Dock equipment

Content
1. We take care. p.6

2. Advanced Control Centre p.8

3. Dock design p.12

4. Dock levellers p.16

5. Mini dock levellers & l­oading ramps p.32

6. Lifting platforms p.36

7. Mobile dock leveller &

fixed dock board p.40

8. Dock shelters p.42

9. Dock houses p.52

10. Protection systems p.54

11. Automatic Truck Loading System p.60

12. Renovation & replacement p.64

13. Service p.66

5
 1. We take care.
Loading Systems delivers total solutions for loading and unloading with
the emphasis on ‘total’. As one of the European market leaders and
pioneers in the field of loading and unloading, we manage the complete
end to end process from consultancy, design, production, project super­
vision, ­installation and service. Our state-of-the-art R&D department, as
well as our flexible regional manufacturing locations guarantee a market-
­orientated solution to cater for all your logistical needs.

Managing Directors Ronald and Harald van Wijk

and the Loading Systems Management Team.

Pioneer in the field of

loading and unloading

6
Safe and efficient and the site arrangement is efficiently achieved dur­
Loading Systems organises the layout of your loa­ding ing the construction stage, our state of the art design
and unloading bays to ensure maximum safety and office will provide you with bespoke design details
efficiency. Whether it involves the design, installa­ and construction drawings.
tion, commissioning or maintenance: your require­
ments are the starting point for each element of our Dock equipment, industrial doors &
services. It goes without saying that our products and accessories
services comply with the European Machinery Direc­ Loading Systems offers a complete programme of
tive Guidelines and include CE-marking. All Loading products and services for your loading bays. To further
Systems companies are certified in accordance with complement your loading bay requirements, Loading
the valid national and international quality marks, Systems offers a wide range of supplementary acces­
such as ISO 9001:2000, VCA, Investors in People, and sories for you to choose from. Our ­Advanced Control
HACCP. Centre (ACC) even provides a practical web-based
software programme to assist you in the efficient
Totally free to focus on your own business management of your loading bays. Advanced Control
needs from the beginning to end ­Centre increases your ability to efficiently and pro­
By involving us from the start of the planning proc­ actively coordinate, monitor and manage the activity
ess, the services we provide allow you to have your of the vehicles and dock equipment around your
hands completely free so you can focus on your own ­loading bays.

business needs. We can provide you with extensive Always available

and fully detailed advice based on: your type of or­ With Loading Systems offices located throughout
ganisation, the site’s layout, frequency of loading and ­Europe, we are always close by. We are ready and
unloading, your type of vehicle fleet, your type of available 24 hours per day, 7 days per week. Our
­

internal material handling equipment and the type of ­expertly trained engineers ensure reliable mainte­
goods being moved around the site. Furthermore, we nance, certification, repairs and replacement of your
realise the importance of getting into the finer detail loading bay equipment whenever you call.
and can even advise you on the correct aesthetical
design of the loading and unloading bay openings. No matter where you are, or what your loading bay
To ensure a seamless interface between our products requirements are,
We take care.

7
2. Advanced
Control Centre
With the Loading Systems Advanced Control you can efficiently and
pro-actively coordinate, monitor, control and manage vehicle traffic
around your loading bays. The system is based on Dock Management,
Facility Management, Service and Statistics & Reporting modules.

Your loading and unloading

systems, monitored 24/7

8
2.1 Dock Management 2.2 Facility Management
The Advanced Control Centre Dock Management The Advanced Control Centre Facility Management mod­
module offers live information on the status of all your ule provides a real time status overview of all your load­
loading and unloading dock stations. Vehicles can ing and unloading bays at a glance. For instance, you can
be allocated to a loading bay by making a real-time quickly establish which doors are open or closed. With
reservation at the loading and unloading dock from authorisations in place, you can operate the doors by re­
a remote location. As soon as the vehicle docks at a mote control. The system allows you to receive an e-mail
loading and unloading bay, you immediately see what or text message if the opening time of a door exceeds a
is happening on the screen. The live status of the load­ preset time. There is also a surveillance walk-around fea­
ing bay equipment at the loading and unloading bay ture for checking loading bay lights which are left on, with
is also made continuously visible, including informa­ an option to switch them off from a remote location.
tion on whether the dock door is open or closed, or
whether a dock leveller is or is not in use. As soon as Energy-saving and safety
the vehicle departs on completion of the loading or Each time a door is unnecessarily opened expensive
unloading operation, the loading dock is automatically utilities energy is lost. The Advanced Control Centre
released for the next vehicle reservation. This elimi­ prevents unnecessary energy losses by improving the
nates unnecessary waiting time for the next vehicle to management of the vehicle fleet and the loading/un­
be loaded or unloaded and always guarantees that the loading process. Doors can be controlled so that they
correct vehicle is allocated to the correct loading bay. can only be opened during the loading and unloading

Dock Management - Advantages process and the doors can immediately be closed after
• Full control and a summary of the vehicles near the the loading/unloading cycle is complete.
loading and unloading bay.
• Improved efficiency and occupancy rate of your load­ Facility Management - Advantages
ing and unloading bay. • Improved security of your building.
• Reduced risk of errors: allocation of vehicles to the • Live summary status of the loading and unloading
correct loading and unloading bay. bays (i.e. door open / closed).
• Reduced waiting times for vehicles and improved • Possibility to link to your WMS system (correct goods
yard management. at the correct loading bay).
• Current summary of the occupancy rate, average • Environmentally-friendly; less energy loss and
loading and unloading times, number of vehicles ­reduced CO2 emission.
loaded/unloaded per loading bay, and a complete • Less absence through illness due to less draught and
overview of the loading and unloading bay status. an improved working environment.

9
2. Advanced Control Centre

2.3 Service All these features guarantee maximum operational up­

With the Advanced Control Centre Service module, time. By ensuring your equipment is maintained at the
your loading and unloading bay equipment is moni­ correct service intervals and by reacting to breakdowns
tored 24/7. The Advanced Control Centre informs a immediately at the time when they occur, you achieve
Loading System specialist on any loading and unload­ optimal efficiency by avoiding unnecessary waiting
ing bay equipment breakdowns. Problems can immedi­ time during the loading and unloading activity.
ately be analysed and solved, at times often remotely,
which significantly reduces operational disruption to Service module - Advantages
your loading and unloading activities. • Maximum uptime of your loading and unloading bay
equipment: 24/7 product monitoring.
Maintenance • Error codes sent automatically using modem tech­
Periodic maintenance guarantees maximum optimisa­ nology, and these can often be solved remotely.
tion of your loading and unloading bay equipment. Our engineers are informed even before you have
Based on measured usage, periodic maintenance can ­detected the problem yourself.
be automatically planned by the Advanced Control • Service and maintenance will be executed at the
Centre Service module. Naturally, any error or peri­ correct service intervals, ensuring extended product
odic maintenance requirements are visible in the Dock lifetime, and reduced lifetime maintenance costs.
­Management module. This module also ensures opti­ • Minimal operational costs and less administrative
mal operational management and prevents vehicles handlings.
from being directed to unavailable loading and
unloading bays.

Efficient,
environmental-
friendly and
safe

10
 2. Advanced Control Centre

2.4 Statistics & Reporting 2.5 Minimum investment

The Advanced Control Centre Statistics & Reporting The Advanced Control Centre is an easily accessible
module allows you to optimise transport and flow of solution and is fully web-based. It only requires minimal
goods. With the Statistics & Reporting module you (hardware) investments. The Advanced Control Centre
have the possibility to retrieve loading bay equipment is accessible from any PC with an internet connection,
usage rates, exact and average loading and unload­ and allows multiple authorised users to use the system
ing times, and the number of movements per loading simultaneously.
and unloading bay. Data can be used effectively and
efficiently to monitor and control your loading and un­ The Advanced Control Centre serves your purpose!
loading activity to optimise efficiency. • Easily accessible web-based solution, minimum hard­
ware investment.
Statistics & Reporting - Advantages • Accessible from multiple PC’s by multiple users si­
• Optimal summary of the loading and unloading bay multaneously.
operational costs. • Automatic software updates: you always have the
• Substantiated analysis to optimise vehicle traffic and latest software release available.
flow of goods.
The Advanced Control Centre allows you to manage
your loading and unloading bays in a cost effective,
environmental-friendly and safe way. Loading Systems
ensures maximum uptime and optimization of your
loading and unloading bay equipment.

We take care.

Accessible
solution and
fully web-based

11
3. Dock design
Loading Systems is eager to prove its reputation as a total solutions
provider and specialist, which is why we prefer to be involved at the
earliest stage of the planning of your new building or renovation of
your existing site. The design phase is the most critical stage of the
planning process for ensuring optimal usage and efficiency is achieved
throughout the facilities lifetime. You can rely on our knowledge and
expertise to assist you in the decision making process to achieve opti­
mal design layout of the loading bays, and best selection of the right
products for your operational needs.

