HOW TO DESIGN A LOADING BAY
Contents
1. 1150 Demountables Container City vehicle Delivery vans Containers 6000 STERTIL SUPERIOR SOLUTIONS BY QUALITY PEOPLE It is not always possible to make an exact estimate of the kinds of trucks that will dock However the most common platform height is 1250 mm which is suitable for an average warehouse or trailer park Trucks with hydraulic tailboards need a space under the dock leveller known as a letter box The tailboard slides under the dock leveller into the letter box to allow unrestricted use of the leveller Letter box slots can be protected by a PVC seal that prevents dirt and debris blowing into the opening cd Dock leveller gt 400 mm This PVC seal bends away as soon as the truck reverses The letter box should be 3000 mm wide and have sufficient depth to accommodate the length of the tailboards However we recommend a minimum depth of 2400 mm and a minimum height of 400 mm also depending on the build in height of the leveller and chosen platform height These dimensions will ensure that the letter box is easily accessible The distance between parked trucks should be big enough to open and close the drivers doors Too small a gap can cause problems with parking and driving out Standard bay centres should be at least 3 00 mm although when accommodating w2. J O CC STERTIL SUPERIOR SOLUTIONS BY QUALITY PEOPLE V V a a The Stertil Group offers its worldwide customers bespoke technologically i S U 0 S sophisticated solutions for their dock equipment and heavy duty lifting E Dy 0 U 2 requirements including the best possible service from stronglocal V a V dartners These superior are with unigue experiefce 7 m Ad OUA DO a in house production process and its international organisation Stertil is a world leader in the field of dock levellers and dock shelters The loading bay makes or breaks a logistics chain Therefore Different issues and factors will be discussed and explained in a lot of things have to be considered when designing a safe various chapters Because of the diversity of circumstances and efficient loading bay This guide will help you not only and environments in which docks are used it is not possible to solve the most tricky problems but also overcome to reflect on every loading situation However if you need unexpected internal and external factors that can cause particular information or would like to receive more specific problems during the transfer of goods details please contact us We will be happy to make an appointment with you to provide all the assistance you need logistics starts and ends with PRODUC pee I
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4. The width of the leveller depends on the internal width of the loading space of the vehicle as well as the accuracy of the driver as he aligns his truck with the dock The main consideration when operating a dock leveller is not the highest or lowest position but the actual working range The working range of an average leveller is about 300 mm above and below platform height When you have a platform height of 1250 mm vehicles with a floor height of 950 to 1550 mm can load and unload When for example a 2000 mm long leveller has a working range gradient of 300 mm above platform level or exceeds your internal transport equipment you will need a longer leveller The maximum legal gradient is 1396 More information is provided in chapter 8 standard multiple leveller widths are available between 1830 and 2250 mm We recommend that you choose the largest width possible because it simplifies the placing of loads Do not however choose the width of the leveller too close to the internal vehicle width because frequently a truck is not parked perfectly straight A margin of at least 150 mm on both sides of the leveller is recommended Wheel guides make it easier to park straight and the required margin can be made smaller Head more in our Leveller brochure Example The minimum internal vehicle width is 2400 mm oubtract a manoeuvring deviation of 150 4 150 mm This leaves a maximum leveller width of 2100 mm
5. rubber damping strips and a hot galvanised mounting console Due to low friction properties and the durability of the front plate the bumpers suffer minimum load forces and damage The main advantage however is that the front plate can be changed quickly and simply without the need to drill new anchors or holes in the concrete C Loading Bay Dock Lighting No more dangerous manoeuvring of heavily loaded forklift trucks in the gloom within a trailer all goods and obstacles can now be brightly lit by a bay lamp The hinged arms ensure precise positioning of the lamp to light up every corner When not in use the lamp is simply folded towards the wall D LA HA mini dock leveller In places where only small differences in height need to be bridged or where a concrete pit is not possible a mini dock leveller can provide the right solution The STERTIL LA HA Series mini dock leveller HA is the hydraulic version mini dock leveller which can be simply mounted against an existing bay Using an operating bar the lip of the LA can be manually positioned on the truck floor within a matter of seconds When the truck moves away the lip will automatically drop between the mounted bumper consoles ready for the next truck E Wheel guides Wheel guides mounted on the approach to the load ing bay increase safety during loading and unloading and increase the life of dock shelters considerably Trucks are forced to en
