Pentalift
Equipment
Corporation
Loading Dock
Design
Presentation
History
Established in 1983 by Arne Pedersen.
Pentalift consists of two Divisions, Loading Dock Division
and Lift Table Division.
Loading Dock Division manufactures a complete line of
Loading Dock Equipment, Vehicle Restraints, Dock Seals
and Dock Shelters.
Lift Table Division focuses on Custom Designed Lifting
Equipment.
25+ Years Industry Experience.
Specifications
Pentalift is proud to be
listed as an approved
supplier on MasterSpec.
Pentalift is incorporating
product specifications
which can be downloaded
from the Pentalift Website.
Our Dock Design Guide
contains important factors
for Architects to consider in
order to achieve proper
dock design.
Factors Affecting Dock Design
[Link] Dock Safety
Issues.
[Link] of Facility.
[Link] Design.
[Link] Equipment Type.
[Link] Design/Apron.
Factor # 1Dock Safety
Dock Safety Issues
Potential Accidents at the
loading Dock.
– Void in the Floor.
– Unscheduled Trailer Departure.
– Trailer Creep.
– Trailer Landing Gear Collapse.
– Trailer Tip Over.
– Forklift Roll Off.
– Stump-Out.
Factor # 1Dock Safety
Factor # 2 Type of Facility
Other Facility Factors
Facility Type, Truck Fleet and Loading style will
affect:
1. Door Size.
2. Dock Height.
3. Dock Leveler Size.
4. Dock Leveler Capacity.
5. Dock Leveler Lip Length.
6. Bumper Projection.
7. Style of Dock Seal or Dock Shelter.
8. Style of Vehicle Restraint required.
Factor # 3 Trailer Design
Trailer Design Affects Dock Design
Trailer Bed Heights.
Rear Impact Guards.
Air Ride Suspension.
Trailer Inside Width.
Trailer Inside Height.
Trailer Tailgates.
Factor # 3 Trailer Design
Trailer Bed Heights
Type of Trucks/Trailers:
Reefer (refrigerated).
Semi Trailers.
Lowboys.
Air Ride suspension.
Step Trailers.
Factor # 3 Trailer Design
Goal is to create a Dock Height
and Door Size that will match up
to the trailers that will be
used.
Factor # 3 Trailer Design
Rear Impact Guards
(R.I.G.)
– Maximum 22” (560mm)
from Grade to R.I.G.
– Many R.I.G.’s can get as
low as 10” depending on
approach slope and
suspension (Air Ride).
– Ensure Axle is placed at
farthest rear position.
– Maximum 12” (305mm)
from rear of trailer to
R.I.G.
– 4” x 4” horizontal member
is now standard.
Factor # 3 Trailer Design
Air Ride Suspensions
Creates a more cushioned ride that helps
protect product.
At the Loading Dock the suspension can cause
problems for dock levelers, vehicle restraints,
dock seals and bumpers.
This trailer movement can cause the trailer to
creep forward away from the dock, causing the
Dock Leveler lip to lose penetration into the
bed of the truck and a potential safety issue.
Factor # 3 Trailer Design
Trailer Height and Width
Inside width on new style Trailers can be
as much as 101” (8’-5”) and allows for a
40” pallet and 48” pallet to fit side by side.
Inside Height of up to
114” allows for double
stacked loads to max
out Trailer volume.
101” Inside width trailer not shown
Factor # 3 Trailer Design
Recommended Door Size
With trailers becoming wider the
recommendation is to consider using 9’W
or even 10’W x 10’H Dock Doors.
This will give full access to the trailer for
possible full width and full height
loading/unloading.
Door size should match truck size and
load style.
Factor # 3 Trailer Design
Dock Leveler Width
Full Width End Loading
– Drop off zone
space created between side of
deck and side of truck/trailer
giving the potential for material
handling equipment to drop
through.
Note: It is not recommended to
taper the lips on 7’ wide Dock
Levelers.
Factor # 3 Trailer Design
Recommended Dock Leveler Width
Wider Trailers allow the possibility of
wider loads and use 2 x 48” W pallets.
Also a 7’W Dock Leveler will assist with
full width access for the forklift over a
standard 6’ wide Dock Leveler.
