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Racking inspection checklist

Use the traffic light system for racking inspections to ensure work safety in the warehouse at all times.

What is a racking inspection checklist?


A racking inspection checklist is used during a pallet rack inspection to identify shelf problems or potential risks of shelf collapse. This checklist can be used to assess shelving components such as frames, beams and braces and to determine the level of risk using a traffic light system. Regular shelf inspections help to prevent serious injury and death from shelf collapse.


This article covers the following topics:

1. Guidelines for pallet rack inspections

2. The traffic light system for pallet rack inspections

3. A digital solution to streamline pallet rack inspections

Guidelines for pallet rack inspections

The Federal Institute for Occupational Safety and Health (BAUA) is an authority of the Ministry of Labour. Its sole purpose is to monitor and promote safety at workplace and for employees. The authority does not provide specific guidelines for a checklist, but the general regulations of the BAUA include safety regulations to ensure safety in the workplace. Important steps of the pallet rack inspection are listed below.

Basics of pallet rack inspection

Racks, as well as all work equipment, must be regularly subjected to a rack inspection based on the risk assessment. Shelving systems as work equipment according to the Industrial Safety Regulation. It is therefore obliged to carry out a shelf inspection and risk assessment and to have the system inspected by a competent person.

Weekly pallet rack inspection

In the weekly pallet rack inspection, the rack systems are inspected using a corresponding form for rack inspection. The shelf inspection checklist is used to check whether the shelves have been properly stocked and the general condition of the load carriers. Depending on the risk assessment, it may make sense to adjust the distance of the shelf inspection.

Pallet Rack Testing: Ridges

In general, inspections and visual checks must be carried out at short intervals. The inspection cycle is carried out by the warehouse manager based on the risk analysis. An expert inspection should take place every 12 months. This includes stationary steel racket systems.

Pallet Rack Inspection: Scope

During the shelf inspection it is important to find and document damages and dangers. Is there any damage caused by impact effects? Are there cracks in welding seams? Is the floor in good condition? In the shelf inspection protocol, besides obvious damage, attention should be paid to details.

The traffic light system for pallet rack inspections

In a pallet rack inspection, a checklist specifies exactly which components of the rack system a safety officer should inspect on frames, beams and bracing. A system of three colours – similar to a traffic light – is used to measure the severity of damage and indicate the level of risk. Each colour corresponds to a required action for recording and monitoring.

Defects found during the shelf inspection are divided into three different damage classes. The category to which the damage belongs is made visible directly on the racking system with an inspection sticker. Due to the danger levels, the employees know how to proceed with the rack. Shelf damage is classified into the following three categories:

  1. Green danger level
  2. Orange danger level
  3. Red security level

The green hazard level means that the damage detected during the shelf inspection does not yet exceed the limit values. The components are classified as operational and safe but require monitoring. The affected component is identified by a colored marking, which must be inspected.

Serious damage has been detected at the orange hazard level, which requires repair or replacement as soon as possible. However, the damage is not so serious that the rack must be unloaded immediately and the defective part replaced. However, if the storage equipment is unloaded, it must not be loaded again before repair. Until the facility is safe again, it must also be locked off by the safety officer.

The red danger level stands for very serious damage to which immediate reaction is required. The shelf must be unloaded immediately and locked for further use. The blockage is maintained until the defective component has been replaced.

The markings must be attached to the shelf in a visible position. The inspection date and sometimes dates for a new inspection can be entered. All test contents and results must be comprehensively documented in the checklist and the subsequent report. Maintaining the safe condition of racks is not only the task of the safety officer. Every employee can help to maintain the occupational safety of the storage facility.

Warehouse worker at the pallet rack

A digital solution to streamline pallet rack inspection

Rack inspectors can take advantage of mobile technologies to streamline rack inspections and reporting. Lumiform is a powerful and mobile app and desktop software for racking inspections. The digital application offers warehouses the following advantages:

  • The flexible form construction kit helps you to convert any individual paper list into digital checklists within minutes.
  • Reports are created automatically – this saves the complete postprocessing.
  • Increase the efficiency of your internal processes: Through more efficient communication within the team, with third parties and with management, as well as faster incident reporting, you solve incidents up to 4x faster than before.
  • Save time by analyzing all data more efficiently and identifying areas that need your attention more quickly.
  • Continuous improvement of quality and safety: With the flexible checklist construction kit, you can constantly optimize internal tests and processes. Since Lumiform guides the examiner through the exam, no training is required.
  • The very simple operation offers no margin for error for inspectors on site. The app offers less complexity in documenting or filling out checklists than complicated paper or Excel lists.
  • Depending on the application, tests are carried out about 30%-50% faster or faster.
  • All audit results are automatically bundled in a report and can be sent to stakeholders automatically.


What is the purpose of a racking inspection checklist?

A pallet rack inspection checklist is a vital tool used by safety officers to systematically assess the condition of warehouse racking systems. It guides inspectors through evaluating components like frames, beams, and braces to ensure stability and safety, preventing potential collapses and injuries.

How often should pallet rack inspections be conducted?

The frequency of pallet rack inspections can vary based on the operational conditions and the initial risk assessment results. Generally, visual checks should be performed regularly, with more formal, expert inspections recommended annually to maintain the integrity and safety of the storage systems.

What should I do if I find damage during a pallet rack inspection?

If damage is detected during an inspection, refer to the traffic light system; green indicates monitoring, orange requires scheduling repairs, and red necessitates immediate unloading and blocking of the rack until repairs are made. Always document the findings and follow up to ensure corrective actions are completed.

two workers at the warehouse organizing the racks
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