6. using the Quick Mounting System the pit is produced first with QMS curb angles which makes it possible to place the leveller in QMS execution in the last stage Curb angles There are several types of curb angles available 1 The straight angle used to cover and protect the horizontal and vertical concrete edges of the pit 2 The QMS version the allow you to create the pit and fit the leveller at the end of the building process The Stertil QMS curb angles protect the pit edges and also assure you the exact dimensions of the pit Once the pit is completed it eases to fit the leveller and weld it to the curb angles Closed box Another way to integrate a leveller into the pit is with a so called closed box This galvanised closed box can be supplied completely assembled including distance profiles which keep the walls at the exact position during the concrete casting process Also levellers can be executed in a closed box execution and completely casted in Prefabricated concrete pits Especially in big projects it can be interesting to use pre fabricated concrete pits These concrete pits are pre fabricated in a concrete mill Stertil can supply galvanised curb angles in the correct dimensions directly to the manufacturer of these prefabricated pits Xz CLOSED PIT CLOSED PIT WITH LETTERBOX OPEN PIT WITH LETTERBOX 1 STRAIGHT CURB ANGLES 2 QMS CURB ANGLES PREFABRICATED CONCRETE PI
7. Advantage of 5 4 Solutions for the food the Stertil Leveller meat industry wit H yd rau C In food chain logistics the highest standards are CVI inder demanded in the loading and unloading of vehicles To avoid sensitive loads being exposed to external High quality reliable high pressure hydraulic influences such as temperature dust insects and cylinder birds the aim is to create the optimum seal between deal position under the platform to transfer all trailer and building This is possible with a cool load forces from the platform to the frame and chain dock which works as follows The dock leveller is specifically designed for this Maximum safety in an emergency stop situation situation and is just under ramp level in resting SAGE ORNE NSE OR position between two recesses in the front section of the miad e position and high pressure ensures of the warehouse floor The sectional door closes Meh MAENE NOR TS CARARE ON FERIENING TG NG In front of the leveller to exclude all thermal bridges impact from the falling platform and the load The trailer docks with closed trailer doors Picture 1 The inflatable dock shelter is activated and seals the trailer as tightly as possible Picture 2 The sectional door of the warehouse can now be opened Picture 3 Than the lip can be extended covering the gap between the building and the back of the trailer Picture 4 The tr
8. have a maximum width of around 2900 mm STERTIL SUPERIOR SOLUTIONS BY NE 6 5 Example of calculating the dimensions of a curtain shelter Basic principles Highest truck 4100 mm unloaded Lowest truck 3600 mm loaded Bay height 1200 mm Widest truck 2800 mm with open doors Narrowest truck 2300 mm The minimum exterior height of the shelter must be Highest truck 4100 mm Plus entry margin 300 mm Less bay height 1200 mm Total 3200 mm A standard height for curtain shelters is 3400 mm The minimum exterior width of the shelter is determined as follows Widest truck 2800 mm plus entry margin 400 mm 200 mm on either side plus manoeuvring room 300 mm for truck driver Total 3500 mm A standard width for eurtain shelters is 3500 mm Because a truck must bend back the shelter curtain some 500 mm the net width between the side curtains must be 2150 mm to provide an adequate seal along the sides of the truck of 2300 mm OVERHEAD T R In order to complete a loading bay an overhead TOO SMALL door is usually fitted These doors constructed from sections measuring about 600 mm high are available Truck width in steel or aluminium The counterbalance spring assembly mounted above the door makes it very easy to operate by hand The door may also be provided with an electronic control This will make its operation even easier while it also allows for the possibility to connec
