Warehouse and logistics risk assessment template (PDF & Excel) – pre-filled
Pre-filled risk assessment for warehousing and logistics with 24 typical hazards – from forklift traffic, racking and loading docks to hazardous substances stores and cold areas – with measures, legal bases and an overview of inspection intervals.
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Warehouses combine many hazards in a small space: forklift traffic next to pedestrians, high racking, loading docks and gates, heavy loads, hazardous substances and, depending on the company, cold. The obligation to carry out a risk assessment (Gefährdungsbeurteilung) follows from Sections 5 and 6 of the Occupational Safety and Health Act (ArbSchG); for work equipment such as forklifts, racking, gates and dock levellers, the Industrial Safety Ordinance (BetrSichV) also applies.
The template uses the same structure as our general risk assessment template and comes pre-filled with 24 typical hazards and common measures – each with its legal basis. You add the rating, owners and deadlines for your company; a second overview lists the periodic inspections and instructions in the warehouse, with automatic due dates in Excel.
What the template contains
- Landscape PDF with 24 pre-filled hazards from forklift traffic and racking to hazardous substances stores and cold areas
- Same structure as the general risk assessment: hazard factor, risk rating, STOP measures, deadlines, effectiveness
- Excel spreadsheet with drop-down lists and automatic risk calculation
- Overview of 12 periodic inspections and instructions – in the PDF and as an Excel sheet that calculates the next due date
How to use the template
- 1
Adapt the template
Delete rows that do not apply and add special features such as narrow aisles, conveyor systems or outdoor storage. Areas with their own hazards – hazardous substances store, charging station, cold store – can be kept as separate work areas.
- 2
Check and rate on site
Walk through the warehouse, loading dock and yard together with the warehouse manager and employees, paying attention to traffic routes, racking damage and manual handling. Rate each hazard by likelihood and severity.
- 3
Follow up measures and inspections
Enter owners and deadlines, check effectiveness after implementation and keep the dates for forklift inspections, racking inspections, gate inspections and instructions up to date in the second sheet.
Legal basis
- Sections 5 and 6 ArbSchG: risk assessment and documentation
- Sections 3, 12 and 14 BetrSichV: risk assessment, instruction and inspection of work equipment such as racking, gates and dock levellers
- DGUV Regulation 68 (industrial trucks): authorisation of forklift drivers (Section 7), loading and unloading (Section 17), inspection at least once a year (Section 37)
- ASR A1.7, A1.8, A2.1, A2.2 and A3.5 (Technical Rules for Workplaces): gates, traffic routes and loading docks, falls, fire protection, room temperature
- TRGS 510 and the Manual Handling Ordinance (LasthandhabV): storage of hazardous substances, manual handling of loads
Frequently asked questions
Do I need a separate risk assessment for every warehouse workstation?
No. Where working conditions are similar, assessing one workstation or activity is sufficient (Section 5 (2) ArbSchG). Look at areas with their own hazards – such as cold stores, hazardous substances stores, battery charging stations or loading docks – separately.
How often do forklifts, racking and gates have to be inspected?
Forklifts at least once a year by a competent person (Section 37 DGUV Regulation 68), racking at least every 12 months by a person qualified to carry out inspections with regular visual checks in between (DIN EN 15635), power-operated gates at least once a year by a competent person (ASR A1.7). The overview is on page 2 and in the second worksheet.
What applies to work in chilled and frozen storage?
Cold belongs in the risk assessment: cold protective clothing, warm-up breaks and precautions against being locked in are common measures. For work with extreme cold exposure of −25 °C and colder, the employer must arrange a mandatory health check (ArbMedVV Annex Part 3 (1) No. 2).
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
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How to do a risk assessment in Germany: a guide in 7 steps
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Forklift licence in Germany: training, authorisation and annual instruction for drivers
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Racking inspection under EN 15635: duties, intervals and process
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Manual handling of loads in Germany: assessing lifting and carrying correctly
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