Rack testing according to DIN EN 15635 and DGUV

Almost every company that stores goods in the form of raw materials, semi-finished products, intermediate and finished products has racking systems. The shelving systems experience high loads due to the weight of the goods, the turnover rate and incorrect operation. Because of this, damage to the rack can occur, causing serious accidents. The consequences are expensive damage to property and, in the worst case, serious personal injury. For this reason, the Industrial Safety Ordinance (BetrSichV) obliges employers to regularly check their shelving systems. In this way, defects and damage should be detected early in order to ensure safety in operation. According to DIN EN 15635 and DGUV 108-007 (formerly BGR 234), the shelf inspections must be carried out at least once a year by a qualified person in the form of an expert inspection.

Shelf Checks FAQ

Here we inform you about everything about shelf inspections. If you still have questions, simply contact us at info(at)inventied.de.

The legal basis for shelf inspections is the Ordinance on Industrial Safety and Health (BetrSichV). This states that all work equipment must be checked regularly based on a previous risk assessment. Since shelving systems are classified as work equipment, they are subject to the BetrSichV. Therefore, the operator of racking systems according to §3 para. 6 of the BetrSichV to determine and specify the type and scope of required tests and the deadlines for recurring tests. In addition, §10 of the BetrSichV states that tests must be carried out by a qualified person. In this context, shelf inspections are subject to the specifications of DIN EN 15635 and DGUV 108-007 (former BGR 234 regulations).

DIN EN 15635 consists of the components DIN, EN and 15635. DIN stands for German Institute for Standardization and EN for European Standard. This means that the standard is recognized in Germany and in Europe. DIN EN 15635 defines the scope and procedure for checking storage facilities and shelves by qualified persons.
The DGUV 108-007 is a trade association rule that contains numerous provisions relating to the nature and operation of racking systems. However, the content of the rules has not been changed since 1988 and is becoming less and less important. For this reason, DIN EN 15635 is preferable to DGUV 108-007. Nevertheless, this rule proves to be helpful if no clear answers can be found elsewhere.
Basically, DIN EN 15635 distinguishes between the visual inspection by a shelf checker and the expert inspection by a shelf inspector. Both tests are visual inspections that are usually performed from the ground.

The visual inspection is carried out by the so-called shelf checker and includes the following tasks:

  • Recognizing damage and defects
  • Documentation of damage and defects in a checklist
  • Handover of the checklist to the supervisor or warehouse manager

This means that the tasks of the shelf checker are less extensive than those of the shelf inspector and can be carried out by the operator’s staff after training.

To make your work easier, we provide you with a checklist for carrying out visual inspections free of charge.

The expert inspection is carried out by our certified shelf inspectors, who take on the following tasks:

  • Inspection of your shelves to identify damage and defects
  • Evaluation and identification of found damage according to DIN EN 15635
  • Determination of causes of damage
  • Making recommendations to fix any damage found and avoid it in the future
  • Check whether the shelving system is set up and loaded according to the load plate
  • Checking for compliance with manufacturer specifications for the construction and operation of the racking systems
  • Analysis of the further security of use and the establishment of corresponding recommendations for action
  • Recording of found damage and defects with corresponding assessment in a detailed test report

The rack inspection must be carried out by a person qualified to inspect rack systems. According to TRBS 1203, this condition is met if the examiner has professional training and professional experience as well as recent professional activity in the field of the test service. In addition, the shelf inspectors must have specialist knowledge of the applicable standards and guidelines for shelf testing in accordance with DIN EN 15635 and DGUV 108-007.

Damage to components of shelving systems must be replaced with original components. If this is not possible, the repair must be agreed with the manufacturer and documented. If this is also not possible, the repairs carried out must be checked with the aid of proof of stability and then documented with a statement of the repair measure. Sometimes there are cases of damage in which both the replacement and repair of components are not sufficient and the entire shelf has to be replaced. We are your partner for all damage situations and will find the best solution for you.

According to §3 para. 6 of the Ordinance on Industrial Safety and Health (BetrSichV), the type, scope and deadlines are to be determined and specified by the operator. In this regard, DIN EN 15635 and DGUV 108-007 (former BGR 234 regulations) reflect the current state of the art and must be taken into account by the operator when setting the deadlines.

DIN EN 15635 prescribes a weekly inspection for the visual inspection. This interval can be deviated from if a risk assessment leads to a different regular inspection interval.

The expert inspection must be carried out at least once a year in accordance with DIN EN 15635 and DGUV 108-007. Operation-specific factors may require shorter expert inspection intervals. In this regard, the following company-specific factors must be taken into account by the operator:

  • The size of the camp
  • The width of the traffic routes
  • The facilities used
  • The staff deployed (quality of driver training, type of shift work)
  • The turnover rate
  • The time pressure

The Industrial Safety Ordinance (BetrSichV) requires that work equipment and thus also shelves must be checked accordingly immediately after the new construction/initial commissioning. Therefore, shelves that are set up by the company itself must then be checked by a shelf inspector. When the shelving manufacturer assembles the shelving, in most cases he does the initial testing.

The rack test must be carried out on different rack systems and their components. The types of shelving include drive-in, flow-through, drive-through, shelving, cantilever and plate racks as well as mezzanine floors. Our shelf inspectors will be happy to support you with all of these shelf variations.

In order for our rack inspectors to be able to optimally adapt to your individual racking system, we need some information about your racking system in advance. We have listed the information you need below:

  • Plant size: length, height and number of rows of shelves
  • types of shelves
  • Age/year of construction of the shelving system
  • Location of the system: indoors, outdoors, in a cold storage area or underground
  • Type/industry of the company/organization
  • Type of stacker operator: manual, forklift, reach truck, stacker crane or stacker crane
  • Operators: Permanent staff, temporary workers
  • Normal or shift operation
  • Type of goods: merchandise, own production or storage of useful materials (e.g. tools, scaffolding material)
  • Type of storage: on pallets, in lattice containers or without storage equipment