Category: Loading Dock Levelers

Dock levelers are used to bridge the gap between the loading dock floor and truck bed. This allows for a smooth and safer transition for material handling equipment during loading and unloading cargo. Dock levelers are available in a variety of sizes and power types based on industry and building application.

Hydraulic vs Air vs Mechanical

Dock levelers have 3 types of operation: hydraulic (powered), air (powered), and mechanical (pull-chain). Often considered the safest style is hydraulic for its’ simple design, push-button activation and interlocking ability with other equipment (restraint, door, etc). Air powered is the middle ground, having push-button activation with more moving mechanical components. Mechanical operation requires more moving parts and maintenance, but generally offers the most economical up-front cost.

Mechanical levelers use main springs to raise the deck allowing a worker to walk the deck down onto a truck bed. An air powered leveler uses an air bladder to raise the deck, and release air to lower. Hydraulic power uses lifting and lip cylinders powered by a motor to raise and place the lip plate onto a truck.

Maintenance and Application

All dock levelers require maintenance. Intervals are determined based on cycle use and environmental conditions. Pull-chain operation requires more frequent adjustments, as there are more components to make it operate. Air powered is sensitive to pit debris to be clear of the fan filter, which is used to inflate the bladder.

Hydraulic powered dock levelers are recommended for docks that see trucks consistently through the day. They are also recommended for warehouses with many docks for ease of use and maintenance. Fewer-dock facilities and less-used docks often see pull-chain activation as adequate to meet their demands. Powered docks can be interlocked with other equipment, requiring the operator to follow procedures to operate.

Size, Capacity, Structure

Dock levelers are available in standard sizes of 6’, 6’-6” and 7’ wide by 6’, 8’, and 10’ long. These sizes are nominal, meaning they are sizes in name only. The actual pit dimensions differ, though are generally standardized across major manufactures. The most common width is 6’, and common length is 8’. Longer decks are generally reserved for low dock heights, to lessen the incline into a truck bed.

Standard capacities range from 25,000# to 50,000#. These are Comparative Industry Ratings (CIR), used as standard measurements for the industry. Roll-over capacities derived from the CIR will range by manufacture, though a shorthand multiplier of .425 can be used to determine the roll-over capacity for Poweramp.

Different manufactures construct their levelers with different designs and components. Poweramp is known for having a structurally-sound dock leveler, using strong steel supports to engineer a leveler that lasts.

myQ Dock Management

Facilities with many docks find it easy to monitor dock activity from an online dashboard. This allows for increasing efficiency, eliminating driver retention fees, and maintenance tracking for better cared-for equipment. For large operations, these overall will reduce the cost of operating your dock, and you will save money (it pays for itself!). Learn more here.