Know-how, quality and

expertise under one roof

12
User-friendliness is largely determined
during the design phase

3.1 Site layout that the vehicle drivers have a clear view in their mir­
The directions of approaching vehicles as well as the rors during the vehicle docking process.
required turning circle space are both important fac­
tors when planning the site lay-out. Another important It situations where insufficient yard space is an issue,
factor to consider is the centre distance between each loading bays can be arranged on a saw tooth arrange­
adjacent loading bay to ensure adequate space is ment, or an indoor platform or a rising loading plat­
available to open the vehicle doors. It is also important form could be an option.

4.000 mm

1.400 mm

6.000 mm

12.000 mm

< 18.000 mm

13
3. Dock design

3.2 Loading and unloading platform 3.3 Platform height & tailgate opening
drainage The dock height is determined by the vehicle bed ride
When designing the yard immediately in front of the heights of most common vehicles. There might be
loading bay it is important to construct the yard drain­ exceptions when loaded and/or unloaded is by non
age so that surface water runs away from the building. standard methods.
The gradient of the yard should always be constructed
to ensure that docked vehicles are as near as ­possible
to the horizontal plane. This will ensure that any sur­ Vehicle bed heights:
face water on the roof of the trailer will run from the International transport (trailers): 1100 - 1400 mm
top of the vehicle top and not fall onto warehouse Distribution vehicles and trailers: 1000 - 1200 mm
operatives or any goods positioned in the door open­ Containers and removable containers: 1200 - 1600 mm
ing. When yard gradients are constructed correctly, it Refrigerator trucks: 1300 - 1500 mm
prevents damage to the dock doors, the surrounding Volume transport: 600 - 1000 mm
walls of the building and any premature damage to the
dock bumpers.

16.500 mm

3%

1,5%

10%
6.000 mm

12.000 mm

18.000 mm

When vehicles using a loading bay are equipped with

a hydraulic tailgate at the rear, we recommend that the
face of the loading bay is created with a tailgate open­
ing below the dock leveller. When docking the vehicle,
the tailgate lip is then positioned safely into the tail­
gate opening and prevents any damage to the vehicle
or dock face.

350 mm

3.000 mm 2.700 mm

14
 3. Dock design

3.4 Dock leveller - dimensions & load The dock leveller width depends on the vehicle clear
capacity width and the goods to be loaded / unloaded.
The dock leveller length is determined by the maximum
permissible working gradients for the internal transport
vehicle and the goods to be loaded/unloaded.

Admissible slope angle (a):

Hand pallet: max. 5.0 %
Electrical transpallet: max. 7.0 %
Electrical fork-lift truck: max. 10.0 %
Diesel or gas fork-lift truck: max. 12 %

2.000 mm

When electrically powered or hand operated pallet

trucks are used or when loading and unloading the last
load onto a vehicle below the warehouse level, then
dock levellers with a width of 2250 mm are recom­
mended.

A proper design 2.250 mm

­prevents ­damages
and ensures The required dock leveller load capacity is based on
the combined weight of the internal MHE equipment,

­functionality the operator weight and the heaviest load, but should
always be in accordance with EN 1398.

3.5 Dock shelter - type & specifications

The type of dock shelter, width, height and specifica­
tion of the sealing material are based on the vehicle
width and height, dock height and the sealing effi­
ciency required.

15
4. Dock levellers
Loading Systems PoweRamp dock levellers offer you the possibility to
bridge the difference in height and distance between the warehouse
floor and vehicle in the most efficient way.

Efficient and Loading Systems dock levellers ensure optimal bridging

is achieved between the dock leveller and the vehicle

safe loading
bed. Even if the vehicle bed is not entirely horizontal
due to uneven loading, the flexible platform construc­
tion will easily compensate the difference in height re­

and unloading sulting from the platform not being horizontal.

16
Everything we do revolves around the The standard load capacities are 60kN or 100kN. How­
needs of our customers ever, most load capacity requirements are possible.
Loading Systems can provide bespoke solutions tai­ During the loading or unloading process the vehicle's
lored to the customer’s specific needs. No project is upward and downward movement, or float, is auto­
too large or too small as we provide solutions for: large matically followed.
distribution centres, small warehouses with a single
loading bay, double-deck trailers or standard vehicles.
We can advise and supply you with solutions for new
build or refurbishment projects.

We have a solution for most loading bay applications.

Our comprehensive product portfolio and range of
options is designed to improve ease of use, safety, and
integration with other products or systems typically as­
sociated with loading bay activity. Naturally our prod­
ucts and solutions are designed to be incorporated
into the architectural aspects of the building.

We have more than 45 years experience of providing

products and solutions to all market sectors including The Loading Systems dock levellers are also suited to
but not limited to: logistics, material handling, storage, load or unload so called end loads below warehouse
food manufacturing, cold storage, transport, construc­ level.
tion, industry and government.

Options
Our dock levellers are available as hydraulic, including
extendable or telescopic lip, in a various range of di­
mensions, capacities, or built bespoke to your require­
ments. By selecting the options which best suit your
needs you can achieve considerable capital savings
but you also profit from lifetime cost savings through
improved efficiency, high quality and reliability and the
safety of your dock leveller.

The working range or lip angle can be adjusted to suit

specific requirements.

Dock levellers can be delivered in most colours or hot-

galvanised.

The 233M with extendable lip can be extended or

retracted by means of a separate control station. This
operation ensures an ultimately accurate positioning of
the dock leveller lip onto the vehicle bed. This ensures
you prevent damaging the last load into the vehicle,
also referred to as the end load.

17
4. Dock levellers

Durability Emergency stop facility

The robust construction and self-bearing characteris­ Loading Systems has a unique emergency stop safety
tics facilitate open or closed pit styles or even tailgate device integrated into the main cylinder which, unlike
openings. most hose rupture valve devices, is not temperature
sensitive or susceptible to failure.
The modular front beam on the lower frame serves to
protect the hydraulic and mechanical construction at
the bottom of the dock leveller.

The Loading Systems dock levellers include a fully

closed hydraulic system. STOP

STOP

Emergency switch
The control box can be provided with an emergency
stop switch with reset protection (panic stop) as an
option.

Anti-skid coating
The platform is provided with tear plate as a standard.
As an option the platform can also include an anti-skid
Safety coating which also has sound-absorbing properties.
The loading bay opening is typically an extremely
­active egress and ingress logistical opening, so good Leveller and door protection
route planning is essential to manage safety. Loading With manual or electrically operated doors, a dock
Systems can increase safety on and around your load­ leveller and door protection interlock can be fitted to
ing bay openings and can offer you an extensive range the dock leveller. This means the dock leveller can only
of products and accessories. be operated if the door is opened.

Low operating hydraulic pressure 1

The use of one single chrome hardened main cylinder
with double sealing ensures that the hydraulic system
has an extreme low operating pressure. This reduces
failures and increases durability.

18
 4. Dock levellers

Energy-saving & sound insulation Stepped dock or dock house

The Loading Systems products are typically located at For cold storage with refrigerator vehicles or fresh
the interface between the internal and external environ­ food processing environments where food contamina­
ments. We are often presented with the challenge of tion is a concern, it is important that vehicle doors are
keeping the cold out and the warmth in, or visa versa. only opened after the vehicle is actually docked. We
can offer a product solution for this requirement.
Loading Systems offers a variety of solutions for these
requirements. Our control boxes, which can be custom
made, play an important part in providing the best
solution. Please do not hesitate to ask for information
on how we can accommodate the sequential logic of
your operational needs into the control box, which can
be programmed to suit your needs.

ISO Dock solutions

Our hydraulic dock levellers 233M with extendable lip
of 1000 mm can be built-in into an ISO-dock layout.
This solution allows the industrial door to close in front
of the dock leveller, which ensures optimal insulation.
Durable draught sealing
Loading Systems has a durable solution to seal even
the smallest of gaps between the pit edge and the
dock leveller at the sides and at the rear.

Platform insulation
Dock leveller platform insulation not only improves
insulation but also provides sound-absorption.

Silent Block
The dock leveller 232M with extendable lip can be pro­
vided with Silent Blocks as an option. This significantly
reduces the impact sound made when the dock level­
ler reaches the lowest position.
Our dock levellers
comply with all safety Legislation
All Loading Systems dock levellers are provided with

requirements aspects a CE marking and complies with all safety aspects

stipulated in the European Directive EN 1398: 2009.

in the European Furthermore, the Loading Systems dock levellers are

extensively tested in both real life and simulation soft­
­Directive ware tests.

