Level Playing Field: Dock Leveller Facts and Figures

Loading bay personnel face problems every day but one everyday problem can be solved with the aid of an essential piece of equipment. The snag lies in any discrepancy between the height of a truck's load deck and that of the loading bay's platform. Should a mismatch exist, it has to be bridged and this is what a dock leveller does.

Sounds simple enough, doesn't it? In a way, it is but there are caveats of which every loading bay manager must be aware. Such as? Well, like any 'link' in the loading bay's chain of components, the dock leveller has to be capable of handling the heavy loads involved. When bearing these loads in mind, it isn't merely a matter of considering the avoirdupois weight of the goods concerned. This may be significant but a dock leveller also has to accommodate the weight of the means by which the goods are moved, be they trolleys, palette trucks or forklifts. In this context, the weight of the individuals handling the goods is insignificant but the dock leveller must also cater for the additional, near-horizontal loads applied by the moving and braking, especially of powered equipment. Load ratings of 6,000 or 9,000kg are popular but it's common for specially rated dock levellers to be offered in a variety of sizes.

The two main types of dock levellers share steel construction and feature proven aspects including an anti-slip deck and a corrosion-resistant finish. The difference exists in the lip that lies adjacent to the truck's load deck. This may be simply hinged but a telescopic lip version is also available. The dock leveller's height adjustment works equally well in either case but a telescopic lip also allows fine-tuning of the dock leveller to the relative positions of itself and the truck bed. Unsurprisingly, a European standard, EN 1938, applies to dock levellers; make sure the chosen unit complies.

Dock levellers may be mounted in a purpose-built pit and there are suspended frame versions for use with tail lifts. Moreover, dock levellers offer a mechanism that makes for ease of use. An electro-hydraulic operating system, powered by an electric motor that has a low-voltage control unit, makes applying the relative adjustments not only child's play but also the work of moments.

While they have to be visibly tough, dock levellers must also have hidden strengths. In a correctly designed unit, the support frame will transmit loads from the truck's deck without incurring fatigue and consequent loss of structural integrity. Limited torsional diagonal loadings should also be tolerated; dealing with a vehicle with a canted bed will impose them. Furthermore, while dock levellers may seem to be laughably simple items, a range of optional extras takes them into a higher realm of functionality. Such extras include practical additions like high impact absorbing buffers, brush seals for the sides and rear of the deck assembly and under-deck foam insulation. More, let's say, active options include automatic, synchronised parking, a vehicle restraint system with an interlock facility, an automatic docking light interface, and a door interlock mechanism.

As is undoubtedly clear, some forethought is needed when choosing dock levellers. Given this, those chosen should give the loading bay long-lived, reliable levellers that make light work of loading and unloading while maximising loading bay uptime.

Chase Equipment are a leading international supplier of dock levellers. See our website at Chase Equipment for more information.

Self-preservation: Staying Safe in a Loading Dock

A loading dock is an environment in which severe or possibly fatal accidents could happen. The presence of heavy vehicles, forklifts and the loads they carry, and workers on foot in an area that is by definition busy could be a recipe for disaster. Need a working loading dock be the scene of an accident waiting to happen? Not if some simple rules, some involving essential equipment, are applied…

Let's begin with the truck. Getting it into place is the first requirement and for this, a banksman, a ‘reversing assistant', is needed. Of course, a reversing camera could handle the job but method notwithstanding, ensure that nobody goes between the truck's tail and the loading dock's seal, for obvious reasons.

Once the trailer is in place, it makes sense for it to stay put. Should the trailer remain hitched to a lorry cab unit, the worst that can happen is that the driver pulls away prematurely. Good communication will prevent this happening. However, if the trailer is freestanding, you need to keep it under control. Wheel chocks are a solution and it makes sense to use a stable trailer jack – the trailer's own nose gear may not be reliable. Then, take a look at the trailer's deck; rotten floorboards aren't unknown.

With the trailer standing ready, the dock levellers warrant attention. Can they support the weights to be handled? Are they at the right height? Are they secure? You need to know. Bear in mind with all the abovementioned factors that laden or unladen forklifts impose considerable loads and not just in terms of weight. Acceleration and braking forces can easily cause an insecure trailer to move unexpectedly. The speed of the forklift(s) involved and the trailer's suspension are factors in this equation and trailer creep also affects dock levellers.

Now for the forklifts themselves. The use of safety barriers to protect unguarded drops is obvious, as is the use of raves. Less obvious is the need for forklift drivers to see what they're doing. Poor lighting aboard the trailer and around the loading area represents false economy…think ‘dangerous' if you can't see how this will slow the work. Moreover, where larger loads are involved, clear lines of sight are crucial. Use mirrors if necessary and rely on human assistance where applicable.

