Racking Inspection: Well-Intentioned is Not Always Well-Done
Many companies take racking inspection seriously – and yet make avoidable mistakes that can be costly in an emergency. Whether it's a lack of documentation, overlooked damage classes, or insufficient training: we show you the 10 most common mistakes in racking inspection and how to avoid them.
Mistake 1: No PRSES Appointed
DIN EN 15635 stipulates that every business with racking systems must appoint a Person Responsible for Storage Equipment Safety (PRSES). This person coordinates all safety-relevant measures related to the racks. In practice, this responsible person is missing in a surprisingly large number of companies.
Tip: Appoint the PRSES in writing and ensure appropriate training. The appointment should also be available to the professional association.
Mistake 2: Weekly Visual Inspection is Ignored
The annual expert inspection alone is not enough. New damage can occur between inspections – due to forklift impacts, overloading, or external influences. Weekly visual inspection by trained warehouse personnel is also mandatory.
Tip: Create a simple checklist for the weekly walk-through check and document the results digitally.
Mistake 3: Damage Not Marked Immediately
A damaged racking element is noticed but not immediately marked. Other employees continue to load the rack – with potentially fatal consequences. According to DIN EN 15635, "Red" level damage must immediately lead to the blocking of the affected bay.
Tip: Keep plenty of red barrier tapes and warning signs ready in the warehouse. Train all employees on how to handle detected damage.
Mistake 4: Missing or Outdated Load Capacity Plates
Every racking bay must carry a clearly visible plate with the maximum shelf load. In practice, these plates are often faded, damaged, or simply non-existent. This is a serious violation.
Tip: Check all load capacity plates for readability and timeliness. If the racking configuration changes, the plates must be adjusted.
Mistake 5: Insufficient Documentation
The Industrial Safety Ordinance (BetrSichV) stipulates that all inspections, defects, and measures must be documented in writing. Records must be kept at least until the next inspection. Verbal agreements do not count as proof in the event of a claim.
Tip: Use a digital inspection report. Tools like RegalCheck enable legally secure documentation including photo documentation.
Mistake 6: Inspection Deadlines Exceeded
The expert inspection must take place at least every 12 months. In the rush of day-to-day business, this date is often forgotten or postponed. This is not just a violation of the standard, but a liability risk.
Tip: Set up automatic reminders – at least 8 weeks before the due date, to allow enough time for scheduling.
Mistake 7: Self-Repair Without Manufacturer Approval
Damaged racking uprights are welded or straightened by the in-house locksmith. This is not permissible, as it can impair the statics of the racking system. Repairs and replacements may only be carried out using original spare parts and according to manufacturer specifications.
Tip: Always have damaged components replaced with original parts. Document every replacement.
Mistake 8: Missing or Damaged Column Protection
Racking uprights in areas with forklift or pallet truck traffic require column protection. This is often forgotten during installation or not replaced after an impact. Unprotected uprights are the most common cause of racking damage.
Tip: Equip all exposed racking uprights with tested column protection and check it regularly.
Mistake 10: No Emergency Plan for Racking Damage
What happens if a rack is severely damaged by a forklift accident? Many companies have no defined process for such situations. An emergency plan regulates who is informed, how blocking occurs, and what steps are taken.
Tip: Create an emergency plan for racking damage and post it clearly in the warehouse. Practice the procedure with warehouse staff.
Conclusion: Prevention Saves Costs and Protects Human Lives
Each of these mistakes can be avoided with reasonable effort. Invest in training, documentation, and regular checks – your employees and your business will thank you. Digital solutions like RegalCheck support you in keeping track and meeting all deadlines.