19
4. Dock levellers

4.1 232M dock leveller with extendable lip In compliance with EN 1398 it is not permitted to use
The Loading Systems 232M is an electro-hydraulic dock levellers outside the permitted gradients of
dock leveller with an extendable lip. Both the platform ± 12.5% (approx. ± 7°).
and lip are hydraulically driven.
Upon request, varying dimensional and working ranges
Dock leveller 232M - dimensions and working range can be provided to ensure the permissible tolerances
are achieved.
Metric dimensions (mm)

Construction
Length height A B A

2000 600 415 290

2500 600 370 280 O

3000 600 355 275
B
3500 600 315 270

4000 600 295 265

4500 900 355 600

5000 900 347 600

Platform width: 2000 or 2250 mm

Imperial dimensions (mm)

Construction
Length height A B

2170 600 400 285

2770 600 365 275

3370 600 325 270

Platform width: 1830 or 2100 mm

20
 4. Dock levellers

Lips Operation
The lip has a standard length of 400 mm and - if 100 The Loading Systems dock leveller 232M is operated
mm dock bumpers are used - a free loading surface of by means of a single button. By keeping the but­
225 mm depth on the vehicle bed can be achieved. As ton pressed, the platform will rise from its rested, or
an option a lip length of 500 mm can be provided, and parked position and will extend the lip automatically
we can also adjust the lip angle to suit your specific when the platform reaches the highest position. If the
applications. button is subsequently released, the platform and lip
will automatically lower to the vehicle bed level.

225 mm 400 mm

100 mm

The orthotropic construction is extremely robust and

also prevents pallet debris from hindering the hinged When used in conjunction with the “Auto-Return" but­
structure. ton option, the Loading Systems dock leveller will au­
tomatically return to its home position as soon as the
To increase the adaptability of the 232M, the lip can loading and unloading process is completed.
be supplied bevelled at the end or supplied with side
sections.

Dimensions,
­working range and
­load ­capacity can
be ­adjusted upon
­request

21
4. Dock levellers

4.2 233M dock leveller with telescopic lip Telescopic lip

The Loading Systems 233M is an electro-hydraulic The standard continuous telescopic lip can slide from
dock leveller with a telescopic lip. The platform and lip 0 mm up to 500 mm and has a free loading surface on
are hydraulically driven. the vehicle bed of 250 mm in depth. The board or lip
can be extended to a length of 1000 mm and the lip
Dock leveller 233M - dimensions and working range angle can be adjusted for specific applications, as an
option.
Dimensions (mm)

Construc-
tion
Length height 500 mm lip 1000 mm lip* 250
500

A B A B
100

2000 700 500 450 - -

2500 700 395 405 470 470

3000 700 415 380 490 430

3500 700 375 365 435 405

4000 700 350 350 400 385

4500 1000 400 640 450 700

5000 1000 400 640 450 700 To increase the adaptability of the 233M dock leveller,
the lip can be supplied bevelled at the end or sup­
Platform width: 2000 or 2250 mm
*) Optional plied with retractable side sections. These smooth run­
ning side sections prevent damage to the rear of the
docked vehicle.

In compliance with EN 1398 it is not permitted to use

dock levellers outside the permitted gradients of ±
12.5% (approx. ± 7°).

Upon request dimensions and working range can be

adjusted to the permissible tolerances.

22
 4. Dock levellers

Operation
The 233M dock leveller is provided with a 4-button Simple operation
control station as a standard.
with which the lip
Operation is extremely simple. By keeping the button
"Up" pressed, the platform will rise from its home or can be positioned in
parked position up to the required loading level.
an ultimate accurate
The individual buttons "Lip-In" and "Lip-Out" are
unique features. They allow operation of the lip when
manner
the platform is in any position. This provides extremely
accurate positioning of the lip onto the vehicle bed.

If the buttons are released, the platform and lip will

automatically lower to the vehicle bed level.

Activating the button “Auto-Return” (impulse) auto­

matically returns the Loading Systems dock leveller to
the home or parked position as soon as the loading
and unloading process is completed.

23
4. Dock levellers

4.3 253 dock leveller for vehicles and 4.4 256 parallel dock leveller for end load
delivery vans and high stacked goods
A single dock leveller solution which facilitates articu­ The parallel dock leveller ensures easy loading and
lated vehicles and delivery vans? The PowerRamp 253 unloading of end loads and high stacked goods. The
can accommodate both. dock leveller is provided with a parallel section at the
front side, to enable the MHE vehicles to always enter
The dock leveller has a segmented lip or board. The the vehicle horizontally.
dock leveller can be used as a "standard" dock level­
ler with telescopic lip for articulated vehicles. Or al­
ternatively, when used for loading or unloading vans
only the centre section of the lip or board slides out.
Furthermore, the dock leveller load capacity can be
adjusted to prevent overloading the delivery van.

1.500 mm

5.500 mm

400 mm
1.200 mm
400 mm

Special dock levellers for

special applications

24
 4. Dock levellers

4.5 CombiControl Easy to install

Loading Systems is a total solution supplier, and not By designing the controls so that only a limited amount
only provides control systems for basic operation of of space is required, our controls can easily be installed
individual products, but we also provide control sys­ in even the most space restricted environments.
tems for totally integrated operating systems. This
means that Loading Systems delivers combined control Accessories
boxes for dock levellers, inflatable dock shelters, dock All control boxes can easily be adapted to accept most
shelters with electrically operated top curtains, and Loading Systems Accessories, and can easily and retro­
industrial doors and accessories. spectively be modified to be integrated in the sequen­
tial logic to improve safety on or around the loading
Integrated solutions dock to reduce damage and reduce energy consump­
From an aesthetic perspective, integrated solutions are tion.
more attractive than individual control boxes delivered
by some suppliers. By combining the operation of your Docking Assistant
loading bay products into one single control station, By means of "green and red" signals the Docking As­
only one power supply is required. You will not only sistant provides an indication of the distance between
save on installation costs but lifetime maintenance and the rear of the vehicle and the loading and unloading
repair costs can also be reduced. bay. This system simplifies docking and reduces risk of
vehicle damage.
Sequential logic
When using sequential logic, the Loading Systems
products and accessories combined with the Combi­
Control control boxes can be programmed to suit your
exact operating sequence as a standard feature.

Standard “Auto-Return” and possibility to include

automatic sequential logic
All dock leveller control boxes can include an “Auto-
Return" button, allowing the dock leveller to automati­
cally return to its home position as soon as the loading
and unloading process is completed.

The automatic sequential logic ensures that the Com­

biControl can be set so that upon activation of the
“Auto-Return” button the industrial door, in conjunc­
tion with the door safety edge option, automatically
closes as soon as the dock leveller returned to its
home position.

Main power switch

All control boxes include a main power switch with pad­
lock safety in accordance with EN 418 as a standard.

Advanced Control Centre

All controls have been prepared for the Advanced
Control System. No error-sensitive and expensive con­
trol boxes are required to detect the product status
when Loading Systems control boxes are used. All con­
trols include LED indication to display the product sta­
tus, and as an option can immediately report a failure.

25
4. Dock levellers

Warning lights Vehicle detection sensor

It is possible to include traffic signal lights to work The sequential logic in the control box can be set ac­
either independently or in conjunction with a warn­ cording to your preferred choices. The sequential
ing light in the control station to improve safety on or logic, combined with the vehicle detection sensor, can
around the loading bay. ensure that the industrial door opens only after a vehi­
cle is docked. This creates a safer loading or unload­
As soon as the loading and unloading system is activat­ ing situation on and around the loading and unloading
ed, the external stop light switches from green to red bay: a fork-lift driver can no longer drive backwards
(unsafe to depart), and as soon as the dock leveller lip onto the platform unexpectedly. Furthermore, this
is positioned on the vehicle bed, the warning light on also significantly reduces energy loss, as the door only
the control box inside, switches from red to green. opens after the vehicle is "sealed' onto the loading
bay.
As soon as loading and unloading is completed, and
the system returned to its home position, the external Alarm
signal light switches from red to green and the warm­ The control box can be supplied with an acoustic alarm
ing light inside switches from green to red (unsafe to which is combined with a vehicle detection system.
load and unload). If the vehicle departs the loading and unloading bay
prematurely, thus creating a dangerous situation, the
acoustic warning signal will automatically be activated.

26
 4. Dock levellers

Wheel chocks Roll off safeguard fence

The wheel chock electric sensor detects the presence The roll off safeguard fence is positioned in front of
of a vehicle at the loading and unloading bay similar the dock door to ensure that no one can accidentally
to the vehicle detection sensor. After the vehicle is de­ fall onto the loading platform as soon as the door is
tected, the sequential logic can be operated by means opened.
of the products (door or leveller).

