Palletized cargo is secured by combining three things: friction between pallet and floor, blocking against fixed structures, and lashing that pulls the load down or holds it back. In Europe, road securing calculations follow EN 12195-1, which uses design accelerations of 0.8 g forward and 0.5 g sideways and rearward. For containers moving by sea, rail and road, the IMO/ILO/UNECE CTU Code of Practice, published in 2014, gives the guidance on packing and securing.
Why unit loads need securing
A unit load that is stable on a warehouse floor can move or collapse when a truck brakes, corners or rides a rough road, or when a ship rolls. The forces are large: a braking truck subjects the cargo to forces close to its own weight. Unsecured pallets slide, tip or fall off the vehicle, damaging goods and creating serious accident risks.
Securing is a system involving the load unit itself (the stability of the stack, the wrapping and the pallet), the vehicle or container (floor, anchor points, body strength) and the securing equipment. Weakness in any link undermines the rest. Pallet handling basics, including unitizing with film, are covered in stretch wrapping pallets.
Design forces in EN 12195-1
EN 12195-1, "Load restraint assemblies on road vehicles – Safety – Part 1: Calculation of securing forces", is the European standard for calculating the forces needed to secure cargo on road vehicles. It also applies to road vehicles carried on ships or trains. The method is based on accelerations that the cargo must withstand, expressed as a fraction of gravity (g).
| Direction | Design acceleration coefficient |
|---|---|
| Forward (braking) | 0.8 g |
| Sideways | 0.5 g |
| Rearward | 0.5 g |
The securing must keep the load from sliding or tipping under these accelerations. Friction contributes to resisting movement, and the remainder must be provided by blocking or lashing. Parts 2, 3 and 4 of the EN 12195 series cover web lashings, lashing chains and lashing wire ropes, and EN 12642 specifies the strength of vehicle bodies. The standard has been revised several times, so users should check the currently valid edition from their national standards body. European roadside inspection rules (Directive 2014/47/EU) apply to cargo securing, and the EN 12195 series is widely used as the technical reference.
The three securing principles
Friction (force-fit)
The weight of a pallet generates friction with the floor. Friction depends on the materials in contact (wood on wood, wood on steel, film or plastic surfaces, anti-slip mats), on cleanliness and moisture. Tabulated friction coefficients are given in the standard and in guidance such as VDI 2700 sheet 14 (a German guideline on load securing); values for smooth, wet or oily surfaces are far lower than those for dry, rough surfaces. Anti-slip material between pallet and floor raises friction and reduces the number of lashings needed.
Blocking (form-fit)
Blocking holds the load against the headboard, side boards, stakes, bars or other cargo. It is the most reliable way to stop forward movement, since it does not rely on friction or strap tension. Gaps must be filled with dunnage, air bags or fillers. Dunnage, blocking and bracing methods are described in dunnage, blocking and bracing in containers. Wooden dunnage that crosses borders must comply with ISPM 15 rules for dunnage.
Lashing
Lashing uses webbing, chains or wire ropes. Two methods dominate:
- Top-over lashing presses the load down onto the floor, increasing friction. Its effectiveness depends on strap tension and angle.
- Direct lashing (diagonal, loop, spring or straight lashings) connects the load to anchor points and resists movement directly.
Lashing equipment has rated capacities (lashing capacity, LC) and standard tension forces marked on labels. Straps with damaged webbing, cuts or no readable label must be taken out of service. Edge protectors protect webbing and cargo corners.
Securing at pallet level
A secured vehicle still fails if the pallet load itself collapses. Good practice includes:
- Stable stack patterns (interlocked cartons, flat top surfaces) and, where needed, corner boards, layer pads and stretch film or strapping.
- Sound pallets: no broken boards or missing blocks, and a pallet suited to the weight.
- Limit overhang, because overhanging cartons lose strength and may be crushed by lashings.
- Pallet-to-pallet connections: adhesive between layers, or netting for high loads.
A European testing method, EUMOS 40509, evaluates the rigidity of a load unit using a dynamic test and specifies how deformation is assessed and how test certificates are issued. EUMOS is a member-driven non-profit organization that develops such standards for cargo securing. Test results help shippers show that a palletized load withstands the forces in transport and help determine how much additional securing is needed. See pallet testing standards for related test methods.
The CTU Code for sea and intermodal transport
The IMO/ILO/UNECE Code of Practice for Packing of Cargo Transport Units (the CTU Code) was endorsed by the three organizations in 2014. It is a non-mandatory global code of practice covering handling and packing of cargo transport units (containers, swap bodies, vehicles) for sea and land transport, replacing earlier IMO/ILO/UNECE guidelines from 1997. It addresses those who pack, receive and unpack units, along with training and dangerous goods. Supplementary informative material is published as MSC.1/Circ.1498.
For anyone loading containers, the Code's key messages include:
- plan the load, including weight distribution and the center of gravity;
- do not exceed the unit's maximum payload;
- use securing methods that prevent movement in the expected conditions, including sea conditions that produce higher accelerations than road transport;
- inspect the container before loading, and check the cargo's own packaging;
- provide the correct documentation, including weight information.
Application guidelines and laws on container packing differ between countries and carriers, and the Code is often adopted into contracts and regulations. Practical loading planning is in how many pallets fit in a shipping container.
Practical checklist for shippers
| Step | What to check |
|---|---|
| Load unit | Stable stack, intact pallet, film or strapping applied, no overhang beyond limits |
| Vehicle | Floor clean and dry, sound body, anchor points rated and undamaged |
| Method | Calculate blocking, friction and lashing needs for each direction |
| Equipment | Labeled straps or chains with valid ratings, edge protectors, anti-slip mats |
| Gaps | Filled or braced to prevent movement |
| After loading | Driver instructed; retension lashings after the first kilometers when specified |
Frequently asked questions
What accelerations does EN 12195-1 use?
It uses 0.8 g forward, and 0.5 g sideways and rearward for road transport. These coefficients are used to calculate the securing force needed.
Is the CTU Code legally binding?
The CTU Code is a non-mandatory code of practice, but regulators, carriers and contracts frequently refer to it, and many countries use it as a basis for national rules.
Does stretch film secure a pallet on a truck?
Film holds the cartons together on the pallet, but it does not secure the pallet to the vehicle. The pallet still needs blocking, friction or lashing.
What is EUMOS 40509?
It is a test method that uses a dynamic test to evaluate the rigidity of a load unit, helping to determine whether palletized cargo can withstand transport forces.
Sources
- IMO/ILO/UNECE Code of Practice for Packing of Cargo Transport Units (CTU Code) — International Maritime Organization
- EUMOS quality standards — European Safe Logistics Association
- DIN EN 12195-1:2011-06 Load restraining on road vehicles — SAI Global
- Safe load guidelines — International Road Transport Union (IRU)