THE STERTIL DOCK PRODUCTS

HOW TO DESIGN
A LOADING BAY

STERTIL
SUPERIOR SOLUTIONS
 Superior
Stertil Dock Products provides quality,

customised and technically advanced

Solutions loading bay dock equipment solutions

throughout the world. The best

possible service is also offered from

skilled local partners. These superior

solutions are conceived, developed

and implemented by a team of

professional specialists with unique

expertise. Thanks to the quality of its

people, its totally in-house production

process and its international

organisation, Stertil Dock Products is

a leading international quality supplier

of loading bay dock equipment.

The loading bay is the logistical

bottleneck of a company site
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.

2
 logistics starts
and ends with

Index
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. The dock platform 10 C. dock lights 43
5. The dock leveller 18 D. mini dock levellers 43
6. The dock shelter 24 E. wheel guides 44
7. The overhead door 34 F. truck restraint 44
8. Internal transport equipment 36 G. dock houses 45
9. Safety standard EN 1398 38

3
 THE NUMBER OF
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 Processing of goods

It’s important to be aware of how many vehicles Another factor to be considered is the way in
are likely to be loaded/unloaded at the same time. which different goods may be handled. If processing
Often, the busiest times at distribution centres occur activities, such as sorting, packing or labelling, need
during the same morning and evening periods. to be carried out within the warehouse, it will be
Of course, a balance needs to be reached that advisable to have a sufficient number of loading
provides enough loading bays to cope with these bays to prevent internal handling equipment having
busy periods without having many standing unused to transport goods over long distances. It therefore
during the rest of the day. makes sense to position loading bays as near as
possible to the areas where on site processing takes
place.

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.

Carefully determine the number of loading bays

4
5
 THE SITE
It is important to avoid bottlenecks as trucks arrive The road itself can be made of concrete, asphalt,
on site to access loading bays. Properly designed concrete plates or brick/clinker paving. Whilst concrete
road layouts that enable vehicles to travel quickly is an expensive option, it will not suffer damage
and safely with a minimum of manoeuvring will help caused by the weight of vehicles and trailers.
to eliminate the problem. Efficient traffic management, Also, the installation of wheel guides onto a concrete
including strict control over the directional flow of road surface is straightforward. Good results have
trucks, will also contribute greatly to safe and smooth also been achieved utilising concrete driving plates
vehicle movement. For instance, in countries where providing these are placed on a well stabilized
trucks are driven on the left, a clockwise system foundation.
around a warehouse makes it easier for drivers whilst
the opposite is true in countries where vehicles use When constructing a loading bay, it is advisable to
the right hand lane. Also, this system ensures that incorporate personnel doors to allow drivers to enter
drivers’ blind spots are eliminated when reversing the warehouse easily and safely.
into position.
During winter, snow and ice must be removed
When designing a loading bay it is essential to take promptly from the parking and manoeuvring areas
into account the different dimensions of trucks. In most to reduce the risk of accidents. As well as maintaining
European countries, a truck with a trailer length of a ready supply of salt, it may be advisable to
18 metres is permitted. If you do not have accurate consider underground heating within the bay.
information concerning your truck dimensions, you Many different systems are available and technical
should assume that it meets maximum permitted advances mean that this can be an effective and
dimensions. cost efficient solution.

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.

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 STERTIL
SUPERIOR SOLUTIONS

38 m 15 m 18 m

Make sure you have enough space

to dock your vehicle

7
 THE LOADING PIT
To reduce the difference in height between the yard • wheeled loads can fall out when the truck’s doors
and the truck floor, two options are possible: are opened
• raise the dock floor up to the level of • the loading/unloading process is more difficult
the truck floor • internal handling equipment is under increased
• create a depressed driveway approach. pressure
• rainwater can run from the roof of the truck into
The construction of the latter may be unsuitable due the building
to soil condition or the ground water level. Also, a • the dock bumpers will be overburdened
steep decline can create problems because when • damage to the overhead door and building.
a truck is not horizontal during loading/unloading
operations, the following problems might occur:

Loading pit design

Platform

Gutter

< 1000 mm
Approximately 17 metres

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 STERTIL
SUPERIOR SOLUTIONS

To solve the problem, depending on the yard, you can

build a flat lane of 16-18 metres directly at the front of A good loading pit
the dock before the slope begins. A drainage channel is straight and has
is necessary to remove rainwater. In this situation the
truck is parked straight which will lead to smooth and
a maximum gradient
simplified loading/ unloading. The height difference of 10%
between the straight lane and the road should be
bridged with a gradient percentage of a maximum of
10%. When this incline is larger than 10%, problems
can arise as trucks drive in and out. In extreme
circumstances, a truck cabin and trailer may even hit
each other.

