During your daily work, you noticed a dent on a rack upright. what should you do? ignore it or stop work immediately? the pn-en 15635 standard introduces a clear “traffic light” system that helps in making decisions regarding the rules for safe rack operation.
Most common types of damage to load-bearing rack components
The most frequent defects include: dents in the front face of the upright, lateral bending of the upright, beam deformation (permanent deflection under load), and damage to baseplates and anchors.
Methodology for measuring upright and beam deformation
The standard precisely defines allowable deviations. Using a 1-meter straightedge applied to the damaged component, the depth of the dent is measured.
- For an upright (frontal dent) – the limit is typically 3 mm over a 1 m length.
- For an upright (lateral buckling) – the limit is typically 5 mm over a 1 m length.
Action procedure based on risk levels
Based on measurements, damage is classified into one of three zones:
Green level – observation
The damage is within the limits of the standard. It does not require repair, but the component must be recorded and subject to increased monitoring during subsequent periodic technical inspections.
Amber level – planned repair and restrictions
The damage exceeds the standard but is not critical.
- Action: The rack does not need to be unloaded immediately, but once the pallet location is emptied, it must not be reloaded.
- Time for repair: The defect must be rectified within 4 weeks. If this does not happen, the status changes to red.
Red level – immediate unloading
Critical damage, posing a risk of collapse.
- Action: Immediate withdrawal of the section from use and unloading of goods. The zone should be cordoned off with tape until the component is repaired or replaced.
Repair or replacement – which is safer?
Most manufacturers and experts recommend replacing the damaged component with a new, original one. Straightening uprights is a controversial process that alters the metal structure and often results in the loss of certification and warranty.