Stillages are workhorses of the UK warehouse and factory floor, but they are only as safe as the people handling them. A dropped load, an overloaded frame or a poorly stacked column can cause serious injury and costly downtime. Under the Provision and Use of Work Equipment Regulations 1998 (PUWER), employers have a clear legal duty to make sure work equipment is suitable, maintained and used only by people who have received adequate training.
This guide sets out a practical, structured approach to training your team to handle stillages safely and stay compliant. It is written for warehouse managers, health and safety officers and supervisors who need a repeatable programme rather than a one-off briefing.
Why stillage handling training matters
PUWER 1998 requires that anyone who uses work equipment, or supervises its use, has received adequate health and safety information and, where appropriate, training. For stillages that means understanding not just how to move a unit, but how to spot when one is no longer safe to use.
Where stillages are designed to be lifted with slings, chains or a crane, a second set of duties applies under the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER). Training should make clear which of your units are certified for lifting and which are not, so operators never improvise. Our LOLER compliance guide and PUWER practical guide explain both frameworks in more depth.
- It is a legal requirement, not a nicety, wherever powered or manual handling equipment is in use.
- It reduces the risk of manual handling injuries, crush injuries and load-collapse incidents.
- It gives you documented evidence of competence if the HSE or an insurer ever asks.
- It protects the stillages themselves, extending service life and reducing repair costs.
Build a training programme, not a one-off talk
Effective training is planned around your actual equipment and tasks, not delivered from a generic slide deck. Start by mapping how stillages move through your site, then design the content around those real handling scenarios.
Set clear objectives
Define what a competent operator should know and be able to do by the end of the session. Typical objectives include understanding the relevant PUWER and LOLER duties, recognising hazards, applying safe manual handling technique, and following correct stacking and storage procedures.
Match training to the equipment on site
A mesh stillage, a post pallet and a collapsible metal pallet each behave differently when loaded, stacked and moved. Tailor the practical content to the units your team actually uses, including any bespoke designs, so the training reflects real weights, dimensions and locking mechanisms.
Core topics to cover
Hazard identification
Train staff to inspect a stillage before every use and to withdraw any unit that is not fit for service. Key warning signs include:
- Bent, cracked or corroded frame members and welds.
- Damaged or seized locking mechanisms, drop-fronts or shoot bolts.
- Missing feet, worn castors or an unstable base.
- Signs of overloading, such as bowed bases or splayed uprights.
- An illegible or missing safe working load (SWL) marking.
Safe manual handling technique
Where units are moved by hand, cover correct lifting posture, keeping loads close to the body, avoiding twisting, and using teamwork and clear communication for larger or awkward units. Reinforce that mechanical aids should be used whenever a load exceeds safe manual limits.
Safe stacking and storage
Poor stacking is one of the most common causes of stillage incidents. Train operators to load within the stated SWL, distribute weight evenly, only stack units that are designed to be stacked, and never exceed the manufacturer’s recommended stack height. Our guide to keeping stillages stable and preventing collapse is a useful reference to build into your session.
Using handling equipment correctly
Make sure operators are competent with the stillage handling equipment and mechanical aids they will use, such as forklift trucks and pallet trucks. Only trained and, where required, licensed operators should drive powered equipment, and fork guides should be used where fitted to ensure clean, controlled pick-ups.
Personal protective equipment
Cover the correct selection, use and inspection of personal protective equipment (PPE), including safety footwear, gloves and any high-visibility clothing required in your traffic-managed areas. Make clear that PPE is the last line of defence, not a substitute for safe systems of work.
Deliver, assess and refresh
Training only counts if it is understood and retained. Combine clear instruction with hands-on practice so learners build genuine competence.
- Demonstrate, then supervise practice. Show the correct method, then let staff practise on real units under supervision, giving constructive feedback and correcting unsafe habits immediately.
- Assess competence. Check understanding and observe technique before signing anyone off as competent to work unsupervised.
- Schedule refresher training. Revisit the training at regular intervals and whenever equipment, layout or regulations change.
- Feed incidents back in. Use near misses and inspection findings to keep the content current and relevant.
For a wider view of safe operating culture, see our guide to stillage safety in the workplace, which covers handling, reporting and incident investigation.
Keep clear records
Documentation is what turns good practice into demonstrable compliance. Keep records of who was trained, on what, by whom and when, along with training materials and assessment results. Well-kept records provide evidence that you have met your PUWER duties and make it easy to plan refresher sessions and inductions for new starters.
Choose equipment that supports safe handling
Safe handling starts with well-designed, correctly certified equipment. As a UK manufacturer, we build UKCA-marked stillages and cages to suit your loads, handling method and site conditions, and we can supply units certified for lifting where LOLER applies. If you are specifying new equipment, our buyer’s and design guide and advice on how to get an accurate stillage quote will help you get the specification right first time. You can also browse our full range of stillages and cages.
Talk to Lowe Stillages & Cages
Well-trained people and well-made equipment work together to keep your operation safe, compliant and efficient. If you need reliable, certified stillages to support safe handling, or bespoke designs matched to your process, we can help. Get a quote or contact our team to discuss your requirements.