max. 10%

9
 THE PLATFORM

Aim for the smallest difference between the

average truck floor height and the platform

10
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

Volume-transport

Delivery vans /
city vehicles

Trailers /
refrigerated trucks

Containers

~ 18000
~ 16500

Double Decker
Jumbo
~ 2950
~ 4800

~ 4200
~ 950

~ 650
~ 400

Volume-transport

~ 18000 ~ 16500
~ 1300
~ 4000

~ 1300
~ 4000

Articulated Trailer

Trailers / refrigerated trucks

~ 7150
~ 6000
~ 4500
~ 1540

~ 4000

Dem o u n tab l es/ C o n tai n er

(1630)
~ 1050
~ 3400

City Vehicle
~ 2000
~ 450

Transit Van

City vehicle Delivery vans Containers

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 STERTIL
SUPERIOR SOLUTIONS

Dock leveller

Letter box ≥ 400 mm

≥ 2400 mm

It is not always possible to make an exact estimate This PVC seal bends away as soon as the truck
of the kinds of trucks that will dock. However, the reverses.
most common platform height is 1250 mm which
is suitable for an average warehouse or trailer park. The letter box should be 3000 mm wide and have
sufficient depth to accommodate the length of the
Trucks with hydraulic tailboards need a space tailboards. However, we recommend a minimum
under the dock leveller, known as a letter box. depth of 2400 mm and a minimum height of 400 mm
The tailboard slides under the dock leveller into the (also depending on the build-in height of the leveller
letter box to allow unrestricted use of the leveller. and chosen platform height). These dimensions will
Letter box slots can be protected by a PVC seal that ensure that the letter box is easily accessible.
prevents dirt and debris blowing into the opening.

12
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 3700 mm although, when accommodating
wide trucks with open doors, this should be
in­creased to approximately 4000 mm.

For refrigerated & Freezer trailers different values

apply. Most refrigerated & freezer trailers require a
distance of 4200 - 4400 mm*. The recommended
distance between the truck and the loading pit
edge is 1500 mm.

4000 mm*

1500 mm

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 STERTIL
SUPERIOR SOLUTIONS

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

14
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 leveller and truck, the leveller
must incorporate a telescopic lip. This continuously
variable, extendable lip can bridge the building,
door and concrete construction without problems.

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 STERTIL
SUPERIOR SOLUTIONS

B. T he 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.

16
Manoeuvring space depends on A

4.3 A saw tooth dock

In situations where manoeuvring space is limited, The trucks need less manoeuvring space because
a saw tooth arrangement may be the best solution. they are already lined up in the ‘drive away’ direction.
The manoeuvring space will be increased relative However, extra building space is required for this
to the angle of the building. Approach roads need saw tooth layout and useable space between the
to be designed in such a way that trucks can leave levellers is limited.
in the direction of the angle of the dock.

17
THE DOCK
LEVELLER
 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.) 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 13%. (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.

More Information?

Example:
The minimum internal vehicle width is 2400 mm
Subtract a manoeuvring deviation of 150 + 150 mm
This leaves a maximum leveller width of 2100 mm

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 STERTIL
SUPERIOR SOLUTIONS

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 lip hinge
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 is 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
One hydraulic main cylinder
guarantee.

To ensure stability when heavily laden fork lifts drive

over a leveller in resting position, two legs support
the front edge to prevent the leveller from sinking.
When the lip extends, these legs automatically
retract. Cross traffic is perfectly safe. The rear hinge
is specially constructed to allow the platform to twist
125 mm on both sides. This means that an uneven
truck floor will not cause a dangerous gap between
lip and floor.
The platform can twist 125 mm on both sides

Two safety supports

The lip angle is standard 7.5°

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5.1 The Hydraulic swing
lip leveller
Simple operation of the S / P 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.

5.2 The 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:
• platform up
• lip goes out
• 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

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 STERTIL
SUPERIOR SOLUTIONS

5.3 The Advantage of 5.4 Solutions for the food/

the Stertil Leveller meat industry
with One Hydraulic In food chain logistics, the highest standards are
Cylinder 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
• Ideal 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:
pit construction.
• The dock leveller is specifically designed for this
• Maximum safety in an ‘emergency stop’ situation
situation and is just under ramp level in resting
requiring just one cylinder to close. The combination
position between two recesses in the front section
of the middle position and high pressure ensures
of the warehouse floor. The sectional door closes
that the cylinder is capable of resisting the high
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 trailer doors can be opened safely and can 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 6 .
• 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.

