Do you want to make
your warehouse safer?
Rely on our expertise in racking inspection.
1
Contents
Does your warehouse experience heavy use?
Prevent damage – by taking the right steps. 4
Are your warehouse facilities subject to inspection?
Consider the consequences if this is not happening. 6
Do you want expertise and knowledge?
We have company approved rack inspectors. 9
What should you do if damage is found?
Ensure that legally you keep your site safe. 10
2
3
Does your warehouse
experience heavy use?
Prevent damage – by taking
the right steps.
How safe is your warehouse?
The productivity of your company is significantly affected
by warehousing within the logistics chain. As a result,
increasing demands are placed on your racking system.
But increased throughput may also raise the risk of
possible damage. Guard against this!
The purpose of this guide is to help you make your
racking system safer and ensure that you are complying
with the law. To this end, we have consulted statutory
framework conditions, recommendations of the trade
association as well as standard regulations regarding your
equipment.
What you can do
In order to prevent damage, and particularly personal
injury, occurring in your warehouse and archive area,
you should consider the following measures:
Prevention
Train your employees. This will ensure the correct
behaviour and operation.
Inspection
Monitor the condition of your racking systems by means
of regular inspections.
Maintenance
Should any damage or operator error be discovered, this
must be reported, rectified or stopped immediately.
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5
Are your warehouse facilities
subject to inspection?
Play close attention if that’s the
case.
What are the statutory requirements? What inspections are necessary on a regular basis?
The obligation of the employer to assess the working Since August 2009, the European standard DIN EN 15635
conditions arises from section 5 of the German Occupa- (see www.din.de) has been applicable to racking.
tional Safety and Health Act [Arbeitsschutzgesetz]. The The standard explicitly states that racking is designed only
risk assessment is substantiated by the German Ordinance for careful and proper use. No additional forces or impact
on Industrial Safety and Health [Betriebssicherheitsver- loads may be introduced, such as those incurred by
ordnung]. Section 4 of this ordinance states: “The em- incorrect operation. Chapter 9 of the standard requires
ployer shall perform the activities called for (...) to ensure the operating company to carry out regular checks. A
that the employees shall be provided with work equip- distinction is made here between immediate notification,
ment (...) which guarantees that safety and health at work visual inspections and expert inspections:
are ensured if it is used according to its intended operating
conditions.” These principles apply in all markets. Immediate notification
All employees must immediately notify the safety officer
Section 10 of the Ordinance on Industrial Safety and of any damage they discover.
Health stipulates in which cases inspections are required:
The employer shall ensure that work equipment exposed Visual inspections
to conditions causing deterioration which is liable to Visual inspections are to be undertaken weekly by trained
result in dangerous situations is subject to periodic personnel. However, alternative intervals may be selected
inspections at intervals determined according to section if determined by a risk assessment. A formal, written
3(3) by qualified persons.” report must be maintained.
Expert inspections
Inspection required for all racking types? An inspection is to be conducted by an expert at intervals
According to the trade association, in principle, all racking of not more than twelve months. According to the trade
types are required to undergo inspection. association, the expert is to be qualified in accordance
These include: with the German Technical Rule for Operational Safety
• Pallet racking 1203. Or market equivalant.
• Modular racking systems
• Multi-level systems What characterises a qualified person?
• Cantilever-type racking German Technical Rule for Operational Safety 1203
• Drive-in and drive-through racking requires that the qualified person must have specialist
• Live storage racking expertise. They must have acquired this expertise by
• Manual mobile racking completing professional training, through professional
• Archive racking experience and through contemporary professional
activity in the scope of the upcoming inspection of the
item to be inspected and appropriate further training. Also
the qualified person may not be subject to any technical
instructions.Or market equivalant
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7
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Do you want expertise and
knowledge?
We have approved rack
inspectors.
How do you benefit from this? Best be on the safe side!
Our approved rack inspectors comply with all statutory If, as a warehouse operator, you want a legally compliant
requirements. The specialist expertise required by the expert inspection with subsequent maintenance of the
German Technical Rule for Operational Safety 1203 racking, then you cannot go wrong with our approved
includes: Or market equivalant racking inspectors, because:
• They are well informed about all regulations such as
Technical knowledge of the specific racking system standards, trade association requirements
including all rack parts. This includes knowledge of as well as statutory framework conditions.
dimensions, structural behaviour and combination • The expert inspection is carried out systematically using
options. Inspectors must also be familiar with the proper a standardised inspection checklist. This checklist was
installation and proper operation of the racking system. devised by trade association experts.
