Dock lifts are often selected because they can solve loading dock problems that a conventional dock leveler cannot. They can provide vertical travel between ground level, truck bed height, and dock height, making them useful for facilities that handle varied vehicles or do not have a standard loading dock.
However, selecting the dock lift is only part of the process. The installation configuration is just as important.
A dock lift may be installed in different ways depending on the building layout, the outside grade, the dock height, the direction of traffic flow, and whether the lift is being used indoors, outdoors, at grade level, or at the front of an elevated dock. Pentalift’s dock lift installation configuration guide identifies several common arrangements, including exterior grade-level recessed pit installation, interior grade-level to higher dock-level full pit installation, exterior grade-level to dock-level front mount installation, exterior grade-level to lower dock-level full pit installation, and interior grade/floor-level recessed pit installation.
Pit: Pit Installation
Surface: Surface Installation
Why Installation Configuration Matters
A dock lift is not simply placed near a dock opening and put into service. The site must be planned around how material will move onto the platform, how it will leave the platform, and how the lift will interact with the building, trailers and trucks, pedestrians, forklifts, pallet trucks, and surrounding equipment.
The wrong installation approach can create problems such as safety concerns, poor traffic flow, difficult access, awkward loading angles, insufficient guarding, exposed equipment, drainage concerns, or unnecessary construction cost.
The right configuration should answer several basic questions:
- Is the lift serving ground level, dock level, or both?
- Is the lift installed indoors or outdoors?
- Will the platform sit in a recessed pit?
- Is the lift positioned at the front of the dock or within the building?
- What will be used to properly position the trailer or truck at the dock lift?
- Will forklifts, pallet trucks, carts, or only product travel on the lift?
- What type of bridge plate, ramp, guard rail, or bumper arrangement is required?
- Where will the power unit, controls, hydraulic hoses, and conduit be located?
These questions should be reviewed before concrete, electrical, and building work are determined.
Common Dock Lift Installation Configurations
Exterior Grade-Level Recessed Pit Installation
An exterior grade-level recessed pit installation places the dock lift in a pit outside the building at grade level. This type of configuration may be used when the lift needs to provide access between the outside ground level and a truck or building opening.
Pentalift’s depiction of this arrangement includes components such as removable guard rails with access chains, bollards, curb angle, a pre-drilled frame for lagging the unit into position, electrical disconnect, hydraulic hoses, push-button control, remote power unit, and conduits from the pit to the power unit.
This type of installation requires careful coordination of pit construction, guarding, vehicle protection, drainage, electrical routing, and platform access.
Interior Grade-Level to Higher Dock-Level Full Pit Installation
In some facilities, the dock lift may be located inside the building and used to move material from an interior grade level up to a higher dock level. Pentalift’s configuration guide describes this as an interior grade-level to higher dock-level full pit installation.
This arrangement can be useful where material must move between two elevations inside or at the dock area. The drawing identifies dock bumpers and notes that the bridge should project 12 inches beyond the face of the bumpers.
This is a good example of why layout details matter. The lift, bridge/lip, bumpers, pit, dock face, and traffic path must be coordinated together.
Exterior Grade-Level to Dock-Level Front Mount Installation
A front mount installation positions the dock lift at the front of the dock. Pentalift’s guide identifies this as an exterior grade-level to dock-level recessed pit installation using a front mount arrangement.
This type of installation can be useful when the lift needs to serve the outside grade area and the elevated dock face. It may also be relevant where the building layout does not support a conventional interior arrangement.
Planning considerations include bollard placement, platform access, bridge/lip projection, power unit location, hose routing, and protection from vehicle impact. Pentalift’s drawing again identifies bollards and notes that the bridge should project 12 inches beyond the face of the bollards.
Exterior Grade-Level to Lower Dock-Level Full Pit Installation
Not every site has a typical elevated dock relationship. Some applications may involve an exterior grade level and a lower dock level. Pentalift’s guide includes an exterior grade-level to lower dock-level full pit installation.
This layout may require additional attention to guarding because of the relationship between the platform, the pit, and the surrounding elevations. Pentalift’s depiction includes removable surface-mounted guard rails and removable deck-mounted guard rails with access chains.
Where changes in elevation are involved, the site should be reviewed carefully for access, fall protection, traffic flow, and how the lift will be used throughout its travel range.
Interior Grade and Floor-Level Recessed Pit Installation
An interior grade and floor-level recessed pit installation can be used where the lift is installed inside the facility and must integrate with the building floor. Pentalift’s guide shows this arrangement with removable guard rails, bollards, curb angle, pre-drilled frame, disconnect box, hoses, push-button control, remote power unit, and conduit.
This style of installation may be appropriate where floor-level access is important and the lift needs to sit recessed into the floor rather than on top of it.
Pit Construction and Site Preparation
Pit-mounted dock lifts require accurate planning. Pentalift’s pit construction guidance notes that, as a planning guideline, pit width is the dock lift platform width plus 2 inches, pit length is the platform length plus 2 inches, with additional allowance if a hinged bridge plate is used. It also states that pit depth is the dock lift closed height plus 1/4 inch, minus 0, and recommends a 3 inch by 3 inch steel angle iron curb angle with suitable anchoring devices.
Most dock lifts have external power units and require conduit to route hydraulic hoses from the power unit to the dock lift. A second conduit may be required if the dock lift has electrical options such as electric toe sensors, limit switches, or controls on the platform.
Drainage may also need to be considered. Depending on the application, a centrally located pit drain connected to a storm sewer may be recommended.
Common Mistakes to Avoid
One common mistake is waiting too long to review the installation parameters and layout. Once concrete work is complete, changes to pit size, conduit routing, drain location, or curb angle can become more difficult and expensive.
Another mistake is overlooking the power unit and control location. These components must be accessible, protected, and coordinated with the lift location.
It is also important not to overlook guarding and impact protection. Depending on the layout, removable guard rails, access chains, bollards, bumpers, and other protective features may be required to accommodate safe use of the lift.
Finally, the bridge or lip projection must be reviewed carefully. In several Pentalift configurations, the drawing notes that the lip should project 12 inches beyond the face of bollards or bumpers.
Information to Gather Before Finalizing the Layout
Before choosing a dock lift installation configuration, gather the following information:
- Site drawings or photos
- Indoor or outdoor location
- Existing or planned dock height
- Outside grade elevation
- Truck bed height range
- Load weight and handling equipment weight
- Platform size required
- Direction of traffic flow
- Pit-mounted or surface-mounted preference
- Bridge plate or ramp requirements
- Guard rail, chain, gate, bumper, or bollard needs
- Power unit location
- Electrical disconnect and control location
- Hydraulic hose and conduit routing
- Drainage requirements
- Any site-specific safety or access concerns
The more complete the site information, the easier it is to select the correct dock lift configuration.
The Bottom Line
Dock lifts can solve challenging loading problems, but the installation configuration must be planned carefully. The correct arrangement depends on whether the lift is serving grade level, dock level, truck bed height, or a combination of elevations.
Pit layout, curb angle, bridge projection, bollards, bumpers, guard rails, power unit location, hydraulic hose routing, conduit, controls, and drainage should all be considered before construction or installation begins.
For new construction or retrofit projects, reviewing the dock lift configuration early can help reduce installation problems, avoid unnecessary rework, and ensure the equipment fits the actual loading application.
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