A single forklift impact can bring down an entire row of racking. Six kilonewtons of impact force are enough to plastically deform an unprotected frame upright — and as soon as an upright loses its load-bearing capacity, the load level of an entire axis tips over. Impact protection is therefore not a comfort feature but a legally required component of warehouse safety. Anyone planning today as a safety officer or warehouse manager must achieve two things at once: comply precisely with the minimum normative requirements and select the right protection class for the actual risks in their own warehouse. This article summarises what DGUV Information 208-061 and DIN EN 15512/15620 actually require, which protection types have become established on the market and how to recognise a robust solution.
Why impact protection is mandatory: the legal situation
In Germany, impact protection is not a recommendation but a mandatory measure. Its binding nature arises from the interplay of several sets of rules that every warehouse operator should know:
- DGUV Information 208-061 (November 2023 edition, updated version July 2024) — successor to the previous DGUV Regel 108-007 (formerly BGR 234). For the first time, it specifies the requirements for impact protection for static racking installations in quantitative terms.
- DIN EN 15512:2021-06 — "Steel static storage systems — Adjustable pallet racking systems — Principles for structural design". Defines, among other things, the design assumptions for impact loads on frame feet.
- DIN EN 15620:2021-11 — Tolerances, deformations and clearances. Specifies which tolerances are permissible and from what point a rack is considered damaged.
- DIN EN 15635 — Application and maintenance of storage equipment, including the annual expert inspection.
- Betriebssicherheitsverordnung (BetrSichV, German Ordinance on Industrial Safety), in particular § 3 (risk assessment) and § 10 (inspection of work equipment). It obliges the employer to inspect work equipment for damage that could lead to dangerous situations.
- ASR A1.3 — German technical rule for workplaces governing safety and health protection signage. It regulates the yellow-and-black hazard marking of impact protection.
Violating these requirements has several consequences: in the event of damage, the operator is personally liable, the employers' liability insurance association can seek recourse, and insurance cover can be restricted. In the approval process for new buildings, building authorities and fire protection assessors now require proof of protective equipment that complies with the standards.
Normative requirements in detail
The central question in planning practice is: which specific values must impact protection demonstrate? In 2023, DGUV Information 208-061 laid down quantitative minimum values for the first time, where previously there had only been a blanket requirement of "adequately dimensioned".
Energy absorption: at least 400 Joules
According to DGUV Information 208-061 (section 4 "Construction and equipment"), impact protection is considered adequately dimensioned if it can absorb at least 400 Joules of kinetic energy without any contact occurring between the impact protection and the rack upright. This value is not chosen at random: it roughly corresponds to the impact energy of a counterbalance forklift in the 1.6–2.5 t class at a typical approach speed of 1.2–1.5 m/s in the warehouse aisle.
Important: in the structural design of the frame feet themselves, DIN EN 15512 requires a minimum impact load, but the 400-Joule value is the operational test criterion for the protective element in front of the upright. In operations with heavier trucks (reach trucks, sideloaders > 3 t) or higher travel speeds, you must dimension considerably higher — in high-bay warehouses, 1500–3000 Joules is today's practical standard.
Height: at least 300 mm, recommended 400 mm
DGUV Information 208-061 prescribes a minimum height of 0.3 m (300 mm). A height of 400 mm is expressly recommended, as operational practice shows that uprights can also be damaged in higher areas — for example by fork tips, load wheels of reach trucks or swinging loads.
For areas with reach trucks or narrow-aisle trucks, a considerably higher version (600–1100 mm) can be advisable. The load wheels of reach trucks in particular travel at a height that a 400 mm guard does not cover.
Structural requirements
Two conditions distinguish standard-compliant impact protection from mere upright protection:
- Not connected to the racking: impact protection in corner areas and at passageways must be structurally separated from the racking. Otherwise it transfers the impact energy into the structure — exactly what it is supposed to prevent.
- Marked yellow and black in accordance with ASR A1.3. The hatching must be executed in such a way that it remains clearly visible even under normal warehouse lighting.
This distinction is important: upright protection devices mounted directly on the frame upright (such as sleeves) are a useful supplement, but do not replace impact protection in corner areas and at aisle ends.
Protection types: what is available on the market
Not every type of impact protection is suitable for every application. The following five designs cover the majority of industrial applications:
1. Steel upright protectors (classic, painted or galvanised)
U- or L-profiles made of 5–8 mm sheet steel, painted in RAL 1023 (traffic yellow) with black stripes or hot-dip galvanised with applied marking. Standard heights 400 mm and 600 mm, fixed with four heavy-duty anchors (M12 or M16). Typical energy absorption: 800–3000 Joules, depending on wall thickness and profile shape. Advantage: high rigidity, well-defined deformation behaviour, low purchase costs. Disadvantage: plastic deformation after impact — as a rule, the entire component must be replaced.