Access to the static calculations and knowledge of the • Even if the operating company no longer has technical
limit states are essential. documentation, our approved rack inspector will as a
rule still have access to the relevant documents.
Our approved rack inspectors receive appropriate further • Only the approved rack inspector has an insight in the
training in the form of a multi-day training course with a static calculation of the existing racking.
final examination. The course content was devised by the • Frequently the layouts are available to the approved rack
Association of Storage and Associated Equipment inspector available and can be used as support during
Manufacturers [Verband für Lagertechnik und Betriebs the inspection.
einrichtungen] and other leading institutes. Only some- • Only the approved rack inspector may contact their
one who has proven their expertise may call themselves technical back-office at any time for information about
an approved rack inspector. They must carry photo possible safety-related effects of damage.
identification and be registered with the Association. Their • Our approved rack inspector is familiar with all the
credentials are valid for five years, which will be extended original parts and is able to identify them clearly to
for another five years after a refresher course is success- ensure rapid and accurate repairs.
fully completed. This ensures that the expertise of our • The product-specific expertise of our approved rack
approved rack inspectors keeps step with the current Inspector ensures that unnecessary purchasing errors
state of technology. Some markets may have different are prevented.
professional associations.
9
What should you do if damage
is found?
Ensure that legally you keep on
the safe side.
Measures to be taken in the event of damage Also regarding modifications to the racking, chapter 7 of
In accordance with the requirements of the trade associa- DIN EN 15635 states the following:
tion and as per DIN EN 15635, any confirmed damage
which may be relevant to safety must be rectified imme- “Changes in the safe carrying capacity can occur when
diately by qualified persons. This is irrespective of whether the storage equipment is modified. In all cases of changes
the damage was discovered by the fork lift driver, ware- the supplier or an appropriate expert shall be consulted
house manager or approved rack inspector. Proceed as and any advice received shall be followed before any
follows: alterations are made. Changes shall be made in accord-
• Safety officer is to be immediately notified of damage ance with the supplier’s instructions which shall contain
discovered. the following:
• Initiate measures to guarantee safety. a) The rack shall be unloaded prior to carrying out the
• Preparation of a written report with obligation to retain alterations;
the report. b) Additions or changes to the storage equipment by
• Investigation of cause in the event of repeated occur- welding or bolting shall not be allowed unless specifi-
rence of damage. cally approved by the equipment supplier;
• Introduction of a damage control procedure as per c) Safe load warning notices shall be updated as neces-
DIN EN 15635, section 9.4.5. sary after all changes to rack configuration; (…)”
Not all types of damage are explicitly named and de- In section 5 of its building inspectorate approvals for
scribed in the standard. It is therefore of great benefit to racking systems – Provision for use, upkeep and mainte-
be able to rely on the expertise of our approved rack nance – the supervisory building inspectorate in Germany,
inspectors. the Deutsche Institut für Bautechnik, states:
“(…) the racking structures are to be checked within the
Use exclusively original parts scope of the inspection intervals specified by
Chapter 9.7.1 of DIN EN 15635 states: “(…) Repairs to DIN EN 15635. Any damage discovered as a result is to
damaged components shall not be allowed unless be rectified as per DIN EN 15635, section 9.7.3. It is
approved by the equipment supplier. (…)” preferred that damaged components are replaced with
original parts. (…)”
and it later continues:
A repair using original parts as a replacement is therefore
“(…) damaged components should be replaced rather the safest method.
than repaired as effective quality control is difficult on
cold formed materials. (…)” These principles apply to all markets.
These principles apply to all markets.
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The Association of Storage and Associated Equipment Manufacturers [Verband LBE] has developed the “Approved
Rack Inspector” training with leading institutes.
Since 1966, the leading manufacturers of storage and associated equipment have been affiliated to the Association of
Storage and Associated Equipment Manufacturers (LBE). Since then, the Association has advocated the safety and
quality of the products of its members. Jungheinrich is a member of this organisation.
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4646.COM.03.2015 · j.r.bd · Technical modifications reserved.
The German production
facilities in Norderstedt and
Moosburg are certified.
Jungheinrich trucks
conform to the European
Safety Requirements.
Jungheinrich Lift Truck Singapore Pte Ltd
7 Joo Koon Way
Singapore 628945
Telephone +65 6558 7600
Telefax +65 6558 7611
[email protected]
www.jungheinrich.com .sg
