Loading Technology
Loading Technology
Loading Technology
6 Sustainable production
7 Sustainable planning
8 Planning principles
12 Proper planning
14 Example plans
24 DOBO system
26 Control systems
28 Docking assistants
32 Fitting variants
34 Loading houses
50 Industrial doors
52 Buffers
55 Accessories
3
Brand Quality from Hörmann
Reliable and oriented towards the future
Alnatura logistics centre in the city of Lorsch in the German state of Hesse
4
As Europe’s leading manufacturer of doors,
frames, operators and loading technology,
we are committed to high product and
service quality. This is how we set standards
on an international scale.
5
Sustainable production
For trend-setting construction
6 * You can find the Environmental Product Declaration (EPD) on the Internet at www.hoermann.de/Dokumentationen.
Simple and Sustainable Planning
with the Hörmann Architects' Program and energy savings compass
Planning with Hörmann products is now even easier thanks Hörmann’s energy saving compass shows
to a modern, user-friendly interface. Clearly structured how external and internal doors are planned
navigation via drop-down menus and symbols, as well as with energy-efficiency and sustainability in mind.
a search function, give you faster access to tender An integrated calculation module estimates
specifications and drawings (in DWG and PDF format) of the amortisation period for door modernisation.
over 850 Hörmann products. Photo-realistic presentations
provide additional information on many products.
7
The right concepts
Efficient planning
Energy efficiency
Thermographic studies confirm that a building’s openings
are a particularly critical factor when it comes to energy
efficiency. With proper planning and the proper
equipment that matches the building’s intended function,
thermal loss can be kept at a minimum.
Safety
Workplace safety is quite rightfully a very important issue.
Accident and health risks as well as damage to goods,
vehicles and building equipment must be avoided.
Especially at loading bays, where your own employees
and external staff work together, suitable measures must
be considered carefully.
Longevity
The rough nature of daily use quickly leaves its mark
on loading bays – quick wear and tear, collision
damage and planning errors can require costly repairs
and replacements within a very short period of time.
High-quality materials, coupled with foresighted planning
and the selection of suitable protection measures protect
your valuable investment.
8
The right products
Developed and manufactured in-house
9
Good reasons to try Hörmann
Individual solutions from the market leader for doors and loading technology
1 Robust
dock levellers 2 Energy-efficient
loading houses
Sustainability and quality go hand in hand. The dock leveller is fit directly in front
Dock levellers have to withstand the rough of the building with a loading house, allowing
day-to-day loading environment. For this the building opening to be sealed efficiently
reason, all components are manufactured with an industrial door.
using high-quality materials. As early as the quotation phase, we are able
The design of all dock levellers corresponds to provide model statistics defining
to EN 1398 and, with regard to loading the maximum wind and snow loads for Hörmann
capacity, is dimensioned generously. loading houses.
Particularly sturdy flat anchors, ventilation
slots in the edge bracket and adjustment Any unevenness in the door can easily
angles to screw ensure reliable fixing be compensated for using adjustable feet.
in the building structure, one of the most
important prerequisites for a long service life. For further information, see pages 34 – 37.
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3 Flexible dock seals
and shelters 4 Compatible
control systems
Dock seals and shelters are particularly efficient From development to production, all Hörmann
when they are optimally adapted to the docking door and dock leveller controls come from
vehicles and the loading situation. This requires the same source, making them optimally
a wide range of flexible solutions. matched to each other. As a result, you benefit
Robust push-in flap dock shelters with different from a uniform operating concept with
frame constructions prevent them from being standardised housing sizes and the same cable
damaged during docking. sets for dock levellers and door controls.
Inflatable dock seals adjust to different vehicle Another advantage: If the dock leveller control
dimensions. Roll-up flaps compensate is placed beneath the door control, both controls
for even larger differences in vehicle heights. can be combined into a single compact unit.
Dock seals and shelters with telescopic
link arms or rising roof constructions For further information, see pages 26 – 27.
are recommended to compensate
for vehicle movements or when placing
interchangeable containers.
