Testing duties

Racking inspection under EN 15635: duties, intervals and process

A damaged upright can bring down an entire rack. How the annual racking inspection (Regalprüfung) works, what happens between inspections and how damage is rated using the traffic light system.

Last updated on 20 October 20267 min readAMS Go editorial team

Key points at a glance

Racking is work equipment and must be inspected regularly (Section 14 BetrSichV). EN 15635 provides for an inspection by a qualified person at least every 12 months.
Between inspections, the racking is checked regularly for damage – often weekly by the person responsible for storage equipment safety or trained employees.
Damage is rated using a traffic light system: green means monitor, orange means repair promptly and do not reload, red means unload and isolate immediately.
Load notices, impact protection and documented inspection reports belong in every warehouse. Since 2024, DGUV Information 208-061 explains the requirements in Germany.

Which rules apply to racking

Racking, cabinets and mezzanines are work equipment under the German Ordinance on Industrial Safety and Health. The employer must assess their hazards, have them inspected regularly and may only use them in a safe condition (Sections 3, 4, 14 BetrSichV).

The inspection process is described in EN 15635 “Steel static storage systems – Application and maintenance of storage equipment” (DIN EN 15635 in Germany). In 2024, DGUV Information 208-061 “Storage equipment and devices” replaced the former DGUV Rule 108-007 and explains the requirements from the accident insurance perspective.

Visual checks and inspection

Visual check
How oftenregularly according to the risk assessment, often weekly
By whomperson responsible for storage equipment safety or trained employees
Purposespot impact damage, missing safety locks and overloading early
Inspection by a qualified person
How oftenat least every 12 months
By whomqualified person with knowledge of racking systems, internal or external
Purposesystematic inspection of all racking with an inspection report
Damage report
How oftenimmediately
By whomeveryone working in the warehouse
Purposenever keep quiet about damage after an impact

Check	How often	By whom	Purpose
Visual check	regularly according to the risk assessment, often weekly	person responsible for storage equipment safety or trained employees	spot impact damage, missing safety locks and overloading early
Inspection by a qualified person	at least every 12 months	qualified person with knowledge of racking systems, internal or external	systematic inspection of all racking with an inspection report
Damage report	immediately	everyone working in the warehouse	never keep quiet about damage after an impact

EN 15635 provides that the operator appoints a person responsible for storage equipment safety (PRSES). This person organises the checks, receives damage reports and arranges repairs.

Rating damage: the traffic light system

Damage found – such as bent uprights or damaged beams – is classified by severity. EN 15635 contains limit values for permissible deformation:

Green
Meaningdamage within tolerance
What to dodocument it and monitor at the next check
Orange
Meaninghazardous damage
What to dorepair promptly; do not reload the area after unloading until it has been repaired
Red
Meaningvery serious damage
What to dounload the area immediately, isolate it and only release it again after repair

Level	Meaning	What to do
Green	damage within tolerance	document it and monitor at the next check
Orange	hazardous damage	repair promptly; do not reload the area after unloading until it has been repaired
Red	very serious damage	unload the area immediately, isolate it and only release it again after repair

Inspection register in AMS GoRecord racking with inspection interval, document damage with photo and traffic light level directly in the warehouse and track repairs as measures with deadlines.

What is checked during a racking inspection

uprights, beams and frames for deformation, cracks and corrosion
beam safety locks present and engaged
floor anchoring and base plates
impact protection at corners and aisle ends present and undamaged
load notices with shelf and bay loads clearly visible
loads within the permissible values, pallets placed correctly
pallet stops and back mesh where intended
racking vertically aligned

Preventing damage

impact protection at all exposed points, especially aisle ends and passageways
traffic routes wide enough and well lit
instruct forklift drivers: approach racking slowly and centrally, report damage immediately
only store pallets and load carriers in perfect condition
only modify racking after consulting the manufacturer – changed beam levels alter the load capacity

Inspection report and records

Every inspection ends with an inspection report: racking inspected, damage found with traffic light level and location, measures taken, name of the inspector and next date. Many companies also mark inspected racking with an inspection sticker.

Closing the loop is what counts: orange and red damage needs a measure with an owner and a deadline – and confirmation that it has been repaired.

Checklist: racking inspection

All racking recorded with location and type
Person responsible for storage equipment safety appointed
Visual checks scheduled at fixed intervals
Annual inspection by a qualified person commissioned
Load notices on all racking
Impact protection at exposed points
Damage rated with the traffic light system, red areas isolated immediately
Repairs with manufacturer parts documented
Employees instructed to report damage

Free templates for this guide

As PDF and Excel, no sign-up – free to use in your own company.

Frequently asked questions

Is racking inspection mandatory?

Yes. Racking is work equipment and must be inspected regularly under the Ordinance on Industrial Safety and Health. EN 15635 specifies this with an inspection by a qualified person at least every 12 months.

Who may inspect racking?

A person qualified to carry out inspections with knowledge of racking systems and EN 15635 – trained employees of your own or external racking inspectors. Visual checks between inspections are carried out by instructed employees.

What do green, orange and red mean in racking inspections?

Green: damage within tolerance, monitor it. Orange: hazardous damage, repair promptly and do not reload the area. Red: very serious damage, unload and isolate immediately.

Does shelving also have to be inspected?

In principle yes, but scope and interval depend on the hazard. A tall pallet rack loaded by forklift needs more attention than office shelving.

What replaced DGUV Rule 108-007?

Since 2024, DGUV Information 208-061 “Storage equipment and devices” explains the requirements for racking and storage equipment in Germany.

Terms from the glossary

This guide gives a general overview of German occupational safety law and does not replace legal advice. The regulations in force and the rules of the statutory accident insurance institutions are authoritative.

Organise occupational safety digitally

With the occupational safety software AMS Go you handle risk assessments, safety instructions, inspections and more in one system – mobile and with AI support.

Request a demo See all modules