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FOOD/MEAT INDUSTRY

1 2

3 4

5 6

23
THE DOCK
SHELTER
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:

• inflatable shelters
• curtain shelters
• cushion shelters

inflatable curtain cushion

shelters shelters shelters
e.g. WI, WIS e.g. WL, WE e.g. TP, TI

More Information?

25
 STERTIL
SUPERIOR SOLUTIONS

6.1 Inflatable shelters

Inflatable shelters incorporate air cushions Because trucks enter the dock 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.

26
6.2 Curtain shelters
Exceptional versatility and relatively low price make This construction ensures that the frame will hinge
this the most popular type of dock shelter. The curtains backwards when a misaligned truck fails to enter
(available in different materials) are positioned at a the dock properly. If the truck does enter correctly,
projection of around 600 mm from the facade. As the the frame remains at its standard projection at all
truck backs up, the curtains clasp the sides and times. However, we recommend that every effort is
roof, sealing the gap tightly. To assist trucks backing made to ensure that trucks always enter the bay
up, the curtains feature high visibility indicators. correctly. Wheel guides offer a cost effective means
The projection of a curtain shelter may be achieved of achieving this. (see chapter 10)
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, 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.

27
 STERTIL
SUPERIOR SOLUTIONS

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 supplied with an inflatable top cushion. The insulating
is not suitable for companies where palletised loads cushion then provides protection at the sides while
are being handled, as this increases the risk of the inflatable top cushion bridges any differences in
damage. During loading and unloading operations, height.

28
29
 STERTIL
SUPERIOR SOLUTIONS

6.4. T he 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:

A the type of dock shelter

B presence of bay or not, and its height

C highest exterior truck dimensions, unloaded

D lowest exterior truck dimensions, loaded

E width of trucks, including doors opening outwards

Dock shelters provide protection from moisture,

wind, rain and insects to promote a healthier
working climate

30
 The type of Highest truck
A C
dock shelter
1) Curtain shelters The minimum height of the dock shelter is
When determining the height and width, you should determined by the highest exterior truck dimensions
take into account, amongst other things, that the when unloaded.
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
Lowest truck
the frame and/or curtains. D
2) Inflatable dock shelters
The length of the dock shelter top cushion/curtain is
In the non-inflated condition, the trucks must stay
determined by the lowest exterior truck dimension
well within the free opening of the shelter. The reach
when loaded.
of the inflatable cushions must be selected such that
all available truck sizes are sealed.

3) Cushion shelters Truck width

In a cushion shelter, the trucks must back up into
E
the cushion with their loading space edges. Cushion
shelters are therefore usually smaller than the other
Particular account has to be taken of the widest
types referred to above.
trucks with open doors. For example, refrigerator
trucks with doors opening outward may have a
maximum width of around 2900 mm.
Presence or absence
B
of a bay, and how high
Dock shelters may be used in situations without
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
option. The height of the shelter is therefore
determined from the road level. In the case of a
loading bay, the dock shelter is usually mounted
with the bottom at dock level. The choice of the
shelter dimensions is therefore influenced, in part,
by the dock height selected.

31
 STERTIL
SUPERIOR SOLUTIONS

6.5 E xample 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 curtain 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.

32
33
 THE OVERHEAD
DOOR
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 connect 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 interior
of the dock shelter. The difference in dimensions is
also determined by the presence or absence of a bay
(is there a bay door or an entry door?). The minimum
width of an entry door is 2400 mm while the height
lies between 4300 and 4500 mm.
DOOR OPENING
TOO SMALL ✘
TOO SMALL CORRECT
The dimensions of a bay door are determined by:
• Truck width of the bay
the height 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 door can vary
between 2800 and 3000 mm.

DOOR OPENING
TOO SMALL
DOOR OPENING
CORRECT
✔

34
In the case of cushion shelters, the door width Another point to consider is how the loading bay
equals the interior width of the shelter. The shelter door should rise when opened. Warehouses are
size, in turn, depends on the truck dimensions. generally tall, enabling the door to rise vertically with
The height of the door opening depends on the little or no travel back into the building. This reduces
maximum truck height (3800 to 4200 mm). It is the risk of damage to the guide tracks by traffic
wise to add a safety margin to the maximum height passing through the opening.
- based on a bay height of 1250 mm, a door with
a height of 3000 mm will suffice.