9. into account amongst other things that the highest truck must have a clearance of at least 300 mm from the top of the shelter and 200 mm from the sides of the shelter to prevent damage to the frame and or curtains 2 Inflatable dock shelters In the non inflated condition the trucks must stay well within the free opening of the shelter The reach of the inflatable cushions must be selected such that all available truck sizes are sealed 3 Cushion shelters In a cushion shelter the trucks must back up into the cushion with their loading space edges Cushion shelters are therefore usually smaller than the other types referred to above Dock shelters may be used in situations without Presence or absence of a bay and how high a loading bay road level and with a loading bay dock level For a dock shelter at road level curtain shelters or inflatable dock shelters are the only sight of the shelter is therefore road level In the case of a ock shelter is usually mounted at dock level The choice of the Highest truck The minimum height of the dock shelter is determined by the highest exterior truck dimensions when unloaded Di Lowest truck The length of the dock shelter top cushion curtain is determined by the lowest exterior truck dimension when loaded Truck width Particular account has to be taken of the widest trucks with open doors For example refrigerator trucks with doors opening outward may
10. of internal transport equipment require different slopes which also implicates that the lip angle see A must be adapted to the internal transport equipment SAFETY STANDARD i EN 1398 Directive is the European safety standard for dock levellers set up at the request of the EC member states The standard lays down a number of points which manufacturers must meet with their design manufacture and mounting of products Below we explain a number of these points The manufacturer must have the full technical docu mentation for each dock leveller including points like stress calculations cylinder buckling calculations and a description of the safety features applied Before a manufacturer markets a dock leveller a prototype must be tested by properly trained staff The required load bearing capacity of a dock leveller is determined by the maximum weight including load of a forklift truck measured over one axle of the truck The load is then measured over two 150 x 150 mm surface areas The capacity of the model in question must be established based on a shock factor of 1 5 and a safety factor of 1 33 compared to the yield point of the material EN 1598 The control box of the dock levellers minimum protective class IP 54 must be equipped with an emergency shutdown feature and a lockable main switch The coils of the electromagnetic valves must be suitable for continuous use Various dock products Naturally
11. G PIT To reduce the difference in height between the yard and the truck floor two options are possible raise the dock floor up to the level of the truck floor create a depressed driveway approach The construction of the latter may be unsuitable due to soil condition or the ground water level Also a steep decline can create problems because when a truck is not horizontal during loading unloading operations the following problems might occur Loading pit design Platform lt 1000 mm e wheeled loads can fall out when the truck s doors are ODened e the loading unloading process is more difficult e internal handling equipment is under increased pressure e rainwater can run from the roof of the truck into the building e the dock bumpers will be overburdened e damage to the overhead door and building Approximately 17 metres To solve the problem depending on the yard you build a flat lane of 16 18 metres directly at the front of the dock before the slope begins A drainage channel is necessary to remove rainwater In this situation the truck is parked straight which will lead to smooth and simplified loading unloading The height difference between the straight lane and the road should be bridged with a gradient percentage of a maximum of 1096 When this incline is larger than 1096 problems can arise as trucks drive in and out In extreme circumstances a truck cabin and trailer may even hit each o
12. STERTIL SUPERIOR SOLUTIONS BY A Choosing the correct type of dock leveller is just as important as determining the right dimensions Stertil dock levellers include both manually and Unique open MWT electro hydraulically operated models Except for the electro hydraulic telescopic lip operated leveller all models feature a special open lip hinge Because of the shape and place of the hinge plates the top plate and beams have a weight absorbing construc tion When the lip js vertical dirt automatically falls through the openings so a self cleaning hinge IS obtained This is a big plus because when dirt piles up it can affect the smooth operation of the leveller The Stertil patented open lip hinge has a lifetime guarantee One hydraulic main cylinder cupi ated Dx E en ei To ensure stability when heavily laden fork lifts drive over a leveller in resting position two legs support a the front edge to prevent the leveller from sinking When the lip extends these legs automatically retract Cross traffic is perfectly safe The rear h is specially constructed to allow the platform 125 mm on both sides This means that an truck floor will not cause a dangerous gap bewe lip and floor The platform can twist 125 mm on both sides The lip angle is standard 7 5 5 1 The Hydraulic swing lio leveller Simple operation of the S P