11
Proper planning
Sustainability begins with planning
12
Planning made simple with Hörmann
Hörmann offers detailed planning documents as well as
descriptive information and demonstrations of special
solutions on the Internet. Utilise the know-how of Hörmann
to optimise your planning!
Planning documents
with detailed
information
and drawings
Information and
demonstrations of
special solutions such
as the DOBO system
13
Logistics solutions inside the building
Example plans
Recommended product
• Mechanical dock leveller MLS
Recommended product
Thermal insulation solution for • Hydraulic telescopic lip dock
temperature controlled buildings leveller with extended lip
• Insulated dock leveller bottom
Most of the time, goods are not being loaded side with insulated panel
at a loading bay and the door is closed. • Industrial sectional door travelling
To minimise thermal losses during those periods, in front of the dock leveller
a double-skinned thermally insulated sectional with a low U value
door is positioned in front of the dock leveller • Dock shelter
• Buffers
and the dock leveller is additionally insulated
• Wheel guide
on the underside by an insulated panel.
14
Logistics solutions in front of the building
Example plans
Recommended product
• Mechanical dock leveller MRS
In cases where lorries with almost identical loading heights are used,
i.e. for uniform fleets, the proper planning of the dock height results in minimal
height differences to the loading surface of the vehicles. With a standard
rated load of 60 kN, the MLS and MRS mechanical dock levellers are able
to meet most demands and are the most economic solution for such situations.
They are simple to operate via a control bar.
Of course they fulfil the requirements for dock levellers stipulated in EN 1398.
16
Hörmann practical application tip
With MRS ramp houses, use a flap dock shelter of at least 900 mm
depth to bridge the depth of the side brackets and buffers.
Work area
MLS, MRS
17
Hydraulic dock levellers
Comfortable operation with great levelling
Hydraulic dock levellers are available as hinged lip or telescopic dock levellers.
With a length of up to 5 metres, they can bridge large height differences between
the ramp and the lorry loading level. Up to a size of 2000 × 3000 mm, the dock
leveller platform is made of a single piece. With wider and longer dock levellers,
a carefully made weld seam joins the plates, resulting in a continuously sturdy
platform. All Hörmann dock levellers comply with the requirements of EN 1398.
18
Detailed quality
For long, sustainable use
Noise-reducing pedestal Adjustable angle and fitting anchors Practical ventilation holes
Steel meeting steel results in a noise that Adjustable angles to screw allow the dock Air pockets, which may above all form
is neither pleasant nor healthy for employees. leveller to be adjusted optimally. Anchor in the area below the edge bracket, weaken
Rubber buffers on the telescopic lip dock brackets on the frame that are welded before the connection of the dock leveller
leveller pedestals reduce the contact noise being cast to reinforcing iron or the to the building structure. Ventilation holes
when positioning the platform. reinforcement ensure a reliable connection. in the edge bracket ensure that the air
Especially in the rear area where strong is released in the sealing process, guaranteeing
forces are at work on the hinges. a closed-linkage connection.
19
Hydraulic dock levellers
Precise levelling, even with great distances from the lorry loading area
Type R, straight
Rated load/carrying capacity Standard up to 2000 mm
Hörmann dock levellers have a carrying capacity ordering width
of 60 kN as standard (rated load according to EN 1398).
Higher rated loads, even up to 180 kN for the HLS-2,
are available upon request.
Surfaces
Moulded, slip-resistant steel, shot-blasted or anodised 100
and coated with two-component PU varnish. Optionally
also available completely galvanized, recommended Type SG, with separate lip
for outdoor use, for example in loading houses. segments to accommodate
different lorry widths (for
Colours telescopic lip dock levellers
Ultra marine blue (RAL 5002) or Traffic black (RAL 9017), 170 mm wide and retractable,
other colours based on RAL available upon request. 145/170 for hinged lip dock levellers
145 mm, the segments
can be loaded with up to 1 tonne)
20
HLS hinged lip
dock leveller
21
Dock levellers for special requirements
With telescopic lip dock leveller HTLV 3, lorries and transit vans can dock on a loading bay The lift leveller is a combination of a telescopic
lip dock leveller and scissors lift table
20 kN
23
DOBO system
Dock first – open doors later
24
Hörmann practical application tip
The DOBO system can also be implemented
in conjunction with a loading house.