Safe and CE-TUV certified

Dock lights The control boxes comply with all relevant European
Dock lights increase visibility around the loading and standards and are CE-TUV certified. Quality and safety
unloading bay. Dock lights can be programmed so that are in accordance with the valid standards.
they illuminate the rear of the vehicle as soon as the
dock leveller is activated.

A wide variety of accessories to

improve safety on and near docks

27
4. Dock levellers

4.6 Built-in possibilities and saving options most applications, and we would be pleased to consult
Loading Systems offers a large variety of built-in with you on the best options to suit your requirements.
possibilities and architectural elements to meet all Good advice will result in significant savings on con­
customer-specific preferences. We have a solution for struction and lifetime cost.

Choose from a range of built-

in options for all situations to
­ensure c­ onsiderable savings on
­construction and lifetime costs

28
 4. Dock levellers

Self-bearing "hang in frame", integrated into the to the leveller during production. The dock leveller and
dock leveller (Pit box system 310) frame are installed in the concrete recess by welding
Pit box model 310 is a fully “open” construction, onto the existing reinforced concrete pin, which is then
whereby the dock leveller "hangs in" the pit box with back filled with concrete.
the tailgate opening immediately below the dock lev­
eller. The frame dimensions are maintained during con­ Advantages:
struction by diagonal bracings which are already fixed • Very quick assembly.

Pit box system 310

Pit box system with intermediate floor (Pit box sys- Advantages:
tem 320), console (Pit box system 330) or fully sus- • The dock leveller is delivered in a lowered transport
pended (Pit box system 350) position, which could result in significant savings (ap­
These pit box models are fully suspended and provid­ prox. 50%) on transportation costs.
ed with a concrete intermediate floor or raised edge. • Filling with concrete is not required.
For this pit box model, the frame is welded onto to the • Very quick assembly.
leveller during production. • After assembly, the dock leveller is immediately
ready for use.

Pit box system 320

Pit box system 330

Pit box system 350

29
4. Dock levellers

Box model with concrete form (Pit box system 340) around the leveller and the permanent formwork is
With pit box model 340, the dock leveller is provided removed under the leveller.
with a concrete form during production. The dock
leveller including concrete form is placed on a "tem­ Advantages:
porary" or permanent wooden formwork or shuttering, • Very quick assembly.
after which the leveller and pit box are welded onto • Low construction costs, no complex and expensive
the reinforced concrete. The concrete is then poured formwork.

Pit box system 340

Self-bearing "hang-in frame", integrated into the Advantages:

dock leveller (Pit box system 360) • Filling with concrete is not required.
Pit box model 360 is a fully “open” construction, • The pre-mounted frame can be fixed to the floor
whereby the dock leveller "hangs in" the pit box with plate prior to mounting the dock leveller.
the tailgate opening positioned immediately below the • Very quick assembly.
dock leveller. The frame diagonal bracings are already • After assembly, the dock leveller is immediately
fixed to the leveller during production. The dock level­ ready for use.
ler is welded on the pre-mounted frame in the con­
crete recess.

Pit box system 360

30
 4. Dock levellers

Self-bearing "hang-in" frame, integrated in the dock 370) or around (pit box system 375/380), to ensure that
leveller, suited for building-in with prefab concrete it can be adjusted to the same level as the warehouse
systems (Pit box system 370 / 375 / 380) finished floor level.
These pit box systems are similar to the pit box system
360, however these also include anchors all around Advantages:
the frame. The front side of the frame is supported by • Very quick assembly.
a prefab concrete system. The frame is provided with • Low construction costs, no complex and expensive
adjustable screws in the back frame (pit box system formwork.

Pit box system 370

Pit box system 375

Pit box system 380

Low construction costs and extreme

quick and simple assembly

31
5. M
 ini dock ­levellers
& ­loading ramps
Loading Systems offers a complete programme of mini dock levellers and
loading ramps for bridging small differences in height between the loading
and unloading bay and the vehicle bed. The mini dock levellers and load­
ing ramps can easily be installed in new buildings or into existing buildings.

For bridging minor

­differences in height

32
5.1 105 mechanical mini dock leveller with 5.2 106 dock leveller - mechanical balance
extendable lop The dock leveller Levelmaster 106 is mechanically bal­
The Loading Systems 105 is a mechanical mini dock anced and is mainly used in situations which do not
leveller with an extendable lip. The platform and lip facilitate a built-in traditional type of dock leveller, or in
are mechanically operated. The mini dock leveller 105 situations which have a minimum difference in height
is mainly used in situations which do not facilitate a between the vehicle bed and the platform.
built-in traditional type of dock leveller, or in situations
which have a minimum difference in height between
the vehicle bed and the platform.

Advantages:
• Compact product, minimum assembly time.
• Operated by one person.
• Automatically follows the vehicle's movements.
• Safe bridging of the difference in height between
loading bay and vehicle bed.
• Automatic return to home position after the vehicle
departs the platform.
• Safety: cannot be removed.
• Minimum maintenance requirements.

33
­5. Mini dock levellers & loading ramps

5.3 115 mobile loading platform 5.4 116 mobile container loading lip
The mobile loading platform includes an aluminium The mobile aluminium and steel container loading lips
anti-skid tear plate for the loading and unloading of are used when loading and unloading containers. This
vehicles with hand pallet trucks or roll containers MHE. product is designed to be lifted by a forklift truck so it
can be moved quickly and easily around the facility.
Advantages:
• Light-weight transport.
• Anti-skid surface.
• Low manual handling weight.
• Easy cleaning.
• Weather resistant.
• Safety against unwanted use.
• Limited investment.

5.5 117 loading lip for train or goods

waggons
Aluminium loading lips are specifically well-suited for
loading and unloading trains or goods waggons. In its
parked position the loading lip is in a vertical position
on the platform. When loading and unloading the lip is
raised or lowered from a guide rail fitted on the edge
of the platform by using an integrated handle to posi­
tion the lip on the goods waggon bed and when not
needed returned back to the guide rail parked position.

34
 ­5. Mini dock levellers & loading ramps

5.6 125 aluminium loading lip 5.7 126 steel loading lip
Aluminium loading lips are well suited for bridging Steel loading lips allow bridging over a greater degree
small to medium differences in height. These lips can of loading and unloading heights. With load capacities
be operated by a single person, with no additional as­ up to 6 tonnes, differences in height of up to 250 mm
sistance required! The loading lips can slide sideways can be bridged. All models are available in either sta­
and are parked in a vertical position on the platform tionary or sliding versions. A maintenance-free spring
when not in use. An automatic lock retains the lip in system allows operation by one single person even on
a safe parked position, preventing any unintentional the higher load capacity models. An automatic lock
movement of the loading lip. retains the lip in a safe parked position when not in
use, preventing any unintentional movement of the
loading lip.

Easy single person operation

35
6. Lifting platforms
The Loading Systems PowerLift lifting platforms bridge large differences
in height between street level and the vehicle bed or between the
platform and vehicle bed.

The PowerLift is a hydraulic scissor lifting platform,

based on a modular concept. The modular concept
facilitates a wide range of heights and loading capaci­
ties. Because our products are made bespoke we can
manufacture a products to suite your requirements.
Durability, quality, safety, functionality and user-friend­
liness are the Loading Systems scissor lifting platform
main characteristic features.

36
Easy bridging of large
­differences in height

Durability and maintenance Customer specific solutions

• High-quality steel ensures ultimate platform stability • Bespoke options are available to meet most cus­
and robustness. tomer specifications and to increase the ease of use,
• The lower frame is vibration free and protected safety, and facilitate integration with other products
against external damage. or systems related to the loading and unloading bay
• The hydraulic power-pack is fully enclosed, offering area. Naturally, these options also include solutions
protection even in the harshest of surrounding envi­ to adjust the system to the architectural aspects of
ronments. the building.
• The platform includes an inspection hatch for quick
and easy maintenance.
• Maintenance-free roller bearings guarantee a longer
life.

Quality and safety

• PowerLift lifting platforms comply with all EN 1570
­safety requirements and CE-marking requirements.
• CNC processes ensure optimum precision and finish
of manufactured components.
• PowerLift lifting platforms include a safety edge to
all sides.
• The hydraulic system includes overpressure protec­
tion and a check valve, to guarantee that the hydrau­
lic system will not be damaged due to overpressure.
• High-quality hydraulic cylinders include hose rupture
protection. In the event of a hose rupture the lifting
table locks in position.
• Support legs at all four corners provide the highest
degree of stability when the platform is in the lowest
position.