13. Series leveller is achieved by pressing a button on the operating panel The platform rises and in the highest position the lip hinges on its own By operating the panel again the platform returns to its original position There is a cylinder on the front angle to support the platform completely in an emergency stop situation The hydraulic pump unit is mounted at the front and can be reached easily for maintenance and inspection There are many sizes of hydraulic leveller details of which you can find in our detailed brochure o 2 Hydraulic leveller with telescopic lip The S P Series levellers referred to previously all have a hinged lip The X Series dock leveller with telescopic lip however is operated using three buttons e platform up e lip goes out e lip goes in The telescopic lip is continuously variable making it perfect for all loading and unloading operations This model is also suitable for an insulated environ ment where the dock leveller is positioned behind an overhead door chapter 4 2a During the transfer of goods both the lip and platform will follow the movements of the truck After loading unloading the leveller can be simply returned to its resting position This leveller is available in more than 30 different sizes and full details are shown in our brochure We have the perfect dock leveller for every application STERTIL SUPERIOR SOLUTIONS BY QUALITY PEOPLE 5 9 he
14. TS STERTIL SUPERIOR SOLUTIONS BY B Dock bumpers When a loaded truck backs up into the bay it can impact heavily on the bay angle Even docks of reinforced concrete can be damaged quickly Trucks and loads are also likely to suffer damage However by installing dock bumpers the impact force and resultant damage will be reduced tremendously Stertil offers several dimensions and versions in its product range R 45 20 5 rectangular rubber model 450 x 200 x 50 mm R 45 20 10 rectangular rubber model 450 x 200 x 100 mm R 45 20 15 rectangular rubber model 450 x 200 x 150 mm L 45 45 10 L shape rubber model 450 200 x 100 mm B 54 21 17 moveable rubber model 540 x 210 x 170 mm PE bumper polyethylene wearing plate 554 x 220 x 140 mm selecting the right bumper depends on many factors but principally on the loading pit and the type of shelter With its extra large entry area an L shaped bumper model offers excellent protection Dock bumpers are constantly subjected to heavy impact particularly when trucks bounce during loading or unloading Also the back of the truck chafes the front of the bumpers time and again To reduce the risk of damage and extreme wear Stertil has developed two solutions a moveable bumper which moves when hit by a truck and arange PE bumpers These incorporate a front plate manufactured from Ultra High Molecular Polyethylene
15. ailer doors be opened safely and be parked in the recesses provided on the ramp next to the leveller Picture 5 With the leveller now released and the lip positioned on the lorry floor loading and unloading can com mence after the traffic light has turned green Picture lel As soon as loading or unloading has finished the above procedure is followed in reverse order Utilising specially designed control software this procedure can take place almost fully automatically The dock shelter Loading bays are exposed to all weathers The use of shelters keeps adverse weather conditions outside by closing the gap between the truck and the building restricting loss of heat Dock shelters protect products by keeping out dust and insects which is why the food sector in particular has made the use of shelters obligatory With the gap around the loading or unloading trucks sealed you have complete control of access to your warehouse even with an open door There are three types of dock shelters namely e inflatable shelters e curtain shelters e cushion shelters inflatable curtain cushion shelters shelters shelters e g WI WIS e g WL WE e g TP TI Head more in our Shelter brochure STERTIL SUPERIOR SOLUTIONS BY QUALITY PEOPLE 6 1 Inflatable shelters Inflatable shelters incorporate air cushions Because trucks enter the do
16. ck shelter before the positioned around the truck that are inflated by a shelter is inflated there is no friction and therefore no fan The pressure of the cushion against the sides wear on the material Pressure on the facade with and the roof of the truck ensures a perfect seal this type of shelter is minimal When the shelter is not The fan provides a continuous air flow thereby in use a large clear opening remains available which guaranteeing a constant pressure of the cushions makes this type of dock shelter also highly suitable against the truck When the dock shelter is not in for applications without loading bays i e at road use the inflatable components deflate neatly level behind the front curtains in the housing made of 40 mm sandwich panels High visibility indicators on the shelter assist trucks reversing 6 2 Curtain shelters Exceptional versatility and relatively low price make this the most popular type of dock shelter The curtains available in different materials are positioned at a projection of around 600 mm from the facade As the truck backs the curtains clasp the sides and roof sealing the gap tightly To assist trucks backing up the curtains feature high visibility indicators The projection of a curtain shelter may be achieved by an inbuilt recess or a shelter frame which may be fixed or collapsible The fixed frame consists of 40 mm sandwich panels and are supported by steel protection bumpers
