The Role of UNI 11636 in Racking Safety
Per garantire un livello di sicurezza adeguato durante l’intero ciclo di vita di una scaffalatura, il quadro normativo elaborato in attuazione del D.Lgs. 81/08 si basa principalmente su due norme tecniche: la UNI 11636, che fornisce la metodologia per definire lo stato funzionale di una scaffalatura e per condurne la validazione d’uso e la UNI EN 15635, che disciplina utilizzo e manutenzione dell’attrezzatura di immagazzinaggio.
The current edition of UNI 11636, published in April 2023, replaces the previous UNI 11636:2017. It applies to all types of steel racking used in storage areas, distribution centres, and industrial or commercial warehouses, whether or not these areas are open to the public.
The standard is primarily aimed at end users, while also applying to manufacturers, designers, specification writers, consultants, installers, distributors, and resellers of racking and storage systems.
L’impiego delle attrezzature di stoccaggio richiede una validazione d’uso finalizzata ad attestare che la scaffalatura sia idonea alle condizioni di esercizio previste, sotto il profilo strutturale, installativo e documentale.
Racking system use conditions throughout its service life
A racking system may go through different operating conditions over the course of its service life, and each change in condition may require a new full or partial validation. The standard identifies the following conditions:
- Initial or original condition
- New condition resulting from a change in the type or weight of the load units
- New condition resulting from environmental changes, including settlement or modifications to the floor or foundations, changes in warehouse temperature, changes in environmental conditions, or modifications to the storage equipment.
- New condition resulting from a change in configuration, such as a change in the number or spacing of load levels.
- New condition resulting from a change in the number of bays or aisles.
- New condition resulting from a change in the position of the racking system within the same area.
- New condition resulting from the replacement of damaged components with identical components.
- New condition resulting from the replacement of damaged components with different types of components.
- New condition resulting from the repair of damaged components.
- New condition resulting from the addition or removal of components.
The distinction between replacing components with identical ones and replacing them with components of a different type has a practical impact: no new structural validation is required in the first case, whereas it is required in the second, as the replacement component has different structural characteristics.
Validations Required by UNI 11636
UNI 11636 distinguishes between an overall validation, referred to as racking compliance certification, and three partial validations that provide the basis for it.
Structural validation
It assesses the load-bearing capacity of the racking system in its current configuration, in accordance with the state of the art and the calculation methods applicable at the time of validation. It applies to racking that is used correctly in accordance with its specified operating conditions and is free from damage caused by day-to-day warehouse operations. It does not refer to the original configuration where this has been modified, nor to the state of the art applicable when the racking was first installed. The validation is issued by the racking supplier or by an expert validator.
Installation validation
It confirms that the racking system, in its current condition, has been installed in accordance with the design specifications, the supplier’s installation instructions, and the requirements for safe use. This is documented by an installation certificate issued by an expert validator. If no such certificate is available, the installation may instead be verified through an inspection report confirming that there are no significant safety risks or serious structural damage.
Documentation Validation
Verifies that all documentation required for the safe use of the racking system is available and consistent:
- Calculation report (or a contractually binding document specifying the permitted configurations and load capacities),
- Design drawings
- Component identification
- Targhe di portata coerenti con le configurazioni in essere,
- Assembly, use and maintenance manual
- Declaration of proper installation
- Registro delle ispezioni e degli interventi di manutenzione.
It is carried out by a qualified validator.
Racking compliance certification
It is the process that establishes the safe use of the racking system as a whole. It does not simply consist of the three individual validation processes; it also requires direct inspection of the structural components and accessories, as well as verification that the operating conditions required for safe use under UNI EN 15512, 15620, 15629 and 15635 are in place. It is issued by the racking supplier or by a qualified validator.
Roles and Responsibilities in Racking Compliance Certification
New racking – supplier’s responsibility. Upon delivery and before the racking is put into service, the supplier must provide the purchaser with the Racking Compliance Certification, consisting of three documents: static validation, installation validation and document validation.
If the installation is completed by the user or a subcontractor rather than by the supplier, it must still be carried out in accordance with the supplier’s instructions, and the validation of the correct execution of the installation must be issued by the party that carried out the installation.
Used racking – Supplier’s or validator’s responsibility. For reused racking, the supplier or a qualified validator must provide the Racking Compliance Certification, including the technical report based on an inspection carried out by a qualified validator. This procedure applies every time the racking is reused, regardless of how long it was previously in service.