2. Polymer or PP impact protection
Made of glass-fibre-reinforced polypropylene or thermoplastic elastomers. The physical operating principle is different: the material deforms elastically on impact, absorbs the energy through internal friction and then largely returns to its original shape. High-quality polymer barriers achieve energy absorption of over 20,000 Joules; specialised protective bollards absorb even more than 24,000 Joules in documented drop tests. Advantage: no component replacement after every impact, considerably less stress on the floor anchors. Disadvantage: higher purchase costs, larger deformation paths require more installation space.
3. Corner protection vs. upright foot protection
The two designs are often confused in practice:
- Corner impact protection (floor-mounted angle guards, inside/outside): heavy L-shaped profile guard, positioned free-standing at the corner area of the racking or at the aisle end. Fulfils the DGUV requirement of "not connected to the racking".
- Upright foot protection / column sleeve: bolted directly onto the frame upright or slipped over it. Primarily protects against light scraping damage, but does not replace corner protection within the meaning of DGUV 208-061.
4. Guard railings and barriers for aisle ends
For continuous lines of protection at aisle ends, traffic routes or in front of workstations, barriers (1500–2500 mm long) with posts are used. This design is particularly important when people and forklifts move around the same area. On impact, the barrier must have sufficient deformation travel to decelerate the truck in a controlled manner while reliably shielding people on the protected side.
5. Anti-collision mesh guards and column sleeves
A special form is mesh guards, which act as rear-wall protection on drive-through racking to prevent pallets falling into the neighbouring aisle. They are not an impact protection solution in the narrower sense, but form part of the overall warehouse protection concept. Polymer column sleeves (often in half-shell design) protect building columns in halls with forklift traffic.
Steel vs. plastic: comparison
The following table directly compares the two dominant material classes. The values are guide values from manufacturers' data sheets and field reports:
| Criterion | Steel impact protection | Polymer impact protection |
|---|---|---|
| Energy absorption (typical) | 800–3000 J | 2000–24,000 J |
| Behaviour on impact | plastic deformation, permanent | elastic deformation, returns to shape |
| Service life with repeated impacts | 1 impact — then replacement | withstands multiple impacts |
| Repair / replacement | replace the entire component | usually no replacement necessary |
| Stress on floor anchors | high (energy goes directly into the concrete) | low (energy is absorbed in the material) |
| Risk of concrete breakout | high with hard impacts | low |
| Maintenance effort | visual inspection, repainting | visual inspection, very low |
| Purchase price per linear metre | from approx. 60–180 € | from approx. 200–500 € |
| Life-cycle costs (10 years) | higher due to replacement + floor repairs | lower |
| Suitable for cold stores / deep-freeze warehouses | observe corrosion protection | special Iceflex variants available |
Neither of the two systems is "better" across the board. Steel remains the economical solution in areas with rare, rather light impacts and a tight budget. Polymer pays off above all where frequent impacts are to be expected — for example in high-frequency picking aisles, in food logistics with short cycle times or in narrow-aisle systems with tight tolerances.
Selection based on risk analysis
Standard-compliant selection does not begin in the catalogue but in the risk assessment in accordance with § 5 ArbSchG (German Occupational Health and Safety Act). Five parameters determine the protection class:
- Forklift tonnage: kinetic energy increases linearly with mass. With a 2 t forklift at an impact speed of 1.5 m/s you are at approx. 2250 Joules — that demands considerably more than the 400-Joule minimum class.
- Aisle width and steering geometry: in narrow aisles (< 2.8 m), angled approaches are typical. Here, the protection must also absorb lateral components.
- Travel speed: kinetic energy increases with the square of the speed. Doubling from 1.0 to 2.0 m/s quadruples the load.
- Traffic frequency: frequent forklift movements increase the probability of impacts. High-frequency areas benefit disproportionately from polymer solutions.
- Pedestrian traffic in the aisle: as soon as people and forklifts move in the same area, continuous barriers or physical separations must be planned — not just corner protection.
Practical tip: have the kinetic energy calculated separately for each aisle type (E = ½ · m · v²) and document the values in the risk assessment. In the event of a dispute, this calculation is the proof that you have designed "adequately dimensioned" protection within the meaning of DGUV 208-061.