17. ears if required In refrigeration and freezer applications locating a dock house may involve specific considerations In order to maintain the extra insulated construction it is often better to place the entire loading and unloading unit outside the facade The dock house can be built with a substructure in steel or concrete framework The top structure comprising of hot dip galvanised profiles can be clad with uninsulated sheeting or insulated panels The size of the dock house will depend on the shelter and dock leveller model selected There is a support section Architects Library on our website available You find there BIM Rivet files specially designed and created for architects and building engineers also including our product brochures Scan the QR code to go there n Further information For further or specific information about our products levellers shelters dock houses vehicle restraint systems etc please get in contact with us We will be happy to assist you with personal advice to ensure that you receive a superior solution 9 member of the Stertil Group e ljoeoJ1eJ pue eonou ui seBueuo exeui o1 1uBu y OM Arg 12915 JO x1eujepea e S 111018 76 02 60 go uBiseq 0o1 MoH OLLPOOSG co ost 2 OL SNOEP 3 DOxtgior22 0 c A
18. educes the risk of damage to the guide tracks by traffic passing through the opening In the case of curtain or inflatable shelters door dimensions of 3000 x 3000 mm is a good choice INTERNAL TRANSPORT As described earlier in chapter 5 the length of the dock leveller is also determined by the type of internal transport equipment being used Such equipment is required to negotiate a slope during loading and unloading operations The steeper the gradient the more energy is required to move the goods The energy needed to operate a hand pallet truck IS the pulling power of the employee Example Pushing a four wheel cart loaded with 270kg of goods requires about 13 5kg pushing power On a slope of 4 this increases to 22kg pushing power and 40 5kg on a slope of 10 i e three times as much The maximum slope for a hand pallet truck is 3 EQUIPMENT With electric hand pallet trucks the battery takes over the operation The maximum slope can then be 5 The steeper the slope the more energy the battery must supply and it will need recharging more frequently With an electric forklift truck the slope can be no steeper than 1096 Here too the same points apply as with electric pallet trucks A forklift truck with a fuel engine petrol gas has sufficient power to take a slope of up to 1596 however the legal maximum is 1396 When a truck needs to be loaded above bay level the platform of the doc
19. ide trucks with open doors this should be increased to approximately 4000 mm except for refrigerated and freezer trailers please see footnote The recommended distance between the truck lt the loading edge 1500 4000 1500 Most refrigerated amp freezer trailers require distance of 4200 4400 mm STERTIL SUPERIOR SOLUTIONS BY QUALITY PEOPLE 4 1 The enclosed dock Here the trailer is parked inside the building or space Also a ventilation system is required sheltered area during loading and unloading but However it provides good protection for goods and the construction costs are high and there is limited personnel 4 2 The flush dock In this situation the truck backs up against the down onto the front of the dock leveller In special building wall The use of a dock shelter creates a cases e g in a temperature controlled space the seal between truck and building This is the most seal may require extra attention common installation and the overhead door closes A line up with extra insulation can be applied in two different ways A A door in front of the dock leveller The door is installed in a tailor made space and the leveller is positioned further back to allow the door to shut along the front side If free access is required to the letter box the door may be shut on an inter mediate floor Since this would create a greater distance between level
20. k leveller is placed at a certain slope relative to the bay However the lip of the dock leveller MUST always lie flat on the truck floor If not dangerous situations can occur Maximum slope percentage for internal transport equipment hand pallet truck N D electric pallet truck electric fork lift truck s fork lift truck powered by fuel engine Hand pallet truck Electric Dallet truck With the lip lying flat on the truck floor and the plat form at a certain slope the LIP ANGLE is created A standard lip angle has been selected such that at a 13 slope the lip lies flat or 7 5 The position of the dock leveller whereby the lip lies flat is the effective range of the dock leveller This means there is an important difference between the highest position of the dock leveller and its effective range With pallet trucks the lip angle may cause problems Electric fork lift truck Fork lift truck powered by fuel engine see A The combination of wheel centres diameter of wheels and clearance from the underside deter mines the maximum lip angle For a pallet truck the lip angle cannot be 7 59 but possibly 3 5 see figure at bottom of page When the lip angle is reduced the slope whereby the lip lies flat will also become smaller In other words the leveller s effective range is reduced and a different dock leveller model may be required Please be aware that the different types
