Proper storage of concrete roof tiles is a critical yet often overlooked practice both on site and in storage yards where good handling practices can
Proper storage of concrete roof tiles is a critical yet often overlooked practice both on site and in storage yards where good handling practices can prevent loss as well as retain strength and colour consistency.
In South Africa concrete roof tiles are a go-to for roofing and our tiles are engineered to deliver decades of weather protection. However their durability begins long before they reach the roof where poor storage can introduce microcracks, edge damage, colour variation and unnecessary wastage which can impact project costs and timelines.
A disciplined storage approach ensures that every tile installed performs as designed and should be implemented by all people handling the tiles from the hardware to the contractors or DIY builders.
Storage area
Concrete tiles must be stored on firm level ground capable of supporting concentrated loads. A pallet of tiles can weigh well over a tonne and uneven surfaces create stress points that lead to cracking within the stack. Compacted sand or reinforced concrete slabs are preferred while avoiding recently backfilled soil, soft sand or areas prone to water pooling.
Equally important is accessibility where storage zones should allow delivery vehicles, wheelbarrows or forklifts to move freely without excessive turning while bearing in mind that the fewer tiles handled, the better with a lower risk of damage.
Elevation considerations
Tiles should never sit directly on the ground and it is best to use pallets or wood to raise stacks at least 75–100 mm above surface level. Elevation prevents moisture ingress and reduces efflorescence risk and keeps packaging dry during rain.
Good airflow beneath pallets also helps stabilise moisture levels within the tiles which is particularly important in humid coastal regions. Concrete tiles are manufactured to withstand harsh climates, but storage exposure can still affect appearance and handling where extended UV exposure may lead to uneven colour curing especially where tiles are partially covered. Shops should rotate stock where possible and avoid storing different batches in mixed sunlight patterns.
Tiles can be stored outdoors but wrapping must remain intact as torn plastic allows water to accumulate between tiles, increasing weight and making manual handling hazardous. Wind also plays a part and high winds can lift plastic covers and topple poorly stacked pallets. Under these circumstances it is best to secure wrapping and maintain stable stack heights. On the highveld repeated freeze-thaw cycles on saturated tiles can cause surface stress increasing the importance of keeping pallets covered and elevated.
Stack Heights
Most manufacturers palletise tiles to safe transport heights. These limits should remain unchanged on site unless mechanical handling equipment is used.
As a practical guideline:
• Do not double-stack pallets unless the base is engineered for the load.
• Ensure the bottom pallet is perfectly level.
• Never rest loose tiles against a pallet as this creates a collapse hazard.
Overstocking is one of the fastest ways to convert saleable stock into breakage or for homeowners to book a trip to the nearest supplier to replenish their expensive supplies.
Human Interference
Building sites and storage yards introduce risk through curiosity, shortcuts and poor handling habits.
Common damage causes include:
• Walking on pallets
• Dropping tiles during inspection
• Dragging tiles instead of lifting
• Removing strapping prematurely
Designate the tile storage area as a controlled zone. A simple barrier or signage can prevent unnecessary traffic. For retail depots, display pallets should be separate from bulk stock to limit repeated handling. Remember that concrete roof tiles are valuable and easily resold making tiles risky to be stored on pavements or open sites. It is best to store tiles within fenced perimeters, position pallets in visible areas, use site lighting where possible, schedule deliveries closer to installation dates and reducing dwell time on site as effective theft deterrents.
Handling techniques
Tiles leave the factory tightly strapped for stability. When unpacking cut straps carefully as sudden release can shift tiles, remove tiles from the top layer first, lift never slide tile to avoid edge abrasion and carry tiles vertically to reduce bending stress. In yards or on large sites use mechanical lifting equipment such as pallet forks and not improvised slings and where tiles must be moved manually it is best to use team lifting for larger volumes to reduce fatigue-related drops.
Safety habits
Tile pallets represent both crush and collapse hazards and workers should always wear gloves to prevent cement abrasion cuts, wear safety footwear as a dropped 5kg tile can cause serious injury. Remember to keep stacks away from excavation edges and at home never allow children or untrained labour near storage areas.
Batch control
Roof tiles are produced in batches and slight tonal differences are normal within industry tolerances. To ensure colour consistency always store and install tiles batch by batch or blend tiles from multiple pallets during installation. This prevents visible banding across the roof plane which is one of the most common aesthetic complaints. DIY builders frequently overlook this step, only noticing variation once the roof is complete and the house is viewed from afar.
Another clever tip is to store with Installation in mind and to plan for workflow. It is best to position pallets as close as safely possible to the structure. This shortens carrying distances and limits handling damage. On larger sites it is also a good idea to stagger deliveries to match roofing progress rather than flooding the site with excess stock. In these instances efficiency on the ground translates directly into efficiency on the roof.
The payoff
Concrete tiles are built for longevity but their performance begins with disciplined site management. Correct storage protects structural integrity, preserves appearance and keeps projects running smoothly. Whether supplying a depot, managing a housing development or building a home yourself, treat tile storage as a technical priority.