In the case of curtain or inflatable shelters,

door dimensions of 3000 x 3000 mm is a
good choice

35
 INTERNAL TRANSPORT
EQUIPMENT
As described earlier in chapter 5, the length of the With electric hand pallet trucks, the battery takes
dock leveller is also determined by the type of internal over the operation. The maximum slope can then
transport equipment being used. Such equipment be 5%. The steeper the slope, the more energy the
is required to negotiate a slope during loading and battery must supply, and it will need recharging
unloading operations. The steeper the gradient, more frequently. With an electric forklift truck, the
the more energy is required to move the goods. slope can be no steeper than 10%. Here, too,
The energy needed to operate a hand pallet truck the same points apply as with electric pallet trucks.
is the pulling power of the employee. A forklift truck with a fuel engine (petrol/gas) has
sufficient power to take a slope of up to 15%;
Example: however, the legal maximum is 13%.
Pushing a four-wheel cart, loaded with 270kg of
goods, requires about 13.5kg pushing power. On a When a truck needs to be loaded above bay level,
slope of 4%, this increases to 22kg pushing power, the platform of the dock leveller is placed at a certain
and 40.5kg on a slope of 10%, i.e. three times as slope relative to the bay. However, the lip of the dock
much. The maximum slope for a hand pallet truck leveller MUST always lie flat on the truck floor. If not,
is 3%. dangerous situations can occur.

Maximum slope percentage for internal transport equipment

hand pallet truck 3 %

electric pallet truck 5%

electric fork lift truck 10 %

fork lift truck powered by fuel engine 15 %

36
Hand pallet truck Electric pallet truck Electric fork lift truck Fork lift truck powered
by fuel engine

With the lip lying flat on the truck floor and the plat- (see A). The combination of wheel centres, diameter
form at a certain slope, the LIP ANGLE is created. of wheels and clearance from the underside, deter-
A standard lip angle has been selected such that, mines the maximum lip angle. For a pallet truck, the
at a 13% slope, the lip lies flat, or 7.5º. The position lip angle cannot be 7.5º, but possibly 3.5º (see figure
of the dock leveller whereby the lip lies flat is the at bottom of page). When the lip angle is reduced,
effective range of the dock leveller. This means the slope whereby the lip lies flat will also become
there is an important difference between the highest smaller. In other words, the leveller’s effective range
position of the dock leveller and its effective range. is reduced and a different dock leveller model may
With pallet trucks, the lip angle may cause problems be required.

Please be aware, that the different types of

internal transport equipment require different
slopes which also implicates that the lip angle
(see A) must be adapted to the internal
transport equipment

37
 SAFETY STANDARD
EN 1398
EN 1398 Directive is the European safety standard The control box of the dock levellers (minimum
for dock levellers set up at the request of the EC protective class IP 54) must be equipped with an
member states. The standard lays down a number emergency shutdown feature and a lockable main
of points which manufacturers must meet with their switch. The coils of the electromagnetic valves must
design, manufacture and mounting of products. be suitable for continuous use.
Below we explain a number of these points.
Various dock products
The manufacturer must have the full technical docu- Naturally, the box must be placed in a location which
mentation for each dock leveller, including points like provides a good view of the dock leveller during its
stress calculations, cylinder buckling calculations operation.
and a description of the safety features applied.
Before a manufacturer markets a dock leveller, a All hydraulic components, such as cylinders and
prototype must be tested by properly trained staff. pipes, must be able to resist at least twice the
normal work load without causing damage or lasting
The required load bearing capacity of a dock leveller deformation.
is determined by the maximum weight (including load)
of a forklift truck, measured over one axle of the truck. A user manual, instruction labels and name plate,
The load is then measured over two 150 x 150 mm to be mounted on every dock leveller, will provide
surface areas. the user with information about user regulations,
manufacturer, country of origin, capacity and serial
The capacity of the model in question must be numbers.
established based on a shock factor of 1.5 and a
safety factor of 1.33 compared to the yield point For a full version of the EN 1398 Directive, please do
of the material. not hesitate to contact us.

