Mastering the Loading Dock Installation Process: From Assessment to Final Inspection

When it comes to loading dock installation, completing each individual step correctly is the key to success. In this comprehensive guide, we cover everything you need to know about the entire journey of a loading dock installation, from the initial assessment to the crucial final inspection. Each phase is a piece of the puzzle, contributing to a seamless and efficient loading dock operation that protects your workers, safeguards your valuable products, and preserves your bottom line.

Initial Assessment and Planning for Loading Dock Installation

When installing a loading dock system, it is crucial to thoroughly assess all relevant portions of the project that are about to be undertaken. 

The first task to complete when undertaking the loading dock installation process is to visit the job site where you plan to install the loading dock, verify the site survey, and double-check you have the correct measurements.

All job sites are different, so confirming the measurements for that particular job site will help towards a smoother installation process further down the line.

Preparing Your Site for Loading Dock Installation 

Once you have completed the necessary checks of your equipment and the site itself, you are ready to embark on the loading dock installation process. 

The first step is to offload the necessary equipment that is needed for the installation process and clean the foundation pits so that they are accessible and ready for the implementation of the loading dock. 

It’s recommended to drop the loading docks in the foundation pits numerically based on the serial number to avoid any confusion later down the line. 

The Loading Dock Installation Process 

Once the foundation pit is ready and the correct equipment is in each corresponding foundation pit, it is time to begin the loading dock installation process. 

First, weld the six factory-notched locations on the rear frame assembly. After completing this, you should be able to lift the loading dock and secure it safely with the Blue Giant safety strut. 

Next, weld both the front legs of the loading dock and shim all three frames upright, ensuring each shim is at least 4 inches wide. You will know this has been done correctly if the lower dock is level with the floor of the foundation pit. Then, you can weld the lip keepers to the loading dock. 

Now, you are in a position to mount the bumpers and weld them to the curb steel. Once completed, install three ⅝ anchors. 

At this point, make sure to lift the loading dock again and install the Blue Giant safety strut. Then, you can finish welding the dock bumpers on the inside edge. 

The loading dock should now be welded into place so you can mount and weld the restraint track to the top of the curb steel using the 15 ½ tapcons provided. 

Loading Dock Doors During the Installation Process 

After completing this step, you are ready to turn your attention to the restraint body. To install the restraint body, first, install the spring bar and the four springs designated for installing the restraint body. Then, you can install the restraint body and secure it to the spring bar you just placed. Finally, install the restraint spring covers and fix the brush seal on the loading dock door openings.

Now, you can shake out the door parts and stage them in front of the loading dock doors, where you should set a reverse angel bottom track and set all anchors. 

The last few steps of the loading dock installation process include stacking the doors with hinges and rollers to enable suitable accessibility when the loading dock door is in use, setting the upper tracks, and installing the cables and spring line. 

Make sure to balance and level the loading dock door at this stage in the installation process to limit the chances of an uneven loading dock door later down the line. Then, install the operator, sprocket, and chain in advance of setting the outside floor level for shelter pads. After the outside floor level has been set, you can mount and level the shelter pads and install the header assembly. 

Finishing Touches Within the Loading Dock Installation Process

Now that your header assembly has been installed, your loading dock should really be coming together. The next step is to simply fix the header curtain with a keeper angle. 

The final technical step in the loading dock installation process is fitting the control panel and wire in place.

The rest is mostly clean up! Make sure to clean all your welds and paint that might have been splattered during the installation process to ensure a neat finish. Equally important for the final finished look is to vacuum up all excess concrete dust and wipe down all equipment. 

Completing the Final Inspection for the Loading Dock Installation 

It is critical to conduct a final inspection after installing a loading dock. 

Blue Giant recommends testing and running all of the newly installed equipment to ensure it works and conducting a final inspection of all welds and functions you put in place during installation. 

Loading docks are used frequently, increasing the chances of items getting worn out or potentially escalating to a malfunction. Components such as tracks, rollers, cables, panels and springs should be inspected often. 

Unfortunately, loading docks tend to be most workplaces' most overlooked area for monthly inspections despite being frequently congested with equipment, goods, and people, and are exposed to elements. Protect your workers by making sure to prioritize your loading docks when it comes to monthly inspections. 

We hope you learned more about the loading dock installation process. Contact us with questions about Blue Giant's loading docks or the installation process. We are happy to answer your questions and determine which loading dock model best suits your business needs.