Installation and maintenance
Even impact protection dimensioned in accordance with the standard loses its effect if it is incorrectly installed or not regularly checked. Three topics are decisive in practice:
Floor anchoring
Steel impact protection is fixed into the concrete floor with heavy-duty anchors. At least four M12 anchors per element, embedment depth as specified by the manufacturer (typically 80–120 mm). The concrete must have a minimum grade of C20/25 — in older halls this cannot be taken for granted. Polymer systems usually use chemical anchors or special bolts with a defined preload that support the energy absorption behaviour.
Visual inspection and annual expert inspection
According to DIN EN 15635 and BetrSichV § 10, two inspection cycles apply:
- Recurring visual inspection at short intervals (typically weekly) by an instructed person from the warehouse. Documentation in a simple inspection log.
- Annual expert inspection by a competent person in accordance with DIN EN 15635. This inspection is mandatory and must be documented in writing.
Obligation to replace after impact
DGUV Information 208-061 is unambiguous: defective or deformed impact protection must be replaced promptly. For steel systems, this generally means replacing the entire component — a plastically deformed steel structure is no longer in its design condition. For polymer systems, the competent person checks in accordance with the manufacturer's specifications (cracks, discolouration, loosened anchors); the element can often continue to be used after returning to shape, provided there is no visible damage.
Common planning errors
From audit reports and damage assessments, six errors can be identified that repeatedly lead to objections:
- Upright protection installed instead of corner impact protection. A sleeve on the frame upright is not impact protection within the meaning of DGUV 208-061 because it is connected to the racking. It is not sufficient in corner areas and at aisle ends.
- Energy class chosen too low. The 400-Joule minimum class suits a 1.6 t forklift at moderate speed — not a 3 t reach truck in a high-bay warehouse.
- Marking faded or covered over. Yellow and black in accordance with ASR A1.3 must remain visible. Repainting is part of the maintenance plan.
- Floor anchors in the wrong concrete grade. Older hall floors often have screed or thin-layer concrete that cannot absorb the loads. Arrange for a core sample before installation.
- Deformation travel ignored. Polymer protection needs installation space for elastic recovery. If you place it too close to the upright, you forfeit the protective effect.
- No documentation of the risk assessment. Without a calculation of the kinetic energy per aisle, there is no proof that you have designed in accordance with the standard.
Frequently asked questions
Does every warehouse aisle need impact protection?
No — but every static rack that is loaded or unloaded by industrial trucks that are not rail- or wire-guided must be fitted with impact protection in the corner areas and at passageways. Narrow-aisle systems with inductive guidance may be exempt if the risk assessment supports this.
Are 400 Joules really enough?
400 Joules is the legal minimum value according to DGUV 208-061. Whether it is sufficient depends on your forklift fleet and travel speed. Calculate the impact energy actually to be expected and choose the next higher protection class. In most industrial warehouses, the requirement is 800–2000 Joules.
May the impact protection touch the rack upright?
No. DGUV 208-061 expressly requires that in the event of an impact there is no contact between the impact protection and the upright. This means: the deformation travel under load must be smaller than the distance to the upright. Manufacturers state the maximum deformation travel in their data sheets.
Who is liable in the event of damage?
The employer is liable as the operator of the warehouse under BetrSichV and ArbSchG. If impact protection is missing or underdimensioned, recourse claims by the employers' liability insurance association apply; in extreme cases, a criminal charge of negligent bodily harm may be added. The annual expert inspection in accordance with DIN EN 15635 and a documented risk assessment are the most effective safeguards.
How often must impact protection be inspected?
At least once a year by a competent person (DIN EN 15635, BetrSichV § 10). In addition, visual inspections take place at shorter intervals — weekly in many companies — by instructed warehouse staff. Both inspections must be documented.
Is polymer also worthwhile in small warehouses?
In small warehouses with low forklift frequency and a 1.6 t counterbalance truck, steel is usually the more economical solution — provided the risk of frequent impacts is low. As soon as you record more than two impacts per year, the life-cycle calculation generally shifts in favour of polymer.
Conclusion
Impact protection is one of the few components in the warehouse where minimum normative requirements and technical necessity are almost congruent. With the values of 400 Joules and 300 mm (recommendation 400 mm), DGUV Information 208-061 established quantitative thresholds for the first time in 2023 that can be verified in an audit. Anyone planning today should regard these values as a lower limit and dimension their protection class on the basis of the actual forklift energies. Steel is the cost-effective solution for areas with a low probability of impacts; polymer pays off over the life cycle in high-frequency zones and with heavy trucks. The decisive factor, however, always remains the triad of documented risk assessment, standard-compliant design and annual expert inspection in accordance with DIN EN 15635 — it is the real protection against damage, liability and business interruption.