21. ler and truck the leveller must incorporate a telescopic lip This continuously variable extendable lip can bridge the building door and concrete construction without problems STERTIL DER OR SOLUTIONS BY BREN PEOPLE B Ihe dock leveller outside the building By using a dock house the dock leveller is located in front of the insulated building thereby ensuring that high insulation values remain intact The dock house construction may incorporate concrete and or a steel framework Manoeuvring space depends on A In situations where manoeuvring space IS limited a saw tooth arrangement may be the best solution The manoeuvring space will be increased relative to the angle of the building Approach roads need to be designed in such a way that trucks can leave in the direction of the angle of the dock 94 The trucks need less manoeuvring space because they are already lined up in the drive away direction However extra building space is required for this saw tooth layout and useable space between the levellers is limited The dock leveller The length of the leveller is closely connected to the height difference between truck floor and platform Also the maximum gradients should be taken into account when making calculations They can be a determining factor as to what kind of internal transport equipment you may need More information is provided in chapter 8
22. ms For more information see chapter 10 It is obvious that both government and leading institutions have given a lot of thought to guidelines concerning safety In addition there is a growing number of companies that have their own specific policies covering such areas as safety maintenance fire prevention and the like It is important to match the operation of products to the regulations that apply to the relevant user sector or application LI i A Loading pit design There are many ways to design a dock leveller pit They all depend on the specific wishes of the builder customer and type of trailers that are being used Pit construction In order to apply a dock leveller in the bay a constructional recess will have to be made the so called pit Generally there are two different types of pits 1 A closed pit in which the leveller will be installed on the concrete pit floor 2 A open pit in which a letterbox tail lift opening is integrated What type of levellers will be integrated in the pit depends on the type of dock leveller selected The different options to choose are 1 The standing frame leveller for closed pit design 2 The conventional hanging frame leveller which will be casted in to the concrete use in open pit design where a letterbox is required 3 When time is important we can offer a leveller which suits the QMS Quick Mounting System In case of
23. ndex 1 The number of loading bays 4 10 Ancillary dock products 40 2 The site 6 A loading pit constructions 40 3 The loading pit 8 B dock bumpers 42 4 dock platform 10 C dock lights 43 5 dock leveller 18 LA HA mini dock leveller 43 6 The dock shelter 24 E wheel guides 44 7 he overhead door 34 F truck restraint 44 8 Internal transport equipment 36 G dock houses 45 9 Safety standard EN 1398 38 THE NUMBER LOADING BAYS When determining the required number of loading bays we recommend that you consider a range of factors that could influence both your current and future business plans Traffic scheduling It s important to be aware of how many vehicles are likely to be loaded unloaded at the same time Often the busiest times at distribution centres occur during the same morning and evening periods Of course a balance needs to be reached that provides enough loading bays to cope with these busy periods without having many standing unused during the rest of the day Receiving and Despatch Many companies rely on separate loading bays for receiving and despatching goods Frequently these loading bays are located on different sides of a warehouse to allow the smooth processing of goods in and goods out This scenario also needs to be considered when deciding upon the number of required loading bays Processing of goods Another factor to be considered is the way in which diffe
24. oading operations supplied with an inflatable top cushion The insulating cushion then provides protection at the sides while the inflatable top cushion bridges any differences in height 01 1 MIELE L1 11 Wi M MI M 111 1 a 111 1111 11 ll i WN Mili QUU M MAR VEA ul ARM DLL MO NN eo BEBE LEGER LEG STERTIL SUPERIOR SOLUTIONS BY QUALITY PEOPLE 6 4 The dimensions of dock shelters When inviting an offer for dock shelters the applica little to do with the door Furthermore the door tion often refers to the dimensions of the door to be opening must be selected to fit the interior mounting included in the building However dock shelters have dimensions of the shelter Key factors in deciding the dock shelter dimensions are the type of dock shelter presence of bay or not and its height B highest exterior truck dimensions unloaded C lowest exterior truck dimensions loaded width of trucks including doors opening outwards Dock shelters provide protection from moisture wind rain and insects to promote a healthier working climate The type of dock shelter 1 Curtain shelters When determining the height and width you should take