Functionality and user-friendliness

• Easy operation by means of a manually operated
control station.
• The lifting height can easily be adjusted by a continu­
ously regulated end stroke switch.

37
6. Lifting platforms

6.1 Electro hydraulic lifting platform for 6.2 Electro hydraulic lifting platform with
loading and unloading goods segmented horizontal exit ramp

• Well-suited for bridging large differences in height • A segmented exit ramp can also be supplied in order
• Simple operation by means of a manual control sta­ to allow adjustment to different vehicle widths.
tions provided with an optional key switch to prevent • The segmented exit ramp is designed and manufac­
unintended use. tured to withstand high wheel point loads, making
• Designed and manufactured to function optimally the platform well suited to fork-lift truck or pallet
even in the most extreme environmental circum­ truck traffic.
stances. • The exit ramps can be fixed to either the short or
• The platform is provided with an anti-slip surface long sides of the platform without jeopardising the
to provide optimum stability and robustness and is stability of the lifting platform.
designed and manufactured to withstand high wheel • The platform and exit ramp include an anti-slip tear
point loads. This makes the lifting table well-suited plate to significantly reduce the risk of sliding.
to use with loaded pallet trucks or fork-lift trucks.

6.3 Electro hydraulic lifting platform

with barriers

• Operator safety is further enhanced by incorporating

safety barriers into the platform.
• Operating stations can be installed on the platform
to increase ease of operation whilst working on the
platform.
• Built from high quality materials guarantees a longer
life span and minimum maintenance.

38
 6. Lifting platforms

6.4 Lifting platforms for double-decked 6.5 Options and accessories

trailers The extensive Loading Systems PowerLift standard
Loading Systems delivers double-decked lifting plat­ programme can be extended based on bespoke cus­
forms for vehicles with a double-deck bed. tomer specific requirements with a variety of options
and accessories.

Some options and accessories are:

1. Horizontal exit ramp supplied as either hydraulic or
mechanical operation.
2. Hot-galvanised steel wire skirts to underside.
3. Anti Roll-off safety stop on the platform.
4. Platform lock in concrete.
5. Increased dimension of the platform upon request.
6. Removable barriers (insert).
7. RAL colour-selection.
8. Partial or fully hot-galvanised model.

1 2

3 4

The standard
­programme can be 5 6

extended with a
­

­variety of options
and accessories

39
7. Mobile dock
leveller & fixed
dock board
When there is no loading platform available, a mobile dock leveller
is the ideal solution to bridge the difference in height between the
­vehicle bed and the yard.

Easy application if no loading

platform is available

40
7.1 130 mobile dock leveller 7.2 135 mobile dock leveller for loading
The fork-lift truck can enter the vehicle by means of the and unloading from three sides
mobile dock leveller. It is easy to change the position of The mobile dock leveller has a hand-operated winch in
the dock leveller by means of a fork-lift truck. the front axle or an electric drive which can be adjusted
in height. The mobile dock leveller allows simultaneous
Often there is only a limited manoeuvring space avail­ loading and unloading of three vehicles or containers.
able however, the mobile dock leveller centre axis allows
easy relocation of the mobile dock leveller. A manually
operated hydraulic or electro-hydraulic pump is used
to raise the mobile dock leveller to the required height
which can then be lowered onto the vehicle bed or con­
tainer floor.

After locking by means of a quick-acting lock the centre

axis is moved into a suspended or floating position. The
centre axis has no bearing function during the loading or
unloading process, which allows the mobile dock leveller
to follow the upward and downward vehicle movements
as the vehicle is loaded or unloaded.

7.3 140 fixed dock board

The dock board is a fixed device which bridges the dif­
ference in height between the loading and unloading
platform and yard level.

41
8. Dock shelters
Loading Systems dock shelters are manufactured to provide optimum
­stability and durability. Dock shelters provide an optimum seal between
the internal and external environments, and assist with the reduction of
energy consumption. As well as protecting your goods, dock shelters also
contribute to an improved workplace atmosphere which can also lower
your absence rates due to illness. A complete range is available to suit
­different types of vehicles.

Quality and durability

All Loading Systems products meet the highest qual­
ity requirements. For dock shelters we only choose the
highest quality materials to provide a high degree of
wear resistance which can also withstand the effects of
UV-radiation as well as extreme temperatures.

Loading Systems only selects stable constructions to

ensure that our dock shelters continue to maintain the
best possible appearance over a prolonged period of
time and the lower sides will show no deflection.

42
8.1 400 cushion dock shelter The horizontal top cushion can be supplied at a fixed
The cushion dock shelters is best suited to vehicles height or can be supplied with an optional manual or
which have minimal differences in size, for example a electrical adjustment.
dedicated vehicle fleet.

Loading Systems cushion dock shelters are often used

at loading bays where high frequency of swapping
­vehicle trailers is common practice, or for use with 250-350 mm
600-700 mm
­mobile containers.

The cushions are available in a variety of different sizes

(depth - width) and can be supplied with variety of col­
our options.

For extreme use, Loading Systems recommends

reinforced side cushions by means of overlapping
The cushion dock shelters ensure best draught seals armoured plates along the entire height. These ar­
and insulation is achieved. Sealing of the smallest moured plates follow the upward and downward
gaps between the vehicle and wall of the building is movement of the docked vehicle. This increases the
achieved in most cases. lifespan and durability of the dock shelter.

Cushion dock shelters ensure the most

­efficient and effective draught sealing
and insulation
43
8. Dock shelters

8.2 403 curtain dock shelter Built-in

The Loading Systems curtain dock shelters can be used Based on your preferred aesthetical requirements, the
for a wider variation of purposes and are well suited curtain dock shelter can be incorporated into the wall
for loading and unloading operations with a wide vari­ of the warehouse or can be installed onto dock houses.
ety of vehicle heights and widths.

A wide range
of ­options
to ­adjust the
­building’s
­architectural
­aspects

44
 8. Dock shelters

Robust hinged frame Enclosing seal or projection cover – continuous

Most curtain dock shelters are delivered including a The top and side curtain (or projection cover) is made
hinged frame. The frame design provides protection from one uninterrupted continuous seal which prevents
against damage if the docking vehicle is too high, or if contamination or draughts into the warehouse environ­
a vehicle docks off centre. The front frame of the shel­ ment.
ter moves on the hinge ensuring that the dock shelter
and/or vehicle will not be damaged.

As a standard the dock shelter will move upwards to

ensure that even in a compressed situation, the top
curtain will not hang in the clear width during loading
or unloading.

Drainage
The design of the uninterrupted seal or projection
cover ensures optimum drainage of the shelter roof,
preventing water ingress into the door opening or
onto the goods during loading and unloading. Drain­
age must be taken into account when designing the
loading and unloading bay to ensure that rainwater will
In situations with a low clearance height between the not run from the vehicle top into the loading and un­
top of the shelter and any building overhang or cano­ loading opening.
py, a shear arm construction is recommended, which
allows the shelter front frame to compress without in­
creasing in height.

Dock markings
To assist the vehicle to dock on the centre of the load­
ing bay opening, markings on the dock shelter curtains
serve as guidance for the driver.

45
8. Dock shelters

Optimal sealing Innovative rolling curtains to bridge differences in

Selecting the correct width, height and depth of the height
dock shelter, in combination with the height of the top When the difference in height between the shelter and
curtain and the width of the side curtains ensures opti­ the vehicle height is too large for a standard length
mal sealing between the warehouse and vehicle whilst top curtain, dock shelter can be supplied with an ad­
also providing a clear opening through which to load justable top curtain. This could apply to loading and
and unload. unloading openings which are used for both high and
low height vehicles, such as double-decked trailers and
Since each loading and unloading situation is unique, single deck vehicles or even delivery vans.
Loading Systems can deliver any required dock shelter
width or height. Furthermore, the top curtain and side
curtains are also available in a variety of dimensions.

Dimensions

Width 3200 up to and including 3600 mm

(standard 3400 / 3500 mm)

Height 3200 up to and including 4600 mm

(standard 3400 / 3500 / 4600*mm)

Depth 0 / 600 / 900 mm

Side curtains - 600 / 700 mm

Width

Top curtains - 900 / 1000 / 1200 mm The electrical driven Loading Systems Rollerblind
Height
bridges a difference in height up to 2500 mm. The
* Exit ramp model Rollerblind is integrated in the Loading Systems
­CombiControl control boxes.

The Rollerblind can also be retrofitted to existing

­shelters and most other dock shelters supplied by
other manufacturers.