On conventional ramps, the driver gets out of the vehicle, opens Take a look at the video at:
the vehicle door and then docks the vehicle. www.hoermann.com/en/videos
If the vehicle has already docked on the previous evening, inconvenient
adjustment processes are necessary to open the doors.
With the DOBO system, a lorry can dock with its doors closed. They
can be opened whenever needed. Until that time the goods remain well
protected inside the vehicle.
Safe docking
The Hörmann Docking Assistant HDA helps
the driver to dock safely. The vehicle doors
remain closed. Sensors in the door leaf
recognise the position of the vehicle.
Reliable sealing
As soon as the lorry is docked, the dock seal
DAS-3 is inflated and seals the vehicle from
3 sides.
25
Control systems
Compatible system solutions
Comfort function
for simple operation
concept with standardised housing sizes dock seal or an electric top flap
can be integrated into the dock
and similar cable sets for all dock levellers leveller control.
both controls can be combined into a single is returned to the normal position,
the door closes automatically
compact unit. and the dock seal switches off
or the top flap extends.
26
The energy saving mode
for controls 420 S / T and 460 S / T
lowers electricity costs by approx. 80 %
External control
DTH-T
Allows for the exact control of
the dock leveller at the loading
point. For further information,
please see page 56.
Dock management
Visualisation ensures controlled processes
You control, monitor and manage the entire
control system via a graphic interface.
It is depicted via a control panel
or a web application.
27
Safe start-up and docking
Docking assistants
28
Docking support and position monitoring
Hörmann Dock Control
Hörmann Dock Control reliably The equipment can be adjusted Take a look at the video at:
monitors and controls the entire depending on the customer’s wishes www.hoermann.com/en/videos
loading process. Working as the control and needs. Let us advise you!
centre for comprehensive safety
equipment, Dock Control evaluates
information coming from
e.g. the sensors in the wheel chock
and the buffer and then controls
specified blocking and signal functions.
Safe docking
The buffer with sensor safely guides the lorry
to the loading bay via the traffic light control.
The sensor system in the buffer reports
the distance of the lorry to the loading platform
and when it has reached the final docking
position. The lorry is then additionally secured
by a wheel chock with a sensor. Upon contact
with the tyres and the correct position,
the sensor releases the door control.
29
Working ranges, dimensions
430
365
360
335
330
305
300
245
235
2000 2500 2750 3000 3500 4000 4500 5000 Dock leveller length
–285
–295
–305
–335
–340 –340
–345
–370
–375
–380
–385
All dimensions in mm
Dimensions
Ordering length Ordering width
Dock leveller 2000 2500 2750 3000 3500 4000 4500 5000 Dock leveller
All dimensions in mm
30
Hörmann practical application tip
Adjust the ramp height to the most frequently used lorry
height. This ensures quick loading and unloading processes
as well as less stress on the dock leveller.
550
540 540
530
490 490
480
470
460
450
430
420
415
405
395
370
340
325
270
2000 2500 2750 3000 3500 4000 4500 5000 Dock leveller length
–345
–350
–395 –395
–400 –400
–405
–410
–415 –415
–420
–425
–430 –430
–450 –450
–455
–470 –470
–490
–510
–630
–650
–690
All dimensions in mm
Dimensions
Ordering length Ordering width
Dock leveller 2000 2500 2750 3000 3500 4000 4500 5000 Dock leveller
HTL2 595 595 645 645 745 745 745 745 2000, 2100, 2250
Installation height
HTLV 3 795 895 2000
All dimensions in mm
31
Hydraulic dock levellers
Model variants for new buildings and modernisation
Pit model P
For new buildings and renovations
Basic model,
open on 3 sides
Rear view of pit model P
Frame model F
For new buildings, for subsequent welding
in a preassembled frame
Self-supporting frame,
closed on sides,
edge brackets on side and rear
Box model B Rear view of frame model FR (Fig. shows casting height of 200 mm)
Remove the old dock leveller, disassemble Position the new dock leveller Weld to the edge brackets – finished!