25. rent goods may be handled If processing activities such as sorting packing or labelling need to be carried out within the warehouse it will be advisable to have a sufficient number of loading bays to prevent internal handling equipment having to transport goods over long distances It therefore makes sense to position loading bays as near as possible to the areas where on site processing takes place Carefully determine the number of loading bays Groente me Fruit It is important to avoid bottlenecks as trucks arrive on site to access loading bays Properly designed road layouts that enable vehicles to travel quickly and safely with a minimum of manoeuvring will help to eliminate the problem Efficient traffic management including strict control over the directional flow of trucks will also contribute greatly to safe and smooth vehicle movement For instance in countries where trucks are driven on the left a clockwise system around a warehouse makes it easier for drivers whilst the opposite is true in countries where vehicles use the right hand lane Also this system ensures that drivers blind spots are eliminated when reversing into position When designing a loading bay it is essential to take into account the different dimensions of trucks In most European countries a truck with a trailer length of 18 metres is permitted If you do not have accurate information concerning your truck dimensions you sho
26. t the operation of the door in series with other dock products The doors are available in different sizes colours and styles The door must always be smaller than the of the dock shelter The difference in also determined by the presence or al is there a bay door or an entry door The min DOOR OPENING width of an entry door is 2400 mm while the height TOO SMALL lies between 4300 and 4500 mm CORRECT The dimensions of a bay door are determined by the height of the bay Truck width the type and dimensions of the trucks the type of goods the type of dock shelters With curtain shelters and inflatable shelters the width of the door must equal the internal width of the truck plus 300 mm This tolerance is needed to unload trucks that are not centred in the door opening Based on an average fleet the width of the vary DOOR OPENING i CORRECT In the case of cushion shelters the door width equals the interior width of the shelter The shelter size in turn depends on the truck dimensions The height of the door opening depends on the maximum truck height 3800 to 4200 mm It is wise to add a safety margin to the maximum height based on a bay height of 1250 mm a door with a height of 3000 mm will suffice Another point to consider is how the loading bay door should rise when opened Warehouses are generally tall enabling the door to rise vertically with little or no travel back into the building This r
27. ter centrally and the rounded shapes of the steel wheel guides are safe to tyres unlike the relatively sharp edges of concrete ramps The recommended interior distance between the left and right wheel guide is 2600 mm Wheel guides are easy to mount on concrete concrete driving plates or in bases poured into the access route F Vehicle Truck Restraint System COMBILOK To manage business operations in a responsible manner a reliable vehicle restraint system Is a necessity within all loading bays The risk of damage caused by accidents during loading and unloading activities increases significantly as a result of tight time constraints The communication between ware house staff and drivers in their cabs often leaves a lot to be desired Prematurely driving away from the dock while the lorry is still being loaded or unloaded is not uncommon The same applies when considering the risk of a docked lorry creeping forwards The unique COMBILOK from Stertil limits all of these risks and offers many unique safety benefits Read more in our COMBILOK brochure G Dock house A doek house is a construction combining a dock leveller and a dock shelter It offers a good solution for situations where pit recesses cannot be built for example in existing concrete bays Cutting out floors is often an expensive and awkward job When a dock house can be placed against the existing facade it can be simply moved after a few y