46
 8. Dock shelters

Top curtains and side curtains Recommended options:

To ensure optimum flexibility and durability the side 1. dock number on top curtain
curtains on Loading Systems dock shelters include a 2. bottom corner pads
monofilament in the fabric or we can reinforce the ma­
terial with a laminated suspension spring.

To achieve an optimal seal it is essential that the top

curtain folds over the corners of the vehicle. This re­
quires an extremely flexible construction which is why
Loading Systems uses a polyester fibre with multifila­
ment weft or fabric which is reinforced with laminated
suspension springs.

Top curtains are also available with the following

options:
1. standard top curtain
2. double laminated top curtain
3. cut-in top curtain

1 2 3

Heavy fabric can be delivered as a standard, either in

black (≈RAL 9011) or in blue (≈RAL 5010). The fabric
reinforced with laminated suspensions spring is avail­
able in a variety of colours.

The dock markings are available in a wide variety of

colours. This allows you to fine-tune the colours to
your corporate image or you might want to match the
­colour scheme to the dock leveller or industrial door.

Wide range and flexibility is well suited for

loading bays with a variety of vehicles

47
8. Dock shelters

8.3 405 curtians dock shelter with a special Roof section - adjustable in height
foam core The 405 curtain dock shelter is provided with a roof
The Loading Systems PowerShelter 405 curtain dock section which has an automated lifting roof, which al­
shelter is extremely durable. This is achieved by a lows the roof to lift or move backwards when used by
special foam core built into the side sections and an "high"vehicles (up to 4500 mm).
automated lifting roof section. This increases the life
span of the dock shelter and improves the aesthetical
appearance of the warehouse.

Side sections - allowing sideward and backward

compression
The Loading Systems 405 curtain dock shelter side sec­
The 405 dock shelter is particularly well suited to con­ tions provide optimum flexibility and are supplied with
tainer vehicles or vehicles which raise and lower over a foam core which significantly prevents damage which
extreme distances during the loading and unloading can frequently occur if a vehicle docks on off centre.
process. For this type of situation the 405 curtain dock
shelter is the perfect solution.

Loading Systems dock shelters

are attractive, ultimately robust
and durable

48
 8. Dock shelters

8.4 407 inflatable dock shelter Built-in or front building

The Loading Systems PowerShelter 407 inflatable dock Based on aesthetics of the building, the dock shelter
shelter moulds itself into the contours of the vehicle can built-in into the warehouse at the construction
and is the most effective way of sealing between the stage or it could be incorporated into a dock house.
vehicle and the warehouse. It is particularly well suited
to vehicles which vary significantly in size.

Large variety of vehicles

The 407 inflatable dock shelter is extremely well-suited
for a large variety of vehicle heights and widths. The
inflatable top cushion can be inflated up to a height of
1700 mm without bulging outward, as an option. The
Loading Systems 407 inflatable top cushion stops un­
folding upon contact with the roof of the vehicle.

Extremely well-suited to level access ramps

The inflatable dock shelter is excellently suited to level
access ramps. When not inflated, it leaves the opening
of the level access ramp completely free of obstruction
allowing the building to be accessed without any hin­
drance to the opening. The 407 dock shelter facilitates
the effective sealing of both high and low vehicles in­
cluding delivery vans.

49
8. Dock shelters

Dimensions Durable materials & construction

The inflatable cushion, which includes a folding opera­ During the docking process, the inflatable cushions are
tion, is delivered by Loading Systems in a variety of fully retracted behind the docking lane markings. Only
dimensions. inflates when the vehicle has effectively docked on the
loading bay with the cushions inflating within seconds.
The steel insulation sandwich panels for the roof and Due to low contact friction between the shelter and
side panels can be manufactured in various colours. the vehicle, the 407 dock shelter is an extremely dura­
The same applies to the dock markings and cushions. ble model.

Dimensions

Width 3200 up to and including 4500 mm

(standard 3500 mm)
Height 3700 up to and including 6000 mm
(standard 3700 mm)
Depth 0 up to and including 1200 mm
(standard 800 mm)

Side cushions -
Width 600 / 700 / 800 mm

Top cushion -
Height 1100 / 1300 / 1500 / 1700 mm

The most
­efficient and
durable sealing
for loading
and unloading
bays

50
 8. Dock shelters

In the event of a docked vehicle departing unexpect­ Integrated operation

edly while the cushions are still inflated, the free mov­ The Loading Systems 407 dock shelter control station
ing fastening ensures that the inflated cushions can is integrated in the Loading Systems CombiControl
rotate outward, which prevents damage to the shelter control boxes. Upon request, the 407 dock shelter can
components and cushions. also be programmed to suit the logic of your preferred
operating sequence. To ensure optimum effective­
When compared to other Loading Systems dock shel­ ness is achieved we always ensure that the loading bay
ters, the 407 dock shelter cushions are extremely tear- door can not be opened until the 407 dock shelter is
resistant and are resilient to damage by sharp or pro­ inflated.
truding vehicle parts or premature vehicle departures.
The welded black PVC fabric cushions are also resilient
to extreme weather conditions.

The heavy duty fabric used in the Loading Systems

cushions is extremely leak resistant. Loading Systems
also uses a mechanical tube motor driven retraction
which ensures the cushions are always neatly stacked
behind the dock lane markings when not inflated.

51
9. Dock houses
Investments and tax advantages are something you should always con­
sider when designing the warehouse layout. This is where dock houses
can be an economic attractive alternative to traditional dock leveller
pit systems. A cost-effective externally mounted dock house improves
the utilisation of the relative expensive internal warehouse space within
the building.

Economically attractive
Only a minimum of structural factors need to be con­
sidered for a dock house. This is why dock houses are
also well suited to expanding existing buildings, and as
the design is a modular portable construction they are
particularly well suited to locating on leased proper­
ties. Furthermore, in new building projects, dock houses

52
are significantly more cost effective because the design Dock houses can be delivered either as individual units
does not require expensive concrete openings or pits or linked together. When external yard space restric­
creating in the building for dock levellers. Dock houses tions are an issue, we can even offer single units or
can easily be relocated to another part of the building linked units in a saw tooth arrangement.
or can even be relocated to an alternative site if this
is something which you are considering at sometime
throughout the products lifetime. Furthermore, be­
cause the loading and unloading opening is situated in
a dock house externally, this allows the warehouse en­
vironment to be fully closed which means that the dock
house is also a HACCP solution.

Thermal insulation benefits

Due to thermal separation between the building and Dock houses can also be designed to allow the vehicle
dock equipment, sealing of the building is improved doors to be opened after docking.
resulting in significantly improved energy efficiency.
Platform construction
Fully integrated modular construction In situations where insulation or extreme weather
The dock house incorporates a steel platform with conditions are an issue, Loading Systems can offer
the required size of dock leveller and dock bumpers standard or customized dock house platforms in either
to suite your operational needs. We offer a selection insulated or un-insulated constructions.
of insulated and non-insulated roof and wall panels in
several colours, profiles and finishes to match your re­
quirements and in most cases we can even match the
existing scheme of the building. The front of the dock
house can be sealed with the addition of a dock shel­
ter which is available as an option.

By integrating a dock leveller into the dock house most

dock heights can be adapted to provide a seamless
interface between the vehicle height and the internal
warehouse floor.

53
10. Protection
­systems
The area around the loading bay and the vehicle can be a dangerous
working zone. Vehicles have been known to drive away from the loading
bay prematurely during the loading or unloading process, this is known
as a “Drive-Off”. When this happens, the resulting consequences can
lead to serious injury or even a fatality. Vehicles “creeping” from the
loading bay can also lead to a dangerous situation.

10.1 505 vehicle restraint system "Creeping" of a vehicle or trailer

Another unsafe scenario is caused by "creeping".
Premature vehicle departure or “Drive-Off” When a forklift truck or MHE moves from the ware­
Most accidents near and on the loading and unloading house to the vehicle the resulting momentum forces
platform are caused by premature vehicle departure or can cause the vehicle to creep away from the ware­
“Drive-Off”. This is often due to inadequate commu­ house. When this scenario occurs, the dock leveller lip
nication between the vehicle driver and forklift truck can drop from the bed of the vehicle which can also
driver, or perhaps the warehouse operative. lead to a dangerous situation. This scenario can occur
even when the brakes of the vehicle are activated and
the wheels are chocked. When this scenario occurs, the
dock leveller lip can drop from the bed of the vehicle
which can also lead to a dangerous situation.

