leads to problems such as:
- Pallet damage: Fork tips bearing the full load can crack boards or even pierce through the timber.
- Load instability: The load may rock, tilt, or even fall off entirely.
- Overworked equipment: Forklifts operating with unbalanced loads experience more wear and tear.
- Reduced operator safety: An unstable load increases the risk of tip-overs and workplace injury.
Always make sure forks are level and centred before entering a pallet. Avoid entering on an angle or partially, especially when dealing with heavier loads or when lifting above chest height.
How to ensure proper fork entry
Correct technique and consistent training make all the difference. Here are a few simple tips every operator should follow:
- Align the forks with the pallet before moving forward. Enter straight and avoid hitting edges.
- Keep forks level and adjust the height to match the pallet opening—too low and you risk scraping the ground; too high and you’ll miss the entry point.
- Enter the pallet fully, aiming for full depth or a minimum of 80%.
- Check your load before lifting. Make sure it’s centred and evenly distributed on the forks.
- Use the tilt carefully—only tilt the mast once the forks are fully engaged and lifted slightly from the ground.
Regular safety training and forklift refresher courses can help operators stay sharp and prevent costly mistakes.
Choosing the right forklift for pallet handling
The right machine can make pallet handling much easier and safer. At Hyworth Forklifts, our fleet includes equipment specifically designed for precise pallet entry:
- Walk-behind and Pallet movers are ideal for tight warehouse spaces. Their compact build and responsive controls allow for exact fork placement.
- Electric counterbalance forklifts offer excellent visibility and control, making them perfect for indoor pallet handling.
- Reach trucks are a great fit for narrow aisles and high-density storage, where exact fork control is vital.
Choosing the right forklift isn’t just about size or fuel type—it’s also about how well it handles pallets. If you’re unsure what model suits your workspace, our team is here to help with expert recommendations and flexible hire plans. Explore our range of forklifts for hire and sale.
Industry guidelines and standards in Australia
Safe pallet handling is best practice and part of Australia’s workplace safety regulations.
Safe Work Australia outlines duties for businesses operating forklifts, including proper training, equipment maintenance, and load handling. While there is no specific legal requirement for fork depth, industry standards recommend full insertion or 80% minimum to avoid breaches of safety.
Operators should also refer to their forklift manufacturer’s manual, which often includes load charts and stability guidance specific to the machine.
Conclusion
Forks should enter a pallet as far as possible—ideally, the full depth, or at least 80%. This practice helps prevent pallet damage, keeps the load stable, and supports safe forklift operation.
Whether you’re training new staff or reviewing internal warehouse processes, this simple rule can make a big difference in safety and efficiency.
At Hyworth Forklifts, we offer equipment that makes pallet handling safer and more accurate. If you’re unsure which forklift is best for your needs, we’re just a phone call away.
Get in touch today to speak with our team and receive a tailored forklift recommendation that supports your operations from the ground up.