New or used racking – User’s responsibility. The user is responsible for maintaining the complete technical file relating to the Racking Compliance Certification and ensuring that it is kept up to date, both for new installations and for installations involving used racking. The file must include the static validation document, the installation validation document, the document validation, the Racking Compliance Certification, the latest technical inspection report, and the records of inspection and maintenance activities. The requirements for ensuring the structural safety of the racking for workers and others who access the area are considered to have been met once this documentation has been reviewed and validated by a qualified validator. However, the conditions of use and maintenance must remain consistent over time with those covered by the validation.
The periodic technical inspections required by the standard
Under UNI EN 15635, storage equipment must undergo two different types of inspection, in addition to the daily checks carried out by operators during use.
Ispezione a vista. È stabilita ed eseguita dal PRSES, secondo un programma e una frequenza prefissati. Deve avvenire con cadenza almeno settimanale, o secondo intervalli regolari definiti dal datore di lavoro sulla base della valutazione dei rischi del magazzino. Serve a verificare il mantenimento delle condizioni di sicurezza, la presenza e l’efficacia di segnaletica e dispositivi di protezione, e a individuare danni non segnalati durante l’attività giornaliera. Il PRSES deve mantenerne la registrazione.
Inspection by the expert validator. The inspector assesses the overall safety of the racking system and its surrounding environment. The inspection must be carried out at least once every 12 months, and a record of all inspections must be kept. The inspector’s competence must be verified by the user and properly documented.
The inspection programme includes, among other steps:
- Racking documentation review
- Unit load compliance and handling equipment suitability checks;
- Visual inspection of the warehouse and racking;
- L’identificazione e la registrazione dei danni rilevati;
- Risk assessment of any findings;
- Root cause analysis;
- Recommended corrective actions, submitted to warehouse and company management.
The inspection must always cover every component and accessory of the racking in place, working systematically upwards from the lower levels, where the risk of serious damage is greater. Unit loads do not need to be removed during the inspection, unless the competent person has good reason to doubt the condition of part of the structure. Climbing the racking to inspect the upper levels is not permitted under any circumstances.
Common mistakes in managing racking compliance certification
Mistakes in racking management are not always the result of obvious damage. More often, they stem from modifications made without the necessary checks or from incomplete record-keeping. Here are some of the most common ones.
Confusing racking compliance certification with the annual technical inspection.
The periodic inspection required by UNI EN 15635 is carried out to check the condition of the racking and identify any damage or potential hazards. Racking compliance certification, by contrast, is a much broader process. It covers structural, documentation and installation checks in addition to the technical inspection of the racking, and confirms that the structure is fit for its operating conditions.
Altering the configuration without assessing the impact.
Adding load levels, changing load capacities or relocating the racking may require a new compliance certification, either full or partial. Carrying out any of these changes without first checking their impact can undermine the safety conditions specified in the original design.
Replacing components with non-equivalent parts.
When a damaged upright, beam or other component is replaced with a part that differs from the one specified by the manufacturer, the structural characteristics of the racking may change. UNI 11636 treats this situation differently from a like-for-like replacement and therefore requires a new structural validation.
Neglecting technical documentation.
The design calculations, drawings, load capacity plates, manuals, installation declaration and inspection log together make up the technical file for the racking. Incomplete or out-of-date documentation can make it difficult to demonstrate that the installation is compliant and that safety is being properly managed.
Postponing repairs to any damage found.
Any damage found during an inspection must be followed by a risk assessment and, where necessary, by the prescribed corrective actions. Continuing to use damaged racking without putting the required measures in place increases the risk of structural failure and can expose the company to liability in the event of an accident.
Di Massa srl, your partner for racking compliance certification
Racking compliance certification is a multi-faceted process that involves structural, documentation and organisational aspects. In the event of an accident, missing or incomplete technical documentation can have significant consequences for safety, for liability and for the company’s insurance cover.
Di Massa supporta le aziende nella gestione della validazione d’uso delle scaffalature, affiancandole nella verifica tecnica e documentale richiesta dalle normative vigenti.
If you have changed your racking configuration, have doubts about your technical documentation or are not sure whether you need a new compliance certification, we can help you check that your racking is compliant.