What’s the best way to stack materials with a loader?

Knowing how to properly stack materials with a loader is crucial for both safety and efficiency – good stacking technique saves you money and reduces the chance of damage or loss to the materials you are moving. Whether you’re handling roading metal, aggregate, timber, or other construction materials, proper stacking techniques can make a huge difference in your worksite’s organisation and safety.

The main attachments you’ll use on a loader are a bucket for loose materials, or forks for lifting palletised goods – if you’re looking to improve your skills, taking our wheel loader training course is great for new or experienced operators. If you are using forks, our forklift training will help you understand good stacking for palletised products.

Understanding Your Loader’s Capabilities

It’s important to understand what your loader can handle. You can find this in the manufacturer documentation, and it will look something like this:

In this case, the heaped capacity in the bucket is 1.9 cubic metres, and then rated loads are given in relation to what operation you are performing with the loader, and that’s between 3060kg and 7556kg.

Choosing the Right Location for Material Stacks

When it comes to safe stacking of materials, location is everything. You want to choose a spot that’s:

• Flat and Level: Any slope can make your stack unstable and create hazards.
• Well-Drained: Water sitting at the bottom of the materials increases the weight and can degrade some materials.
• Away from Traffic: Keep your material stacks away from heavy traffic areas. You want at least three meters between stacks and any vehicle paths—about the length of a small car.
• Accessible: It’s ideal if your loader can easily access at least 2 sides of the stack to give you options.

Understanding Material Stacking Height Regulations

The general rule of thumb is that no stack should be higher than three times its base width. However, this can vary depending on the material type and site conditions.

For loose materials like aggregate or sand, you’ll want to keep the stack height lower and maintain a natural angle of repose—that’s the steepest angle your material can maintain without sliding. Think of it like building a sandcastle at the beach—there’s only so high you can go before it starts to collapse.

Proper Stacking Techniques

When you’re operating your loader to stack materials, you want to use a technique that’s both efficient and safe. Start by creating a solid base layer. This is like building a house—you need a good foundation.

Layer by layer, build up your stack gradually. Don’t just dump material in one spot and hope for the best—that’s a recipe for disaster, mate. Instead, spread each layer evenly and compact it if necessary. This helps maintain stability and makes it easier to measure and manage your quantities.

Maintaining Stack Stability

The key to maintaining stable material stacks is proper distribution. Think of it like packing a chilly bin for a beach day—you want everything balanced and secure. Here are some important considerations:

For granular materials like gravel or sand, maintain the natural angle of repose. Don’t try to stack these materials with vertical sides—they need to slope naturally to remain stable.

When stacking boxed or containerised materials, use a pyramid pattern. This means each layer should be slightly smaller than the one below it, creating a stable, stepped appearance.

Safety Considerations During Stacking Operations

When you’re operating a loader to stack materials, safety needs to be your top priority, mate. Every year in New Zealand, we see injuries from poorly stacked materials or unsafe loader operations. Let’s make sure you’re not adding to those statistics.

Keep an eye on your surroundings like a rugby ref watching for forward passes. Make sure no one’s walking or working in your operating zone. A good rule of thumb is to maintain an exclusion zone of at least 1.5 times the full reach of your loader. That means if your loader can reach 6 meters, you want at least 9 meters clear around your work area.

Weather Considerations for Material Stacking

Here in Aotearoa, we’re no strangers to four seasons in one day. Weather plays a massive role in safe stacking of materials. When it’s windy, you’ll need to be extra careful with your stacking height. Strong winds can destabilise stacks, especially if you’re handling lighter materials like empty pallets or sheet materials.

During wet weather, keep an eye on how the rain affects your stacked materials. Some materials, like cement bags or timber, need to be covered to prevent damage. Also, watch out for ground conditions—wet soil can become unstable and affect the safety of your stacks.

Monitoring Stack Conditions

Just like checking the sheep after a storm, you need to regularly monitor your material stacks. Look for signs of:

Shifting or Leaning: If a stack starts to lean, it’s telling you something’s not right. Address this immediately by either re-stacking or reducing the height.

Base Erosion: Check that the ground around your stacks isn’t being eroded by rain or other factors.

Material Degradation: Some materials can break down over time, especially if exposed to the elements. This can affect stack stability.

Different Materials, Different Approaches

Let’s talk about specific materials and how to handle them:

Aggregate and Sand: These loose materials need to be stacked with proper slope angles. Use your loader to build up the stack gradually, maintaining the natural angle of repose. Don’t try to create vertical sides—it won’t end well.

Palletised Materials: When stacking pallets, keep them level and aligned. Your loader should have fork attachments for this job. Remember to check the condition of pallets—a dodgy pallet can cause your whole stack to collapse.

Pipes and Poles: These need to be stacked with proper supports to prevent rolling. Use your loader to place them carefully, and make sure you’ve got chocks or wedges ready to secure them.

Record Keeping and Documentation

Yeah, I know paperwork isn’t the most exciting part of the job, but keeping records of your material stacking operations is important. Document things like:

• Stack locations and heights
• Material quantities Regular safety checks
• Any incidents or near misses

This information can be crucial for site management and safety compliance. It’s also dead helpful when you need to know what materials you’ve got and where they are.

Final Thoughts

Proper material stacking with a loader isn’t just about getting the job done—it’s about getting it done safely and efficiently. Remember, every site is different, and conditions can change faster than a southerly wind in Wellington. Stay alert, follow these guidelines, and don’t be afraid to ask for help if you’re unsure about anything.

By following these practices for stacking of materials on construction sites, you’ll create a safer, more efficient workplace for everyone. Keep in mind that WorkSafe guidelines and site-specific rules always take precedence, so make sure you’re familiar with these as well.