Posted on 25th November 2024
Safety Procedures to Follow Before Installation
To ensure a safe and efficient installation of your dock leveller, it’s essential to follow these key safety precautions:
- Consult a Professional if Needed: If you’re unfamiliar with dock leveller installation or if the setup poses any safety risks, it’s best to consult a professional installer.
- Refer to Safety Standards: The BS EN 12453:2017 standard outlines safety requirements for powered doors, including loading dock doors and hydraulic dock levellers. You’ll need to make sure the installation of your dock leveller meets these standards to reduce risks and maintain compliance.
- Use Personal Protective Equipment (PPE): Always wear the appropriate safety gear, such as gloves, safety goggles, hard hats, and steel-toe boots.
- Inspect the Work Area: Ensure that the installation area is free of any obstructions, hazards, or unauthorised personnel.
- Confirm Load Capacity: Check the dock leveller’s load capacity and verify that it aligns with the expected load requirements.
- Level and Stabilise Equipment: Make sure the dock leveller is level and stable before completing installation to avoid imbalances that can affect its functionality and safety.
Common Installation Methods for Dock Levellers
Choosing the best installation method for your dock leveller depends on the layout of your loading dock, the type of leveller, and how frequently it will be used. Here, we explain three straightforward installation methods, highlighting the key points for each to help you decide which is right for your facility.
Using Preformed Pits with Curb Angles
In this method, a “preformed pit” or prepared space in the concrete floor is made in advance for the dock leveller. Metal edges called “curb angles” are secured around the edges of this pit to reinforce the opening and keep everything steady. Although this setup comes with a higher long-term cost, it’s great for docks that will handle lots of heavy use, as the curb angles help prevent damage to the edges of the pit over time.
Installing with Pit Kits
Pit kits make it easier to install a dock leveller if you don’t already have a preformed pit. A pit kit comes with parts that create a suitable frame for the leveller, making the setup process simpler. This option works well if you’re working with an existing loading dock that doesn’t have a prepared space.
Pour-in-Pan Installation
This method is often used in new builds where concrete work is already underway. Here, a pan or frame is positioned in the foundation wall where the leveller will go, and then concrete is poured around it, bonding the leveller base into the dock’s structure. This approach results in a very durable installation suited to high-traffic loading docks and is useful when you need to install several dock levellers at once.
How to Install a Dock Leveller: Step-by-Step Guide
There are three types of dock leveller (or dock leveler): hydraulic, vertical and edge-of-dock. If you’re replacing an old dock leveller, measuring is an essential step to make sure your new dock leveller will fit into the same space—it’s something you don’t want to find out half way through!
The dock leveller should extend at least 4 inches into the trailer bed to create a safe bridge, and you should select a width slightly wider than your typical load to allow for safe loading and unloading. Keep in mind that the pit width is typically about 2 inches higher than the dock leveller width. Levellers are also often lower than the pit depth, which means you’ll need to adjust the leveller to the proper height.
How to Install a Hydraulic Dock Leveller
Hydraulic dock levellers are widely used for their ease of operation and powerful lifting capability. Here’s how to install one:
- Position the Leveller: Using a forklift, lift the dock leveller carefully and place it into the pit prepared for it. Make sure the back edge sits level with the ground. Secure it by welding the back edges, adding extra support underneath if needed to keep it stable.
- Level the Front: Shim the front edge to make sure the top of the dock leveller lines up with the sides of the pit and sits flush with the top. It’s important to weld shims to the leveller at this stage. Then, weld the front edge and spacers to the front curb angle to hold them in place.
- Remove Temporary Supports: If there were any temporary fasteners used to keep the leveller in position, take them off at this stage.
- Hold the Leveller Open for Access: Lift the main deck surface and attach a lifting ring to the nut at the front of the deck help with support, then raise the front angle lip of the leveller and prop it open using a maintenance strut.
- Add Extra Support Underneath: Place additional shims under the primary lift cylinder to give it extra strength. Secure these supports by welding them in place.