Clearly recognisable CE symbol

38
Because of the permanent 380/400 Volt set-up, the restraint systems. (For more information, see chapter
INSTALLER guidelines apply to the installation of 10.) It is obvious that both government and leading
dock levellers as well as certain shelters. Operation institutions have given a lot of thought to guidelines
switches are one of the features that result from this concerning safety. In addition, there is a growing
guideline. The Veterinary Service has laid down a number of companies that have their own specific
number of requirements for certain sectors. In spaces policies covering such areas as safety, maintenance,
where open foodstuffs are being processed, dock fire prevention and the like. It is important to match
shelters have even been made obligatory. In many the operation of products to the regulations that
cases dock levellers must be specially prepared, for apply to the relevant user, sector or application.
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

39
ANCILLARY DOCK
PRODUCTS

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
 CLOSED PIT
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 CLOSED PIT
WITH LETTERBOX
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
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.

OPEN PIT
Curb angles WITH LETTERBOX

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.
1. STRAIGHT CURB ANGLES 2. QMS 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
CLOSED BOX
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.

PREFABRICATED CONCRETE PITS

41
 STERTIL
SUPERIOR SOLUTIONS

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:

Rubber Bumpers
• R-45-20-5 rectangular 450 x 200 x 50 mm
• R-45-20-10 rectangular 450 x 200 x 100 mm
• R-45-20-15 rectangular 450 x 200 x 150 mm
• L-45-45-10 L-shape 450 x 450 x 100 mm
• B-54-21-17 moveable 540 x 210 x 170 mm

Polyethylene (PE) Bumpers

• PE fixed model 554 x 220 x 140 mm
• PE-M height adjustable model
554 x 254 x 140 mm in lowest position and
811 x 254 x 173 mm in highest position

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 a range
of PE bumpers. These incorporate a front plate
manufactured from Ultra High Molecular Polyethylene,
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.

42
C. L oading 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. M ini Dock Levellers

EDGEDOCK Series and LA/HA Series
The flexible solution for small height
differences and existing loading bays
The EDGEDOCK and LA/HA Series Mini Dock
Levellers offer safety, operational effectiveness, and
easy installation. Mini Dock Levellers are an ideal
solution for situations where there is a minimal height
difference between the warehouse floor and the
vehicle and as a replacement in an existing loading
bay situation.

The EDGEDOCK has a patented design allowing for

maximum security with a 500 mm safety distance
between the dock and the vehicle and the platform
locks in an upright position. The EDGEDOCK and
LA/HA can simply be mounted on the front of the
EDGEDOCK/HA Series:
building and the LA/HA, if required can also be
electro-hydraulically operated
installed in a pit. The LA/HA has an open hinge lip
construction which has a lifetime warranty.

Both the EDGEDOCK and LA/HA Series have

dynamic capacities of 6 tons and meet all of the
safety requirements of the European Directive
EN 1398.

LA Series: manually operated

43
 E. Wheel guides. F. Vehicle Truck Restraint
Wheel guides, mounted on the approach to the load-
System COMBILOK ®
ing bay, increase safety during loading and unloading
To manage business operations in a responsible
and increase the life of dock shelters considerably.
manner, a reliable vehicle restraint system is a
Trucks are forced to enter centrally and the rounded
necessity within all loading bays. The risk of damage
shapes of the steel wheel guides are safe to tyres,
caused by accidents during loading and unloading
unlike the relatively sharp edges of concrete ramps.
activities increases significantly as a result of tight
The recommended interior distance between the left
time constraints. The communication between ware-
and right wheel guide is 2600 mm.
house staff and drivers (in their cabs) often leaves a
lot to be desired.
Wheel guides are easy to mount on concrete, concrete
Prematurely driving away from the dock while the
driving plates or cast models available for concrete.
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.

More Information?

44
G. Dock house
A dock house is a construction combining a dock The dock house can be built with a substructure
leveller and a dock shelter. It offers a good solution in steel or concrete framework. The top structure,
for situations where pit recesses cannot be built, for comprising of hot-dip galvanised profiles, can be
example in existing concrete bays. Cutting out floors clad with uninsulated sheeting or insulated panels.
is often an expensive and awkward job. When a dock The size of the dock house will depend on the
house can be placed against the existing facade, it shelter and dock leveller model selected.
can be simply moved after a few years 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.

45
Designed to make it
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!

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.

a member of the Stertil Group

a member of the Stertil Group
/Stertil-b-v- @Stertil
Stertil Dock Products
dp@stertil.nl
www.stertil-dockproducts.com
Tel. +31 (0)512 334444
The Netherlands
9288 ZG Kootstertille
P.O.Box 23
Stertil B.V.
95004110 How-to-Design-GB 12-2017. Stertil is a registered trademark of Stertil B.V.. We reserve the right to make changes in specifications without notice and without making changes retroactive.