How to Load a Roll Cage Safely
Knowing how to load a roll cage safely is one of the simplest ways to prevent injuries in a warehouse, distribution centre or store. According to the Health and Safety Executive (HSE), some companies that use roll cages continuously found that up to a third of their accidents were related to them. A fully loaded roll cage can weigh 500kg or more, so poor loading or careless movement can cause serious harm.
Common roll cage injuries
The most common problem is strain from repeatedly loading and unloading cages. Workers should be trained to lift correctly, bending the knees and keeping loads close to the body, and should be given regular breaks. The HSE lists the main causes of roll cage injuries as:
- Pushing or pulling cages, especially up slopes
- Trying to stop a cage from overbalancing, which can cause crush injuries
- Repetitive loading and unloading
- Hands and feet getting trapped
- Cages falling from lorries during loading or unloading, for example from a tail lift
Before you load: pre-use checks
Always inspect a roll cage before use. A damaged cage is harder to control and more likely to tip or jam.
- Check the castors and wheels turn freely and are not cracked or worn flat
- Check the frame, gates, shelves and catches for bent or broken parts
- Make sure brakes (where fitted) hold the cage still
- Take any damaged cage out of use and book it for roll cage repair
How to load a roll cage: step by step
- Park the empty cage on a flat, level surface and apply the brake if it has one.
- Put the heaviest items at the bottom to keep the centre of gravity low.
- Stack goods in layers across the cage rather than in tall columns, so the load stays stable when it moves.
- Keep the load inside the cage frame, with nothing hanging over the sides.
- Do not load above the load line, or above the height where the person moving the cage can see over the load. HSE notes that most operators cannot see over 1,400mm, while roll cages are usually 1,550mm to 1,830mm tall.
- Stay within the cage’s rated load. For example, our new A-frame roll cages are rated to 500kg; check the rating for your own model.
- Close and secure gates, shelves and straps before the cage is moved.
Moving a loaded roll cage safely
Set clear rules for moving roll cages around the site. HSE guidance and good practice include:
- Move only one cage at a time
- Keep to a slow walking pace, as speed adds momentum and makes the cage harder to stop
- Push the roll cage rather than pull it
- Get help on ramps, slopes and uneven floors
- Keep hands on the handles, away from the corners and edges of the frame
Loading roll cages onto vehicles and tail lifts
Cages falling from lorries and tail lifts are a known cause of serious injury. Load one cage at a time onto the tail lift, apply the brakes, and keep feet clear of the lift edge. Once inside the vehicle, secure cages with load restraint bars or straps so they cannot roll or tip in transit.
Choosing a safer roll cage
The design of the cage also affects how safe it is to load and move. HSE guidance points to a few features worth looking for:
- Larger wheels: a small step needs about 20% more force with a 100mm wheel than with a 125mm wheel
- Castors fitted close to the corners for better stability
- Handles at about 1,000mm height, which keep fingers away from the corners
- A robust, rigid frame and shelves that stand up to long-term use
All our new roll cages are fitted with 125mm castors, and we also supply refurbished roll cages that are checked and repaired before sale. See our guide to the types of roll cages for help choosing the right one.
Roll cage repair and maintenance
Regular maintenance is one of the best ways to prevent roll cage accidents. Check cages often, especially the castors and wheels, and repair or refurbish damaged units before they cause problems. Our roll cage maintenance tips cover the checks to make.
At Distribution Maintenance, we provide roll cage repair on your site or at our repair centre, and supply new and refurbished roll cages. We understand how important safe transit equipment is to your business.
Roll cage loading FAQs
How much weight can a roll cage hold?
It depends on the model, so always check the rated load on the cage or from the supplier. Many standard roll cages, including our new A-frame cages, are rated to 500kg.
How high can you load a roll cage?
Never load above the load line, or above the height where the person moving the cage can see over it. HSE notes that most operators cannot see over 1,400mm.
Should you push or pull a roll cage?
Push it. Pushing is ergonomically better than pulling and gives you more control, especially when stopping.
How many roll cages can you move at once?
One. Moving cages one at a time, at walking pace, reduces the risk of losing control.
These are general recommendations only. For official health and safety advice, see the HSE guidance on roll cages and wheeled racks. For repairs, new or refurbished cages, contact us or call 01279 883 286.