Just as on the roads, good traffic management applies to loading and unloading. A congested staging area is necessarily inefficient at best. At worst it's dangerous so it's wise to have a traffic system. Traffic cones, signs and marking tape denoting inbound, outbound and no-go areas will pay dividends very quickly. Similarly, ensuring that all personnel, pedestrians included, know what the markings mean could save more than just time. Once again as in traffic, congestion is a major potential problem. A system of storing empty pallets and containers away from the loading area, at a sensible stack height, contributes both to safety and speed of operation.

There are safety factors specifically for the workers on foot, the pedestrians. The traffic system mentioned makes a good starting point but pedestrians also need guard rails and proper, secure ladders for safe movement. They also need a clean working environment, so make sure that debris is cleared frequently.

These are by no means all the rules but there's one simple, overarching practice that must be followed…for safety's sake. This is, in a word, application. All the safety equipment and training in the world are worthless if they aren't present and used correctly.

Chase Equipment are a leading international supplier of loading bay equipment. See our website at Chase Equipment for more information.

Three Essential Types of Loading Bay Equipment

Mobile Yard Ramps

Not every warehouse is large enough to have a permanent docking area. Rear loading vehicles and standard ISO containers can be unloaded using a pallet truck. However this requires the pallets to be arranged inside the container, allowing the pallet truck access. Often the pallets are stacked high with heavy items making them difficult to move manually in a confined space. It can create a safety risk for those involved.

This is why a mobile yard ramp is ideal. As the name suggests it can be easily moved from one location to the next. The ramp is attached to the back of the container or lorry. A forklift can then be used to remove the goods. Because it can be driven into the back of the container/lorry, unloading takes a fraction of the time that it would with a pallet truck and it creates a safer working environment without the need for manual lifting.

Mobile yard ramps can be rented or purchased. Renting is the best short term solution. Purchasing a mobile yard ramp can be the more cost effective in the long term because of the expense of transporting a yard ramp to its location.

A loading bay specialist can provide the best advice and find the most cost effective solution for your requirements.

Dock Levellers

When there is a difference between the level of the trailer being unloaded and the dock, a dock leveller is the perfect solution. Its height can be adjusted to the height of the vehicle trailer, which allows for fast loading and unloading using a forklift or pallet truck.

Made of a sturdy steel construction, dock levellers incorporate an electro-hydraulic system to enable their height to be adjusted with the push of a button.

Scissor Lifts

When not in use scissor lifts, or table lifts, take up little space in a warehouse. But when fully extended they can reach heights of 18.2 metres (depending on the type).

Scissor lifts work by the criss-crossing supports pushing a flat platform upwards when drawn together. Pallets can be loaded onto a scissor lift platform using a forklift or pallet truck to minimise manual lifting. The goods are then raised on the level platform preventing spillage of liquids or damage to fragile items.

Scissor lifts can either be stationary or mobile. Originally designed as an industrial lift they are increasingly seen in operation in the retail and wholesale environment.

Two additions to a scissor lift, that further minimises manual lifting, includes turntables and tilters. Turntables allow the operator to rotate the loads being lifted. This ideal if the scissor lift is being used in restricted spaces. Tilters allow the platform to be positioned at an angle. It is useful for sliding the goods off the lift so the operator does not risk injury by manoeuvring heavy loads.

If you need loading bay equipment for a short period due to changing requirements, want to hire long term to minimise capital expenditure or simply would like try before you buy, contact Chase Equipment for our current rates.

Tailored ramp and dock leveller installation

Chase Equipment have recently installed two static ramps and dock levellers for a Worldwide Chemical Company. The shortened Titan 7 mobile yard ramps are fitted to dock levellers on modules complete with traffic lifts and pedestrian access stairs. The scheme is designed to accommodate heavy usage and quick turnaround to vehicles. The static ramps were shortened to give the minimum length of scheme possible (whilst giving a workable ramp gradient) due to turning circle constraints within the road.

Helping Retailers Go Green

A national retailer with over 200 shops has converted an old building into a very efficient recycling unit. The building had no loading facility and a floor at road level. To provide a suitable area for unloading of goods from trucks, Chase Equipment designed and installed a modular dock system with 6 loading bays- 5 edge of dock levelers and one integral dock leveler. The dock covers some 600m2 with anti-slip paint, removable handrails, traffic lights and stairs. Truckloads of materials for recycling are unloaded, and materials sent down a climate for compacting. The system also includes a washing machine to clean trays and pallets used for the supply of food. Additional access to the scheme by forklift is provided by a Titan 7 mobile yard ramp.

Integration of New with Old

It can be difficult to ensure that the upgrading of an old site is done sympathetically such that the new equipment blends in with its surrounding. Chase Equipment Ltd was tasked with supplying a goods lift with handrails and interlocking to match existing black wrought-iron spindles and handrails. Designed and manufactured in house the finished products is indistiquishable from the old rails.