Factor # 3 Trailer Design
Determining Dock Leveler Deck Length
Type of Material Handling Equipment can
affect Dock Leveler length.
Slope requirements.
Maximum Ideal
– Pallet Truck 7% 3.5%
– Electric Forklift 10% 5.0%
– Gas Forklift 15% 7.5%
Factor # 3 Trailer Design
Recommended Dock Leveler Length
The wider variety of trailer styles seen at
the dock, the longer the Dock Leveler has
to be to maintain smooth transition to the
trailers and to maintain the float range with
air ride suspensions.
Standard lengths of 6’ to 8’ Long may not
be enough.
Consider 10’ Long or more if needed.
Factor # 4 Dock Equipment Type
Types Of Dock Equipment
Hydraulic Dock Levelers.
Mechanical Dock Levelers.
Edge of Dock Levelers.
Automatic Vehicle Restraints.
Mechanical Vehicle Restraints.
Automatic and Manual and Wheel
Chocks.
Dock Seals & Shelters.
Dock Bumpers & Lights.
Edge of Dock
Available in both
Mechanical and Hydraulic
models.
Lower cost alternative to
the pit style Dock Leveler.
Suitable for lesser
capacities and facilities
with less frequent use.
Suited for servicing
minimal deviation in
above and below level
ranges.
Excellent upgrade to
aluminum plates.
Factor # 4 Dock Equipment Type
Mechanical Dock Levelers
Features:
Upward Bias Spring Systems.
Mechanical Fallsafe.
– Legs prevent deck from
descending below dock
level under a fallsafe
situation.
Fallsafe - where there is a
WHEN TRUCK PULLS AWAY,
load on the deck of the Dock LEGS WILL STOP THE FREE FALL
Leveler and the truck/trailer
supporting the lip of the Dock THESE LEGS CAN CAUSE STUMP-OUT
Leveler pulls away allowing
deck to descend to lowest
position.
Factor # 3 Trailer Design
Air Ride Trailer Effects
on Mechanical Dock Levelers
Mechanical Dock Levelers equipped with
Fallsafe legs can complicate loading operations
since they can prematurely engage and stop the
downward movement of the Dock Leveler deck
until the legs are manually disengaged.
This causes the issue commonly referred to as
“Stump-Out”. Stump-Out can damage the Dock
Leveler and increase the potential for injuries to
the dock worker.
Stump-Out is eliminated by specifying Hydraulic
Dock Levelers.
Factor # 4 Dock Equipment Type
Issues with Mechanical Dock Levelers
Fallsafe Legs can Cause Stump-Out:
– The truck/trailer lowers
when being loaded/unloaded
allowing the mechanical
fallsafe legs to engage.
– Then only the lip of the Dock
Leveler will float with the truck/trailer
after the deck stops descending.
– This creates an obstacle preventing the
material handling equipment from
leaving the truck/trailer (STUMP-OUT).
Factor # 4 Dock Equipment Type
Hydraulic Dock Levelers
Features:
Why use a Hydraulic Dock
Leveler?
– A Hydraulic Dock Leveler requires
less maintenance than a Mechanical
Dock Leveler, to keep operating
efficiently.
– Auto Return to Dock feature helps to
eliminate void in the floor potential.
– Uses Hydraulic vertical Float to
maintain smooth transition and Hydraulic Dock Levelers
contact with trailer bed at all times create a more safe and
eliminating Stump-Out. ergonomic dock environment
– Industry Proven Velocity Fuse
system stops Dock Leveler within 3”
in a free fall situation.
Factor # 4 Dock Equipment Type
Vertical Storing Dock Leveler
Vertical Storing Dock Leveler
uses a fully hydraulic system
to lower/raise deck and
extend lip.
Control Panel operation
allowing interlocking to other
electrical equipment.
Used in facilities where
cleanliness or temperature USED IN AREAS WHERE
conditions must be ENERGY EFFICIENCY IS
maintained. REQUIRED
Factor # 4 Dock Equipment Type
Recommendation – GO HYDRAULIC!
Why use a Hydraulic Dock Leveler?
– Less Maintenance.
– Increases Safety Factor at the dock area.
– Ability to be interlocked to Door, Vehicle
Restraint and / or Dock Shelter.
– Eliminates “Stump-Out” from occurring.
– Greater operating Range.
