Use the traffic light system for racking inspections to ensure work safety in the warehouse at all times.
This racking inspection checklist aims to identify exactly which components of warehouse racks are damaged.Download template
This pallet racking inspection checklist includes damage guidelines and risk assessment based on the traffic light system.Download template
A rack inspection checklist is used by authorized warehouse inspectors 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.
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 workplaces 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.
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.
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.
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.
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.
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:
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 coloured 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.
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