Overall an outdated and manual lift was replaced by a modern hydraulic lift giving full BS EN 1570 compliance with full integration of the lift within an aesthetically sensitive area.

Wherever you are in the UK, you’re never more than 30miles from a Chase Mobile yard ramp*.

Chase Equipment have manufactured mobile yard ramps for over 30 years. As the pioneers in mobile yard ramp design, whilst styles and capacities have changed as they are updated to reflect technology improvements, one principle is constant- Chase Mobile Yard Ramps are designed to last. As such a very large % of the several thousand built over the last 30 years are still giving excellent service. Often potential customers requested a site visit to view our ramps in operation and more often than not this is done local to them. Of course customers are always welcome to visit our factory.

Whilst we provide three standard sizes of ramps 7t, 10t and 12t, we can also produce specials if your needs dictate. Optional product training is a sensible investment to ensure the safe operation of your ramp.

You can be sure that if you invest in a Chase Mobile Yard Ramp you’ll be in good company.

For further information on Chase Equipment visit http://www.chaseequipment.co.uk/
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Don’t get buried in Concrete

Today flexibility is key to the success of any company. When it comes to loading and unloading of vehicles any solution must ideally be able to be adapted to changing requirements over the lease of a building. To this end Chase Equipment Ltd, produce a Modular docking system. Manufactured in various capacities from 3000 to 9000kg capacities the modular dock can include element such as dock levelers, ramps, edge of docks and scissor lifst. Consisting of a mix and match of standard (or bespoke) modules the finished scheme can be as simple or complex as you need. The modular dock allows you to convert warehouse space not though suitable for distribution through the lack of dedicated loading equipment ( or a floor at ground level) into a highly efficient distribution operation.

At the end of the lease the scheme can be removed and re-installed at a new site. With many years of experience of the design and manufacture of modular docking systems, Chase Equipment have a tried and tested product range, designed to ensure longevity despite the punishment of the typical harsh loading bay environment. Suitable for both inside and outside application, our modular docks are as durable as concrete, without the permanency.

For further information on Chase Equipment visit www.chaseequipment.co.uk

St Pancras Upgrade with dock levellers and loading bay equipment from Chase

Chase Equipment Ltd have recently completed a project for Eurostar at the spectacular and newly refurbished St Pancras station.

Solving the problem of how best to utilise a loading bank with a height of just 900mm - significantly below normal which precluded the use of standard loading bay equipment - Chase provided bespoke 6m long levellers, designed to ensure gradients were kept within regulation.

The levellers were a small part of a modular dock scheme designed and manufactured by Chase, totalling some 64m2 which also included an insulated, clad wall with roller shutter doors to secure the front of the customs controlled area.

Elsewhere on the development, Chase were tasked with designing a raised platform area with island unit to assist in loading foodstuffs into trailers pulled by electric tugs. Setting up a simulation in their Midland factory and heavily testing the system in conjunction with Eurostar prior to build, ensured that the most cost-effective solution could be designed. An antislip surface was specially developed and included, to ensure safe footing for operators, even in the wet.

Chase’s design expertise was further tested when a simple scissor lift that they provided to London and Continental Station Properties required added safety features. Required to move materials from the loading bank to the ground level, Chase designed and incorporated interlocking drop-arm barriers on the lift and upper bank, in addition to installing a small ramp complete with handrails.

Chase’s MD, Derek Sweeney commented, “Although only a small part of the near £800 million re-development, we are proud to have been involved in developing innovative solutions for what has become a major international destination in it’s own right.”

For further information on Chase Equipment visit www.chaseequipment.co.uk

Understanding your loading equipment service needs

All loading bay equipment should be inspected regularly to ensure it continues to operate safely as the consequences of a failure (where fork trucks and heavy weights are involved) is potentially very serious. It's therefore important to choose a company that understands your loading equipment service needs on the basis of years of experience designing, manufacturing, installing and servicing all types of loading bay equipment.

Chase Equipment Limited, based in the West Midlands is the only company in the U.K that designs, manufactures and installs its own complete range of loading bay products from ramps, through dock levellers to complete solutions including modular docks and is therefore uniquely placed to service the needs of companies who wish to safely maintain their existing equipment.

From a basic service through to complete overhauls or upgrades to keep equipment legal to current regulations Chase are the preferred choice for a wide range of customers – those with one mobile yard ramp through to national contracts for regional distribution centres where all the loading bay equipment is serviced including the doors on a contract basis.

Changing requirements can lead to the need to change your loading equipment For example you may want to change dock leveller lips to cope with new trailer configurations or fit longer levellers into existing pits - Chase Equipment have the knowledge, the experience and the in-house capability to satisfy your needs.

For further information on Chase Equipment visit www.chaseequipment.co.uk