– Floats 12” above and 12” below dock to
maintain Lip contact with Trailer.
Capacity
What is Static Capacity?
The amount of evenly distributed static weight that a
Dock Leveler can support in the stored position.
What is Dynamic Capacity?
The total rolling load that a Dock Leveler can safely
support while the lip is resting on the truck/trailer bed.
Industry Standards are rated using Static Capacity.
Capacity
Determine Static Capacity
Determine Impact Factor (I)
What is the Impact Factor?
– Multiplier used to compensate for the forces
applied by a moving load.
– For normal applications, Pentalift uses a
minimum impact factor of 2.5 for its standard
series of Dock Levelers and a 2.0 for its
Ultima series Dock Levelers.
Capacity
Sample Calculation
WHE=Weight of material handling equipment (plus any
attachments)
WL=Weight of the load
I= Impact force
WHE = 10,000 lb
WL = 5,000 lb
I = 2.5
Static Capacity = (10,000 lb + 5,000 lb) x 2.5
= 15,000 lb x 2.5
= 37,500 lbs Or 40,000 lbs
Capacity is rounded up to the next standard capacity.
Factor # 4 Dock Equipment Type
Pit Design
Preformed Pit installation for:
Mechanical and Hydraulic Dock Levelers
Advantages Disadvantages
Installed after the floor Pit formed in advance
is poured. Separate curb angle
Easily removed for required.
replacement. Extra installation with
welding in place.
Factor # 4 Dock Equipment Type
Pour-In-Place Design
Pour-In Place style for:
Mechanical and Hydraulic Dock Levelers
Advantages Disadvantages
Requires concrete pad Must be set up before
for installation. pouring concrete.
Concrete pours around
Harder to replace after
Dock Leveler once
leveled and secured. installed.
Pour-In-Place
Advantages of Pour-In-
Place Dock Levelers for new
construction or renovation.
Cost savings:
No forming of pits by
contractor.
Dock Leveler comes installed
in Pour in Place unit.
No curb angles.
– Pits are always square allowing
leveler to perform better.
– Controls the quality of the
installation.
Factor # 4 Dock Equipment Type
Pit Design
Individual Pit or “T” Style for:
Vertical Storing Dock Leveler
Advantages Disadvantages
Provides concrete floor Pit formed in advance
beside Dock Leveler.
Separate curb angle
Flat plate option welds to required.
embedded channel.
Channel required when
concrete poured.
Factor # 4 Dock Equipment Type
Pit Design
Continuous Pit for:
Vertical Storing Dock Leveler
Advantages Disadvantages
Step in floor requiring no Channel required when
concrete poured.
preformed pit.
Open area beside Dock
Easy cleaning pit floor Leveler.
Flat plate option welds to Stand required to mount
embedded channel. controls.
Factor # 1Dock Safety
Why Wheel Chocks Don’t Work
Truck has enough force to
easily pull over rubber
chocks.
Ice, snow and rain can
affect its grip.
Has to be manually placed
creating a possible human
error situation.
They are easily lost and or
damaged.
Factor # 4 Dock Equipment Type
Hydraulic Vehicle Restraint
Features and Benefits:
Creates a safe working
environment at the dock.
Locks onto Trailer R.I.G.
Prevents trailer from early
departure.
Easy operation from
Control Panel inside
building.
Effective communication
with truck driver via outside
lights.
Factor # 4 Dock Equipment Type
Low Profile Vehicle Restraint
Same Features and Benefits
as HFR restraint Plus:
8-3/4” low profile stored
height to lock to lower
R.I.G. trailers.
Perfect option for certain
decline approaches.
Factor # 4 Dock Equipment Type
Under Dock Leveler Vehicle
Restraint
Features and Benefits:
Stored under Hydraulic
Dock Leveler creates a
unobstructed dock
approach.
Has 40,000lb of
restraining force.
Ideal option at New
Construction phase.
Factor # 4 Dock Equipment Type
Under Dock Leveler Vehicle
Restraint
Trailer Creep/Early Departure Alarm.
– When a truck/trailer tries to drive away while the
Ultrahook is engaged on the R.I.G., an audible
alarm will sound and the interior red light will flash to
inform the operator of this situation.
Under Dock Leveler.