28. the box must be placed in a location which provides a good view of the dock leveller during its operation All hydraulic components such as cylinders and pipes must be able to resist at least twice the normal work load without causing damage or lasting deformation A user manual instruction labels and name plate to be mounted on every dock leveller will provide the user with information about user regulations manufacturer country of origin capacity and serial numbers For a full version of the EN 1398 Directive please do not hesitate to contact us Clearly recognisable CE symbol CLLT 1 AUR A AA IS i a Because Of the permanent 380 400 Volt set up the INSTALLER guidelines apply to the installation of dock levellers as well as certain shelters Operation switches are one of the features that result from this guideline The Veterinary Service has laid down a number of requirements for certain sectors In spaces where open foodstuffs are being processed dock shelters have even been made obligatory In many cases dock levellers must be specially prepared for example with hot dip galvanisation Last but not least there is growing safety awareness partly due to the new Labour Safety regulations which stress improved security during loading and unload ing The accidental movement and early departure of trucks from a dock can be prevented by truck restraint syste
29. the shelter forms a permanent unit within the facade construction The collapsible frame which is built from either galvanized steel or extruded aluminium profiles is connected by means of hinged arms This construction ensures that the frame will hinge backwards when a misaligned truck fails to enter the dock properly If the truck does enter correctly the frame remains at its standard projection at all times However we recommend that every effort is made to ensure that trucks always enter the bay correctly Wheel guides offer a cost effective means of achieving this see chapter 10 STERTIL SUPERIOR SOLUTIONS BY QUALITY PEOPLE 6 3 Cushion shelters On loading bays supporting many trucks of mostly trucks can bounce up and down The special the same height and width and where climate armour pleats at the front of the cushions are perfect control is vital cushion shelters provide the best for dealing with these chafing movements keeping solution Cushion shelters ensure an almost airtight wear and tear to a minimum For fleets comprising seal between the truck and the warehouse trucks that are virtually the same in width but with Because part of the load opening of the truck is great variations in height a combination can be backed up against the cushions this type of shelter is not suitable for companies where palletised loads are being handled as this increases the risk of damage During loading and unl
30. ther STERTIL SUPERIOR SOLUTIONS BY QUALITY A good loading pit IS straight and has a maximum gradient of 10 max 10 Aim for the smallest difference between the average truck floor height and the platform The platform There is wide variety in models and truck dimensions so it is likely that trucks of different heights will park at the same dock Special trucks such as refrigerated trucks will be higher even when they are built on the same frame as other trucks due to the insulated floor To determine the average floor height of the trucks you should look at the lowest loaded truck and the highest unloaded truck However it is advisable to omit occasional vehicles with extremely low or high floor when calculating the average floor height To accommodate these special trucks you may consider dedicating certain docks to ensure efficient loading and unloading These docks could feature particular platform heights or longer dock levellers also look at chapter DOCK LEVELLER Of course it is essential to minimize the gap between the average truck floor and platform height The chart below shows how big the differences can be with various types of trucks Truck floor heights in mm 450 650 800 900 1 000 1 100 1 200 1 300 1 400 1 500 1 600 Delivery vans city vehicles Trailers refrigerated trucks 18000 16500 Double Decker
31. uld assume that it meets maximum permitted dimensions The parking and manoeuvring space in front of the dock should be twice the length of the largest truck plus two metres e g an 18 metres long trailer requires a space of 38 metres Furthermore the minimum space between the truck and the dock wall should be 1 4 metres THE SITE The road itself can be made of concrete asphalt concrete plates or brick clinker paving Whilst concrete is an expensive option it will not suffer damage caused by the weight of vehicles and trailers Also the installation of wheel guides onto a concrete road surface is straightforward Good results have also been achieved utilising concrete driving plates providing these are placed on a well stabilized foundation When constructing a loading bay it is advisable to incorporate personnel doors to allow drivers to enter the warehouse easily and safely During winter snow and ice must be removed promptly from the parking and manoeuvring areas to reduce the risk of accidents As well as maintaining a ready supply of salt it may be advisable to consider underground heating within the bay Many different systems are available and technical advances mean that this can be an effective and cost efficient solution STERTIL SUPERIOR SOLUTIONS BY QUALI PS K X X 7 Make sure you have enough space to dock your vehicle b THE LOADIN
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