54
When this happens, the resulting consequences can Communication
lead to serious injury or even a fatality. The Loading The wheel lock system's movement is indicated by
Systems PowerLock 505 prevents vehicles and trailers means of an acoustic and optic signal. External (red/
from “Drive-Off’” situations and also prevents vehicles green) and internal (red/orange/green) signal lights
from "creeping" away from the loading bay. indicate that the vehicle is locked and restrained, and
that loading and unloading process can be safely initi­
The Loading Systems vehicle restraint system locks ated. Clear and concise signage is also provided for
most vehicles or trailers onto the loading bay to create the vehicle driver giving clear instructions on when it is
an ultimately safe situation. safe for the driver to depart from the loading bay.

Construction
The robust, hot-galvanised construction is designed
to keep a parked vehicle locked safely in place. The
design also incorporates an integrated vehicle wheel
guide which ensures that the vehicle is always posi­
tioned in the centre of the loading or unloading bay.
These design features ensure the loading and unload­
ing process is a simple process and also prevents dam­
age to the equipment and vehicle.

The hydraulic Powerlock 505 can easily be installed on

a concrete floor, steel plates and most other surfaces.
PowerLock 505 - Benefits The system is designed to be robust enough to cope
The PowerLock 505 can easily be operated and is and perform under all weather conditions.
virtually free from failures. This is achieved because
we have designed a product with a limited number Benefits
of moving parts. We have designed a product which • Optimal safety.
restricts the number of mechanical drives to only the • Suitable for most types of vehicle models.
essential components. This also results in simple and • Push button operation for hydraulically locking /
minimum maintenance requirements. ­unlocking of the vehicle.
• Possibility to interface and interlock with dock
­leveller and industrial door controls.
• Automatic vehicle wheel detection.
• Theft-prevention benefits (unlocking of wheel from
the inside only).
• Functions as a wheel guides for docking vehicles.
• Functions under all weather conditions.
• Hot-galvanised materials.
• Powerpack mounted remotely.
• Maintenance-friendly due to minimal mechanical
drive components.
• Emergency override unlocking system in the event of
Operation power failure.
The warehouse operative controls a push button sta­
tion inside the warehouse which operates a hydraulic
cylinder to mechanically lock the rear most wheel of
the vehicle. Built-in sensors detects the vehicle wheel
position to ensure the wheel lock system is always ex­
tended to the correct position, guaranteeing that the
arm of the wheel lock is always locked up hard against
the vehicle wheel and preventing any "creeping" from
the loading bay.

55
10. Protection systems

10.2 Wheel chocks They can be integrated with sensors, and can even be
Wheel chocks are an alternative to increase safety near connected to Loading Systems CombiControl control
and on the loading and unloading bay. Wheel chocks boxes. If required, the dock door can only be opened
are available in a variety of models. after the wheel chock has been positioned in front of
the wheel, after which the external traffic lights signal
switch to red and the internal signal lights switch from
red to green.

Loading Systems,
a safe choice

56
 10. Protection systems

10.3 Dock Management System When a driver arrives on-site and checks into the trans­
The Dock Management System, jointly developed by port office, the keys are snapped onto the iFob. The
Loading Systems and Traka is a unique, easily installed electronic cabinet identifies and confirms which load­
and affordable solution to prevent an industry problem ing or unloading bay is to be used.
that has caused countless accidents and injuries.
The more advanced versions ensure that the dock door
It prevents vehicles driving away from the loading bay cannot be opened until the keys are safely retained
before the dock doors have been safely closed. in the cabinet and the keys cannot be taken until the
dock door is fully closed.
How does it work?
There are a number of possible implementations de­ The dock door may then be opened using the exist­
pending upon the degree of management control ing door control or with an iFob, depending upon the
required, however, in all cases the process will involve method selected.
attaching the drivers’ vehicle keys to an iFob – an
intelligent metal bullet shaped device containing an
electronic chip with a unique identification that is then
stored in a special electronic cabinet.

Prevent departure
prior to the safe
closing of the dock
doors

57
10. Protection systems

Scenario 1 Scenario 3
Identification and Vehicle Key Management Intelligent Dock Control and integrated
A simple solution that retains a driver’s vehicle keys (internal) transportation means control
and identifies which loading or unloading bay the vehi- An advanced solution to retain a drivers’ vehicle keys,
cle has been directed to. to identify which loading bay the vehicle has been
directed to, and to ensure that the dock door cannot
The supervisor then has control over the driver’s keys be operated without the vehicle keys secured in the
and can see that the vehicle is on site. electronic key control cabine. It also allows the intel-
ligent iFob to operate additional products, such as
There is also an audit of the transport office taking and fork-lift trucks.
returning the keys to the driver.
The incoming driver reports to the transport office,
parks the vehicle at the loading and unloading bay,
Scenario 2 and hands over the vehicle keys, (as in scenario two)
Vehicle Key Management and Intelligent and the interlock ensures that the keys cannot be tak­
Dock Control en until the door is safe.
A solution to retain a driver’s vehicle keys, identifies
which loading and unloading bay the vehicle has been
directed to, and ensures that the dock door cannot be
operated without the vehicle keys secured in the elec-
tronic key control cabinet.

The incoming driver is allocated the loading and un­

loading bay, parks up and reports to the transport
office where his keys are handed in. The keys are then
temporarily attached to an iFob and inserted into a
socket within the electronic key control cabinet which
corresponds to the particular loading and unloading
bay door. As the iFob is inserted, and locked in place,
an interlock indicates that the dock door may now be
opened. At the same time a “paired” iFob is released
from the key control cabinet. This paired iFob is the
electronic key that will allow the dock door to be ac­
tivated and can be used by an authorised member of
staff or even the driver, if applicable.

Upon completion of the vehicle loading / unloading

and after the dock door is fully closed, an automatic
signal is sent to the electronic key control cabinet, in­
dicating that the door is safe and that the driver’s keys
can be released. However, the temporary owner of the
paired iFob must return and insert the iFob into the
electronic key control cabinet before the iFob with the
driver’s keys are released.

This process prevents the driver from driving the vehi­

cle away from the loading and unloading bay, until the
dock door is securely closed and the area safe.

There is also an audit of the transport office taking and

returning the keys to the driver.

58
 10. Protection systems

But the dock door may only be opened by a user who System benefits
already carries a valid personal iFob, one that may also An increased safety, security and an improved opera­
activate additional products, such as fork-lift trucks, tional efficiency are the primary system benefits.
cleaning machines or other specialist equipment. The
activity of opening the door is also recorded in the The Dock Management System has been designed
iFob providing an audit of use. for installation in warehouses and distribution centres
where greater control and flexibility is required and it
This offers the concept of an integrated system and can easily be retro-fitted to existing systems as well as
the use of an electronic key for all warehouse equip­ being specified on new installations.
ment. Furthermore the system may also be integrated
with an existing access control system to allow man­ In summary the principal benefits of the system are to:
agement of the available movable equipment as well 1. Prevent vehicles from driving away from a loading
as access to the building. and unloading bay until the dock door is closed.
2. Ensure that vehicles are directed to the correct
­loading bay.
3. Control related to who can control product
­operation:
a. Improved safety;
b. Improved building management;
c. Minimising human errors;
d. Increased energy-saving potential.
4. Integrated intelligent system:
a. Managing dock equipment control;
b. Applicable in combination with other products,
vehicles and facilities.
5. Provides management of performance indicators,
such as:
a. Complete log of all user activities;
b. Number of cycles the doors have been activated;
Goods office c. Average duration of loading and unloading;
d. Planned service and maintenance.
6. Allows full integration with the Loading Systems
­Advanced Control Centre.

By integrating the Loading Systems Advanced

Control Centre with the Traka Dock Management
System a complete warehouse management is
created. It creates structure, increases safety and
reduced the risk on human error.

59
11. Automatic
Truck Loading
System
ATLS is a fully automated truck loading system, which makes your ­loading
and unloading operations faster, safer and with lower operational costs.

60
How it works

1. When the truck is fully docked on the opening a 2. ATLS receives the order and moves to the
light curtain secures the area. ­designated dock opening.

3. Once in position ATLS opens its doors, measures 4. Simultaneously ATLS centres itself with the actual
the truck and compares it with the desired loading truck position.
pattern.

A fully automatic and efficient loading and

unloading system

61
11. Automatic Truck Loading System

5. Pallets, or load units can be delivered in three b. via a plant conveyor aligned with the dock doors;
­different ways:
a. via an overhead conveyor above the dock doors;

It is impossible to
­imagine a logistic
­environment today
without automation
processes

c. via an ATLS Transfer Cart, which moves pallets from

the preparation area.

6. ATLS Loading Module enters the truck and deposits 7. When loading is finished ATLS closes its doors and
the load. moves to the next task.