the old base frame and adjust it with adapter
profiles if necessary
32
Hydraulic dock levellers
Fitting variants in the building
Pit model P
Welded on the reverse
Box model B
Casting with
sub-construction
33
Loading houses
The energy-efficient and space-saving solution
Loading houses are placed in front of the building, which is particularly energy-
efficient and space-saving. This means that the entire building space can be used,
right up to the exterior walls. The building door extends to the building floor
not on top of the dock leveller, but behind it. This way, the door opening is optimally
insulated, especially outside loading times. Loading houses are also suited
for modernisation, as a complete loading bay can be added to the building without
costly reconstruction measures.
34
We also help you to plan the roof
and side connections to the building.
Static calculation
A static calculation according to EN 1990 is available for all models.
Depending on the version, the particularly stable design carries
a roof load bearing capacity of max. 1 kN/m² or 3 kN/m² and is also
recommended for snowy regions. The max. wind load is 0.65 kN/m².
Thus, with Hörmann you can plan loading houses simply and safely.
For higher requirements, please speak to your Hörmann partner.
Optimal drainage
Loading houses are drained via a standard roof slope of 2 %
towards the front. Under certain conditions, an optional roof slope
of 10 % is possible. Contact us.
On request, a gutter can also be fitted to the loading houses
in combination with a drainpipe.
Flexible control
The optional external control DTH-T enables exact control directly
at the loading point. This allows for the dock leveller telescopic lip
to be positioned exactly onto the loading house even though
the main control is located in the building. The external control
can also be retrofitted to existing Hörmann door systems.
35
Loading houses
The right solution for any requirement
36
Hörmann practical application tip
On request, loading houses can be prepared for fitting rolling shutter SB
Decotherm as an exterior door.
Panel versions
Loading house with recess As standard, the roof
and side cladding
for inflatable dock seal are supplied in Grey white,
With this solution, appearance, RAL 9002, on the inside
design and use of materials and outside. The outside is also
are optimally co-ordinated. available in White aluminium,
RAL 9006. Available on request
in many RAL colours.
Series in element
assembly arrangement
Arranged as a series with a 90° angle,
several loading houses can be
combined into a single compact
space-saving unit. This is not possible
with Thermo loading houses.
Single-skinned
Double-skinned
37
Flap dock shelters
Universally applicable
Hörmann flap dock shelters adjust to the lorry’s size and can thus
be used universally.
As dock or roadway models, they are available in many variations
and can therefore be optimally customised to most situations. High-quality
top and side flaps, mounted on a galvanized, compressible steel frame,
result in a stable, flexible and robust construction.
Flaps and frame parts are manufactured as easy-to-assemble individual
elements that can be screwed together. This also makes replacements simple
and inexpensive.
38
Flap dock shelters Hörmann practical application tip
The lorry determines the dimensions Cuts in the top flap reduce the load during
docking.
For fitting the dock seal, the door opening may have BT = B – 200 mm
the following maximum dimensions: b
Door width = Width of the dock seal – 200 mm
Door height = Height of the dock seal – 100 mm
40
Hörmann practical application tip
Equip the docking zone with wheel guides. They ensure that the lorries always dock
correctly, allowing the flap shelter to seal properly and collision damage is prevented.
