In this article, ArcWest partner, Todd Heirls, shares best practices for designing distribution docks. Todd specializes in integrating architectural planning, design, and engineering for the construction of commercial architecture and retail types of buildings, including renovations, new construction, and tenant improvements.
For nearly a decade, Todd has been designing highly efficient distribution docks for companies such as R + L Carriers.
Here are Todd’s top considerations when designing a distribution dock system:
Safety: If not the most important aspect of the dock, it should be. By far the most critical element is the movement of product from the stable surface of the dock to the variable surface of the truck. The truck must be immobilized in a way that the momentum and braking of the fork truck does not move the trailer out of position widening the gap between the trailer and the dock. This immobilization could be verified by tire chocking on one end of the spectrum to mechanical dock lights and go / no go lights inside the dock area. Material movement vehicles should not be permitted to enter the trailer without verification the trailer is immobilized.
Trailer Height: How does one bridge the gap between the trailer and the dock? Trailer or truck deck heights vary greatly over types but only minimally within types. The basic over-the-road semi-trailer is approximately 4 feet over the pavement. If the variability is no more than 2 inches in either direction, this can be easily accommodated with a simple articulating dock edge plate and these can be either manual or automatic depending on budgetary constraints and needs for automation. If the actual trailer type is highly variable, such as with low deck panel trucks and over-the-road semi-trailers, a dock leveler can be employed to accommodate an approximate 2-foot deviation. Even the dock leveler can be either manual spring operated or fully automated. The key to the operation relates back to safety. The methodology should provide a clear identification to the material handling operator that it is ok to bridge the gap.
Environmental Seals: What is the interior environment where material is stored or handled? Is the interior environment intended to simply protect the product from moisture and simply provide an extension of the exterior temperature or is it to be an interior environment? Possibly an overhang over the door, but above the trailer is all that is needed to prevent moisture from infiltrating the gap between building and trailer. If the interior environment is meant to either maintain higher or lower temperature, dock seals should be employed. Dock seals will allow a moderately complete seal around the truck trailer. Trailers are extremely hard on dock seals, so the level of sealing should be considered with cost constraints and the next subject of longevity.
Dock Longevity: Dock doors are notorious for abuse. Thousands of pounds of material are moved by multiple thousand-pound vehicles all under deadline. As much as safety is the primary concern, the continued operation of the dock is at least a close second. Damage to the door tracks or curtain can easily occur with a misaligned truck entry or as material handling truck backs out of the back of a truck. If the door cannot be closed or opened, this will render the dock out of operation until the mechanism is returned to operation. The material handling vehicles are multi-ton devises that even in low velocity, impacts can damage the building or even the structural infrastructure of the building. Deployment of structural bollards set in concrete foundations (not bolt down) at the jamb of each dock door with the inner surface inside of the aperture of the door may help. In this position any grazing impact will be deflected away from the door jambs, building elements, and the aperture of the truck door. Although, as any dock manager will attest, this will not eliminate damage; there is a diminishing return as more elements are added.
Learn more about Todd’s experience and projects, and/or reach out to him with questions at https://arcwestarchitects.com/staff/todd-l-heirls/