62
 11. Automatic Truck Loading System

In today’s logistics and manufacturing environments au­ Improved environmental protection

tomation plays an important role, but automation is not • ATLS uses the power supply of the facility and
always the first choice due to the following concerns: ­eliminates the need for batteries and the handling of
hazardous materials.
• Expensive to implement, with a long payback period. • Low energy consumption (approximately 2.5 kwh per
• Difficult to move, remove or modify. truck load).
• High mechanical and/or software complexity, which • Reduced loading area lowers the energy consump­
often makes implementation and operator familiari­ tion for chilled and frozen distribution.
sation difficult.
• When any part of the system fails, the whole system Quick Return on Investment
is usually disrupted. • Reduces labour cost.
• Reduces product damage.
ATLS success is based on the ability to address these • No battery maintenance.
concerns and deliver benefits through: • Reduced floor space for loading.
• Minimizes truck waiting times.
High Capacity
• High loading speed (up to 150 pallets per hour).
• ATLS has a high capacity of loading 4-5 trucks per
hour and one ATLS machine can service up to 20
loading bays.

Improved operation
• Compact, easy to integrate with existing operation.
• Greatly improves shipping accuracy.
• Full traceability of product.

Safety
• Eliminates / reduces fork lift traffic.
• Eliminates / reduces fork lift related
­accidents.
• Eliminates/reduces human input.

Flexibility
• Handles any type of pallet, slip sheet,
skid, rack or other unitized products.
• Works with non modified trucks, trailers
and containers.
• ATLS works with soft, or hard side trailers.
• ATLS uses standard, non modified
­loading docks.
• One ATLS performs both automated
loading and unloading.
• ATLS still allows manual operation.
• ATLS works with solid panel, or folding
doors.
• ATLS is suited to work in ambient or
refrigerated warehouses and freezers.

63
12. Renovation &
­replacement
After years of continued use, the economic life span of your industrial
door or dock equipment will eventually come to an end. When this
happens, Loading Systems should be your choice of partner for when
considering what to do next. We can deliver most door and loading bay
equipment as standard solutions.

Practical and customer-

focussed solutions for
your existing platform

64
12.1 Dock leveller - quick replacement 12.4 From design to completion
Loading Systems manufactures customized dock level­ Since we have the expertise to offer all aspects of
lers for the replacement market which are designed to project management from design to completion,
speed up the replacement process so that your loading Loading Systems is able to offer you a total package.
and unloading bay is up and running again within hours. Design and engineering drawings are made in collabo­
ration with your own needs. Our own production units
ensure customized manufactured solutions. Loading
Systems will manage and coordinate the total project
for your organisation, even including the civil and
building works.

Loading Systems can even create additional short-term,

temporary or permanent loading and unloading space.

12.5 Flexible solutions

We offer a comprehensive range of standard or be­
spoke dock houses and modular steel platforms which
are extremely adaptable to your needs. These can
either be permanent or manufactured so that they can
be relocated at an alternative location in the event of a
relocation or re-organisation.
12.2 Dock shelter curtains replacement
Dock shelter curtains are subjected to extreme wear
and tear and are often damaged by protruding vehicle
parts.

Loading Systems ensures the swift replacement of your

dock shelter curtains. Often, we can avoid the need to
replace the supporting shelter frame so that only the
curtains need to be replaced.

12.3 New loading and unloading station for

an existing building
Loading Systems offers you a practical and customer-
oriented solution to quickly transform the look and feel
of your existing building with new replacement loading
and unloading bay equipment.

65
13. Service
Besides providing products and systems, you can also contact Loading
Systems for an extensive range of service programme options through­
out Europe. Our service concept focuses on a full service programme
24 hours per day, 7 days per week.

Our expertise and experience in this field means we

are able to repair, replace and maintain dock equip­
ment and industrial doors manufactured not only by
Loading Systems but also by all other leading manu­
facturers. When you call on Loading Systems services
you can be assured that we will do everything possible
to bring your equipment back on line so that you can
continue using your loading bay equipment with mini­
mal disruptions to your operations: We take care.

66
13.1 Efficiency, comfortable working 13.2 One partner for all your needs
conditions and safety When it comes to arranging the layout of the loading
We manufacture products developed by our own and unloading bay area, Loading Systems has a proven
­Research & Development department. To ensure you track record of being a leading and reliable consultan­
always receive the best products we only use the cy partner. Once you have chosen your solution, you
­highest quality materials in conjunction with the most can rely on us to deliver and install the products. We
technologically advanced manufacturing processes. fully understand the importance of delivering the pro­
We never lose track of the actual application of the gramme and failure to achieve the completion date is
products and we ensure your logistics environment never an option. After completion, we provide a guar­
achieves optimal accessibility and practicality. Efficiency, antee and all the relevant supporting documentation
effectiveness, comfortable working conditions and safety for the end user. We can also advise you on the recom­
are our priorities. mended maintenance and service schedules specifically

tailored to your usage rates and operational require­

One single reliable ments. We take care to ensure that after completion of

partner for all your the installation stage that you continue to achieve the
optimal usage of your investment.

products

67
13. Service

13.3 Service programme 13.4 Safety and regulatory requirements

A good maintenance regime guarantees and protects In most countries, there is a number of health and safe­
the lifetime of your equipment and products, and also ty related statutory and legislative obligations which
minimises the impact of downtime. You can further you have a responsibility to adhere, and which are very
minimise disruption to your operations by entering specific to loading and unloading bay equipment. All
into a service contract. Loading Systems offers you an Loading Systems products are delivered in accordance
extensive service programme tailor-made to your own with the relevant EN standards and Machinery Direc­
situation. All you need to do is determine which serv­ tive Guidelines, and have a CE marking.
ice contract best fits your operational needs. After this
you can rely on us to take care of all your maintenance Most legislation requires that only an expert with thor­
requirements. ough specialised knowledge is able to inspect, service
and maintain certain types of loading bay equipment.
Through prior consultation, you can even determine In the event of equipment damage or operator ac­
when our service engineers attend your premises. If cidents, insurance companies often require evidence
you need our attendance at weekends or throughout that the equipment has been subjected to a good
the evening, no problem, we can tailor a solution to maintenance regime by a competent person as a pre­
suit your needs allowing you to fully focus on your op­ requisite condition to settling any claim. With Loading
erational management without unnecessary interrup­ Systems servicing and maintaining your equipment you
tions. are well-prepared. In the event of an insurance inspec­

If you choose a service contract including the A

­ dvanced tion, the maintenance history can be quickly proven.
Control Centre option, your loading bay worries are Our extensive range of service and maintenance
guaranteed to be a thing of the past. Besides benefiting contracts, do not only meet all legal and regulatory
from an extended guarantee period we ensure a quick requirements, but they also meet many of the require­
solution for any loading bay equipment failures, carried ments set by insurance companies.
out free of charge. Please refer to the options described
in our Service brochure.

45 years of ­experience as specialist

in loading and u
­ nloading
68
 13. Service

13.5 Energy-saving and environment

Loading Systems accepts its responsibility to create a
better environment. This includes our manufacturing From start
processes, which involves products and installations
designed and manufactured using state-of-the-art to finish,
technologies. As such we prevent energy loss resulting
from ‘leaking’ heat or cooling. We offer a wide prod­ guaranteed
uct programme which contributes to energy-saving
­measures. We manage our fleet of vehicles using the
no worries
latest planning tools and satellite navigation systems to
reduce our carbon footprint.

13.6 Renovation and replacement

Everything has a lifetime and loading bay equipment is
no different. If after many years of use, the economic
lifetime of your industrial door or dock equipment
reaches an end, we would be pleased to assist you
in finding the best and most cost effective solution.
We are confident that we have standard products and
services readily available for you, for all manufacturers’
products and all types of installations. However, if a
standard solution is not adequate for your loading and
unloading situation, Loading Systems will find a solu­
tion specifically tailored to your logistic environment.
In nearly all situations, an assessment indicates that no
significant modifications are required. As such you
profit from a suitable solution and avoid unneces­
sary additional costs.

We can also ensure constructional solutions

for you. Even if you need an additional dock
leveller or industrial door for example, we can
provide a solution to suit your needs.

13.7 Lease Contracts

If you need to spread the costs of your
capital investments over several years,
then Loading Systems also offers attrac­
tive lease contracts for new equipment.

Continuity and accessibility are the key priori­

ties in our Service Concept. Our aim is to have
our products and services support your opera­
tional management as best as possible.

We take care.

69
Dock equipment

Disclaimer
No part of this publication may be copied or reproduced in any way without prior permission in writing by Loading Systems. Although the contents of this
­publication have been compiled with the greatest possible care, Loading Systems cannot accept liability for any damage that might arise from errors or
­omissions in this publication. We reserve the right to make technical modifications/replacements without prior notice.

www.loading-systems.com