Machinery risk assessment template (PDF & Excel)
Form and Excel sheet for the risk assessment (Gefährdungsbeurteilung) of each machine under German law: master data, CE and documents, hazards by life cycle phase with typical examples, risk rating, STOP measures, inspection intervals and instruction.
As of PDF and ExcelAMS Go editorial team
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Before a machine is used, the employer must assess its hazards, derive protective measures and document the result – including the type, scope and intervals of inspections (Section 3 of the German Ordinance on Industrial Safety and Health, BetrSichV). CE marking does not release the employer from this duty.
The template maps these duties per machine: master data and documents such as the declaration of conformity and operating manual, hazards by life cycle phase from installation to disposal with typical examples, risk rating, measures according to the STOP principle as well as inspection intervals, checks and instruction.
What the template contains
- Landscape PDF form per machine with master data and check items on CE marking, declaration of conformity, operating manual and operating instructions
- Table with 13 typical hazards by life cycle phase and hazard factor, risk rating and example measures
- Specifications for checks, inspections, maintenance, instruction and review
- Excel with machine list, automatically calculated inspection and instruction dates and risk calculation
- Worksheet with eight life cycle phases as a checklist
How to use the template
- 1
Record the machine and documents
Enter master data, tasks and operating modes and check whether CE marking, declaration of conformity, a German operating manual and operating instructions are available. For older machines without CE marking, assess the state of the art particularly carefully.
- 2
Assess hazards per life cycle phase
Go through the examples with the operators at the machine, delete what does not apply and add missing hazards. Rate likelihood and severity and define measures according to the STOP principle with an owner and deadline.
- 3
Define inspection intervals and instruction
Define checks, type of inspection, interval and the person qualified to carry out inspections, instruct employees before first use and at least annually, and set the date for the next review. In Excel you can see all due dates for your machines at a glance.
Legal basis
- Section 3 Ordinance on Industrial Safety and Health: risk assessment before use, inspection intervals, review and documentation
- Sections 4 to 6 Ordinance on Industrial Safety and Health: basic duties, requirements for work equipment, basic protective measures
- Section 10 Ordinance on Industrial Safety and Health: maintenance and modification of work equipment
- Sections 12 and 14 Ordinance on Industrial Safety and Health: instruction at least annually, operating instructions, inspection of work equipment
- TRBS 1111: Risk assessment
Frequently asked questions
Do I need a separate form for every machine?
The template is designed for one machine per form. Where working conditions are similar, assessing one workplace or activity is sufficient under Section 5(2) ArbSchG – so you can assess identical machines under the same conditions together. Enter all inventory numbers so it is clear which machines are covered.
Where do the inspection intervals come from?
There are no fixed intervals for all machines. The employer defines type, scope and intervals in the risk assessment – so that the machine can be used safely until the next inspection (Section 3(6) BetrSichV). Guidance comes from manufacturer information, DGUV regulations and technical rules, and experience from previous inspections.
What do I do with an older machine without CE marking?
It may continue to be operated if it complies with the rules that applied when it was made available on the market (Section 5(3) BetrSichV) and can be used safely according to the state of the art. In the risk assessment, pay particular attention to protective devices, emergency stop and controls, and retrofit where necessary.
You may use and adapt the template freely in your own company and for your own clients. It reflects the regulations named as they stand.
Never search a spreadsheet for a deadline again
In AMS Go, what this template covers lives in one system with reminders, history and records at the push of a button – mobile and with AI support.
Related guides
- Risk assessment
Machinery risk assessment in Germany: procedure under the BetrSichV
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How to do a risk assessment in Germany: a guide in 7 steps
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Inspection intervals for work equipment in Germany: overview, duties and records
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Lockout-tagout in Germany: isolating machinery safely for maintenance
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