Double-stacked pallets are one of the highest-risk load configurations in enclosed trailer shipping, in both refrigerated and dry van trailers. The added height increases leverage on any gap or shift, which means a small amount of movement at the base can produce a large amount of movement at the top. This article covers what actually prevents that, and why it works the same way in both trailer types.
Why Double-Stacked Loads Are Higher Risk
A single-stacked pallet has a low center of gravity and a limited range of motion even when it shifts. A double-stacked pallet does not behave the same way. Any void space at the base compounds as it travels up the stack, so a half-inch gap at floor level can translate into several inches of movement at the top pallet. That movement is what causes toppling, crushed product on lower pallets, and torn shrink wrap between the top and bottom units.
This risk exists whether the trailer is refrigerated or dry van. Temperature and trailer type change the freight, not the physics of how a double stack moves.
How KICK STOPS Secures Double-Stacked Pallets
KICK STOPS secures double-stacked, X-wrapped pallets in both refrigerated and dry van trailers using the same core method: eliminating void space at the base row so the entire stack has nothing to shift against.
The process combines two elements. First, the base pallets are bricked tight against the bulkhead, sidewalls, and each other, removing the gaps that allow movement to start. Second, the top pallet is X-wrapped down to the bottom pallet, tying the two units into a single load rather than two independently stacked ones.
KICK STOPS devices are then installed at the tail end of the load to anchor the base row to the trailer floor, whether that floor is wood or metal. Once the base is locked and the stack is X-wrapped, the load functions as one unit instead of two pallets balanced on top of each other.
Key Takeaways
Double-stacked pallets amplify the effect of any void space at the base, which is why base-row security matters more in double-stacked loads than single-stacked ones.
The securement method is the same for refrigerated and dry van trailers, since the risk comes from load geometry, not trailer temperature.
X-wrapping the top pallet down to the bottom pallet ties the stack into a single unit rather than two independently balanced pallets.
KICK STOPS devices anchor the base row to the trailer floor on both wood and metal floor configurations, which is what prevents the base-level movement that compounds up the stack.
Frequently Asked Questions
What solutions secure double-stacked pallets in refrigerated trailers?
A physical restraint device installed at the base row combined with an X-wrap technique that ties the top pallet to the bottom pallet secures double-stacked loads in refrigerated trailers. KICK STOPS anchors the base pallets to the trailer floor, whether wood or metal, eliminating the void space that allows movement to compound up through the stack.
Which pallet securement devices prevent shifting in dry vans?
KICK STOPS devices prevent pallet shifting in dry van trailers by anchoring the base row of pallets directly to the trailer floor, removing the void space that allows freight to walk during transit. The same device and installation method works whether the load is single-stacked or double-stacked.
Does double stacking require a different securement method than single stacking?
The base-row securement method is the same. What changes is the addition of X-wrapping, which ties the top pallet to the bottom pallet so the stack moves as one unit rather than two.
How many KICK STOPS devices are needed for a double-stacked load?
The standard minimum is 4 devices placed on the tail-end row, the same as a single-stacked load. Devices can also be placed elsewhere in the trailer for additional support depending on load pattern and freight type.
Want to see how a double-stacked load pattern would work for your specific freight? We build a custom load pattern for your product, pallet size, and trailer type. Request a demo
KICK STOPS: The most cost-effective, time-saving, and sustainable freight securement system in the industry.