– Restraint stores completely under the Dock Leveler
to protect it from the weather and any damage from
equipment being used at the grade level.
Factor # 4 Dock Equipment Type
Dock Seals/Shelters
Generally Dock Seals offer a
tighter environmental Seal.
Truck Shelters allow for a
wider variety of Trailers at
the Dock and Larger Doors
for End Loading.
Application will determine
Dock Seal or Dock Shelter
type that best fits.
Factor # 4 Dock Equipment Type
Dock Bumpers
Molded Rubber – Basic style of bumper
– Can easily wear due to air ride suspensions.
Laminated – Provide good wear protection against air
ride trailers.
Steel Faced - Provides the best protection against air
ride wear issues.
Trucks can generate up to 300,000 lb of force at the
dock.
Air Ride Suspensions increase the wear on a bumper.
Longer Bumpers are recommended to protect the wall
from Air Ride trailers that can move vertically 6” to 8”.
Bumper length will depend on dock height and trailer
height.
Elevating Dock Lifts
Available in pit-mounted
and low-profile.
Available in 3 sided pit
design for greater flexibility
at the loading dock.
Suitable for applications
where a traditional loading
dock does not exist.
Vertical travel of 59” allows
for a wide range of truck
bed heights.
Pentalift Surface Mounted Design
Surface Mounted
– LPE685
Factor # 4 Dock Equipment Type
Equipment Recommendations
Specify:
Hydraulic Dock Levelers.
Vehicle Restraints.
Interlocking of Dock Equipment and
Overhead Door.
Laminated or Steel faced Bumpers.
Factor # 2 Type of Facility
Facility Style Affects Dock Design
Application Affects Design:
Refrigerated Warehouses
– Cold temperature/Freezer - Clean operation.
– May Require Vertical Storing Dock Levelers.
Trucking Terminals
– Fast paced - Cross Docking – Shunting
– May use Mechanical or Hydraulic Dock
Levelers.
Distribution/Manufacturing Centers
– System integration - Just in time delivery
– Type of Loading/shipping will affect size of
Dock Levelers needed.
Factor # 5 Building Design
Building Design
Dock Approach/Grade.
Apron Spacing.
Door Spacing.
Dock Height.
Factor # 5 Building Design
Dock Approach Grade
Most dock approaches
are either Level or Decline.
Decline: Project bumper
thickness 1” for every 1% of
decline beyond the 4” thick
bumpers required for a level
approach.
e.g. 4% decline = 8” total bumper
projection.
This 8” can include a cantilever
or haunch of 4” and Bumpers at
4” to = 8”.
Dock Seals or Dock Shelters will
have to be tapered to match.
Factor # 5 Building Design
Apron Spacing
To give trucks enough room to maneuver
freely in and out of the dock.
Recommendation is to provide twice the
length of longest trailer plus a 10’ safety
factor.
E.g. 70’ Trailer and
Cab x 2 = 140’+10’
= 150’ apron spacing
Factor # 5 Building Design
Door Spacing
Recommendation is to Design Doors with 12’
centers.
This allows for trucks with an overall width of
10’ including side mirrors to easily maneuver in
and out of the dock.
Narrower spacing is possible when room is
limited. In this case consider using Dock Seals
or Dock Shelters with common members or
saw tooth docks to maximize available space.
Factor # 5 Building Design
Dock Height
Most common Dock
Height is 48” to 52”.
Goal is to match the
dock height to the
trailers that will be seen at the dock.
Its ideal is have a slight incline into the
trailer for loading and unloading.
Final Recommendations
Final Recommendations
Safety - Specify Vehicle Restraints and
Interlock to Dock Leveler and/or OHD.
Equipment - Spec Hydraulic Dock Levelers.
Dock Height - Match to Trailer Bed Heights.
Door Size - Match to Trailer Width (est. 9’W x 10’H).
Dock Leveler Size - Spec 7’ Wide for End Loading.
- Spec 8’ long to 10’ long for smooth
Transition into Trailer.
Capacity - Match to MGL and Forklifts Used.
Bumpers - Spec Laminated or Steel Faced.
Door Spacing - Spec 12’ Centers Where Possible.
Apron Spacing - Spec 2x Overall Truck length + 10’.
Please Contact
Pentalift Sales
Representative
For Additional
Information.