- Connect and Test the Hydraulic System: Follow the operating instructions provided by the manufacturer to connect the hydraulic power system. Make sure to run it several times to test that it’s been installed correctly, stopping to release any trapped air from the system.
Hydraulic dock levellers require power for operation, so ensure they’re properly connected to a power source once installed and undergo regular maintenance checks.
How to Install a Vertical Dock Leveller
Vertical dock levellers are installed in an upright position, providing enhanced security and energy efficiency. Here’s how to install one:
- Prepare the Area and Check Measurements: Clear the dock area inside and out to allow for safe access. Double-check the pit’s dimensions to confirm they align with the dock leveller’s requirements.
- Position the Leveller: Carefully lift the leveller from the lip using a forklift. Line up the rear hinges with the hinge slots in the pit, then lower the leveller into place, inserting the two outer hinge pins to hold it securely. The centre pins don’t need to be installed yet, as the maintenance strut needs to be secured first.
- Set Up the Maintenance Strut: To ensure safety, insert the maintenance strut into the frame using pins. Tilt the leveller slightly away from the door and lock it in place with a lock-out pin at the top of the maintenance strut. Adding a padlock here provides additional security by preventing any unintentional movement.
- Secure Remaining Pins: Install the final hinge pins. Following this, lock both the leveller hinge pins and the maintenance strut pin into position with washers and cotter pins, making sure all points are firmly in place.
- Connect Power and Hydraulic Components: Leaving the leveller’s lip fully extended, follow the installation manual to complete the wiring and attach the hydraulic cylinder securely.
How to Install an Edge-of-Dock Leveller
Edge-of-dock levellers are designed to attach directly to the edge of your loading dock, offering a practical solution for smaller spaces. Follow these steps for a successful installation:
- Prepare the Dock Surface: Clear away any dirt, debris, or rough concrete spots from the dock surface and use a plumb line to make sure the channel is straight.
- Mark Alignment Points: Use a measuring tape to find the centre of the installation area and mark it. Next, make clear markings for the right and left edges where the leveller will be placed. This ensures precise alignment when positioning the leveller.
- Lift and Position the Leveller: Use a forklift or lifting harness to raise the leveller into place. Carefully align it with the markings, ensuring that it is level and correctly aligned along the dock edge.
- Tack Weld the Centre: To secure the leveller, apply a tack weld at the top centre of the mounting plate. The leveller’s faceplate edges should sit slightly below the top of the dock edge. Adjust the leveller using shims if necessary to keep everything even and aligned.
- Run a Functional Test: Lower the leveller’s lip and deck into place, then test its movement to ensure it operates smoothly. If there’s any resistance or misalignment, adjust the leveller and test again.
- Attach Bumpers: Place bumpers, making sure they’re level with the mounting plate. Mark the bottom bumper hole, drill an anchor hole, and insert a wedge anchor bolt. Once aligned, secure to the dock by inserting the bottom anchor bolt and nut and then welding the bumpers to the channel.
- Finish Welding and Reinforcing: Complete the welding around the mount plate and bumpers, ensuring all components are firmly attached and stable. Once you’ve done this, apply lubricate to the moving parts and perform a final test cycle.
For Dock Levellers Built to Last
At Rapid Industrial Doors, we don’t just supply loading dock equipment—we make sure it’s exactly right for your facility. It all starts with a friendly, no-pressure consultation where our experts take the time to understand what you need.
From there, we customise each dock leveller to work perfectly with your setup, considering load capacities and unique site conditions, so you’re up and running smoothly from day one.
Our skilled team can handle the entire installation process, saving you time and guaranteeing that your dock leveller meets all UK compliance standards, including the Health and Safety at Work Act of 1974 and BS EN 12453:2017.Once your dock leveller is installed, we provide ongoing maintenance, from emergency loading dock repairs to routine checks, keeping it compliant and in top condition.
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Frequently Asked Questions
Answers to some of the most common questions on dock leveller installation.