Safety in the workplace is an important consideration for warehouses. That includes requirements to provide proof on a regular basis that rack systems are in flawless condition. To repair damaged racks safely and reliably, Jungheinrich replaces rack components exclusively with original parts.

The LogiMAT forum “Racks: Better to exchange than repair?” on March 9, 2016 from 14:30 to 16:00 in Forum A, Building 1 discussed possible measures for repair while providing tips on proper inspection and repair of racks. At the end of the event Jungheinrich felt more than confirmed for its strict handling of this issue in the market.

Jungheinrich has been offering rack inspections as a service to its customers for more than five years now throughout Germany and beyond, and the company has been designing and marketing racks along with fork lift trucks for more than 60 years. With more than 100 trained rack inspectors in Germany and other countries, Jungheinrich conducts about 3500 rack inspections a year. Based on this vast experience, Jungheinrich is only able to recommend replacing damaged rack components with original parts.

In this way DIN EN 15635 is consistently implemented in the market. As the European standard, it represents more than anything else the recognised and current state of the art. Jungheinrich also works within this framework to ensure that the safety of its customers' logistics systems is always at the current state of the art while striving to provide optimum service.

Why use original parts only for replacement?

Section 9.7.1 of DIN EN 15635 reads: “(...) damaged components should be replaced rather than repaired as effective quality control is difficult on cold formed materials. (...)” and further: “(...) Repairs to damaged components shall not be allowed unless approved by the equipment supplier. (...)”.

This is also confirmed by Prof. Dr.-Ing. Dieter Ungermann of the Technical University of Dortmund, Department of Architecture and Construction Engineering, Professorial Chair of Steel Construction: “What's essential is for the support structure to have the originally defined load-bearing and usage safety again. That is always ensured if the damaged component is replaced by an original part and the affected area of the racking is not bearing any weight while the replacement is made.” 1

As manufacturer and supplier of the equipment, Jungheinrich can no longer calculate the static properties of a repaired component and therefore cannot provide proof of the stability of the rack system. Because of this, Jungheinrich will not approve any repair method nor certify any repair companies accordingly.

“It is our view that no physical evidence can be put forward to prove that “straightened” components have at least the static properties of the original component, as the uniqueness of each damage event cannot be reproduced in tests on such components and the calculation is not possible due to the unpredictable static-physical behaviour of an individually straightened component.” explains Marco Harder, head of racking and warehouse equipment at Jungheinrich.

What needs to be considered when making changes to a rack system?

Regarding modifications to the racks, section 7 of DIN EN 15635 states: “Changes in the carrying capacity can occur when the storage equipment is modified. In all cases of changes the supplier or an appropriate expert shall be consulted and any advice received shall be followed before any alterations are made. Changes shall be made in accordance with the supplier's instructions which shall contain the following:

a) The rack shall be unloaded prior to carrying out the alterations;
b) Additions or changes to the storage equipment by welding or bolting shall not be allowed unless specifically approved by the equipment supplier;
c) Safe load warning notices shall be updated as necessary after all changes to rack configuration; (...)”
If there are “straightened” components in a rack system, it would not be possible for Jungheinrich to issue new load capacity signs because the safety features are no longer 100% verifiable and safe, hazard-free operation can no longer be guaranteed on the part of the manufacturer. In each case, the JH rack inspector will recommend immediate replacement if they come across any “straightened” component. “Under these circumstances, we must notify the customer that the system may now pose a safety risk for its employees”, emphasises Marco Harder.

Racks are drawing increased attention from building inspection authorities. The top construction inspection authority in Germany, the Deutsche Institut für Bautechnik (DIBt), states in section 5 of its building inspectorate approvals for racks - Provision for use, upkeep and maintenance: “The racking structures are to be checked within the scope of the inspection intervals specified by DIN EN 15635. Any damage discovered as a result is to be rectified as per DIN EN 15635, section 9.7.3. Damaged components should preferably be replaced with original parts. If this is not possible in specific cases, the structural integrity of the rack must be verified taking into account the repair measure.”

Repair consisting of replacement by original parts is therefore the safest and at the same time the most cost-effective method if the possible costs of providing a verification of structural integrity are also considered.

Legal responsibility of the operator

As the employer, and in line with the German Ordinance on Industrial Safety and Health, the operator may only provide its employees with safe working facilities. Prior to the use of work equipment, the employer must assess any possible hazards (risk assessment) and determine any necessary and appropriate safety measures to be taken as a result. In the event of any safety-related change of work equipment, the employer must carry out a new risk assessment.

Damaged warehouse equipment poses a risk to employees, fork lift trucks and the end customer's stored goods. The “Rack inspection” service helps Jungheinrich customers to minimise this risk. Jungheinrich's approved in-house rack inspectors have the necessary competence to perform qualified expert inspections. Due to the technical expertise of rack inspectors, for example regarding structural behaviour or proper assembly and operation of the specific rack system, they are able to discover fundamental defects that may have existed for a long time and substantiate them with static calculations. Rack parts that are damaged or identified as defective are then replaced by Jungheinrich original replacement parts.

“Ultimately legislation always makes the customer as the operator responsible for safety in the warehouse. Jungheinrich rack inspectors have technical expertise in the specific rack system to be able to make a qualified assessment of defects and damage. They know the interface between trucks and the rack system like no one else. Replacement with original parts thus remains the safest and most efficient way to repair damaged rack systems” recommends Marco Harder.

About Jungheinrich
Jungheinrich AG is one of the world's leading companies in the fork lift truck, warehousing and material flow equipment sectors. As provider of solutions for internal logistics, the company provides close support for its customers with a comprehensive product line of fork lift trucks, logistics systems, services and consulting. Jungheinrich shares are traded on all German stock markets.

1 Association recommendation of the LBE (Warehouse and Operating Equipment Association) in Hagen, Germany number 02.2015)