Why Racking Inspection According to DIN EN 15635 is Mandatory
Operating storage racks comes with responsibility – not only for the goods but, above all, for the safety of employees. The European standard DIN EN 15635 ("Steel static storage systems – Application and maintenance of storage equipment") governs how racking systems must be safely operated, inspected, and maintained.
In combination with the Industrial Safety Ordinance (BetrSichV) and the rules of professional associations, regular racking inspection is not a recommendation but a legal requirement. Violations can lead to serious accidents and result in heavy fines and liability risks.
The Three Inspection Levels at a Glance
1. Weekly Visual Inspection (Internal)
DIN EN 15635 requires warehouse staff to conduct visual inspections of racking systems at regular intervals – ideally weekly. The focus is on obvious damage:
- Bent or dented uprights and beams
- Missing or damaged safety pins
- Loose or missing base plates and anchors
- Overloading of individual racking bays
- Damaged column protection profiles
2. Monthly Check by the Safety Officer
The operational Person Responsible for Storage Equipment Safety (PRSES) carries out a more systematic check regularly. The appointment of a PRSES is mandatory according to DIN EN 15635 for any business using racking systems.
3. Annual Expert Inspection (External)
At least once a year, a qualified person – a certified racking inspector – must perform a comprehensive inspection. This inspection includes:
- Full inventory of all racking components
- Assessment of damage according to the traffic light system (green/yellow/red)
- Check of stability and anchoring
- Inspection of load capacity plates
- Creation of a legally secure inspection report
The Traffic Light System: Correctly Categorising Damage
DIN EN 15635 defines a proven three-level system for assessing racking damage:
| Level | Colour | Meaning | Action |
|---|---|---|---|
| 1 | 🟢 Green | Signs of use, no safety risk | Observe, reassess during the next inspection |
| 2 | 🟡 Yellow/Orange | Damage present, limited use possible | Mark immediately, repair within 4 weeks |
| 3 | 🔴 Red | Significant damage, acute danger | Block and unload the racking bay immediately, urgent repair/replacement |
Common Mistakes in Racking Inspection
- No PRSES appointed: Many companies fail to name a responsible person – this is a violation of the standard.
- Lack of documentation: Every inspection and damage must be recorded in writing. Without documentation, there is no proof in the event of a claim.
- Exceeded inspection intervals: The 12-month period for expert inspection is binding – even if "nothing has happened".
- Self-repair: Welding work on racking components requires approval from the manufacturer. DIY repairs can jeopardise structural integrity.
- Missing load capacity plates: Every racking bay must carry an up-to-date plate with the maximum shelf load.
Checklist: How to Prepare for the Racking Inspection
- ✅ Appoint and train a PRSES
- ✅ Label all racks with load capacity plates
- ✅ Create a racking register (inventory of all racking systems)
- ✅ Document weekly visual inspections
- ✅ Mark and block damaged racks immediately
- ✅ Keep inspection reports at least until the next inspection
- ✅ Appoint a certified racking inspector in good time
What Does a Professional Racking Inspection Cost?
The costs for a racking inspection vary depending on the scope, number of racking bays, and location. As a guideline, you can calculate:
- Small warehouses (up to 50 bays): from approx. €300–600
- Medium warehouses (50–200 bays): from approx. €600–1,500
- Large warehouses (over 200 bays): individual calculation
Remember: The cost of a racking inspection is disproportionate to the follow-up costs of a racking accident – not to mention personal injury.
Conclusion: Racking Inspection is a Management Task
Regular racking inspection according to DIN EN 15635 not only protects your employees but also legally safeguards your business. Those who take inspection obligations seriously and implement them professionally minimise risks and create a safe working environment. Use digital tools like RegalCheck to simplify your inspection processes and document them seamlessly.