DS dock seal
For normal loading frequencies, dock seal DS
DSL with link arm
is the ideal choice. The side and top flaps consist DSL-H with telescopic link arm
of 2-layered, 3-mm-thick substrate fabric DSS with scissors arm
made of polyester monofilament threads with Standard widths: 3350 / 3500 mm
double-sided UPVC coating. For docked lorries, Standard heights: 3500 / 3750 mm
the monofilament threads in the flap material Optionally as roadway model,
ensure the necessary pre-tensioning / seal 4500 mm high, or recess model
Colours
Top and side flaps DT DS
Graphite black, similar to RAL 9011 ● ●
Basalt grey, similar to RAL 7012 ● ●
Gentian blue, similar to RAL 5010 ● ●
Marker stripes
White ● ●
Yellow ● ●
Orange ● –
Red ● –
Side cladding
Graphite black, similar to RAL 9011 ● ●
Basalt grey, similar to RAL 7012 ● –
Gentian blue, similar to RAL 5010 ● – 41
Flap dock shelters
Accessories
DDF
Standard widths: 3300 / 3400 mm
Colours
Top and side flaps DDF
Graphite black, similar to RAL 9011 ●
Basalt grey, similar to RAL 7012 –
Gentian blue, similar to RAL 5010 –
Marker stripes
White ●
Yellow –
Orange –
Red –
Side cladding
Graphite black, similar to RAL 9011
Basalt grey, similar to RAL 7012
Gentian blue, similar to RAL 5010
42
Flap dock shelters
Optional equipment and versions
Top flaps
3-part
On request, you can also receive
the top flap for the dock seal DS,
also with lateral incisions to reduce
the load during docking.
Laminated corners
An alternative to the 3-part top flap,
however with two incisions each
at the right and left corners, possible
with type DS.
Fully laminated
In the scissors arm design we also
optionally provide the top flap
laminated across the entire width
with 100 % overlap.
Roll-up
In order to achieve overhead sealing,
even on very small vehicles,
an additional roll-up flap can
be installed, which is manually
or electrically operated.
Recessed version
Flap dock shelters are also available
with multiple scissor arms which
are manually advanced similar
to an accordion. They are particularly
suitable for retrofitting existing
open ramps.
Corner sealing cushions
The bottom edge of the dock seal
between the wall connection and flap
can optionally be sealed with corner
sealing cushions.
43
Inflatable dock seals
Flexible sealing without restriction to the door opening area
Inflatable dock seals adjust particularly well to the different lorry sizes.
The excellent seal mostly prevents the entrance of cold into heated buildings
or of heat into refrigerated warehouses, saving energy. It envelops the vehicle
without restricting the area of travel of the doors and is the optimal solution
for specific situations, such as a DOBO system. After the loading process
and switching off the fan, the cushions quickly withdraw via their interior
tension cables and counter weights.
44
Hörmann practical application tip
The inflatable dock seal can be operated conveniently
with multi-control 460.
Design features
Frame construction
The roof and side cladding are made of insulated
steel panels, 20 mm thick. They are available
in a choice of White aluminium, RAL 9006,
or Grey white, RAL 9002, with anodised aluminium
corner profiles with a rounded softline look.
Blower
The powerful blower is in operation during
the entire loading process and thus guarantees
a constant seal. Ventilation slots ensure
the required pressure compensation and drain
condensation water.
45
Inflatable dock seals
Versions
DAS-3
3-sided inflatable dock seal
46
Inflatable dock seals
Optional equipment
Roll-up flap
Electrically operated roll-up flaps can also be used instead of a top cushion.
They allow for more flexibility with large differences in vehicle heights.
A three-metre-long version is available in addition to a two-metre-long version
that is lowered and raised via press-and-hold. This function is conveniently
operated together with the side cushions in impulse operation, for example
via dock leveller control 460 S / T. A special mechanism ensures that the flap
follows the vehicle, should it sink. This ensures a constant, good seal.
Recess version
Inflatable dock seals are also available in a recess version. Fitted
in a correspondingly equipped loading house, the dock seal is optimally
protected against rain water and snow loads.
47
Cushion dock seals
Best solution for special areas of application
48
Hörmann practical application tip
During the docking, the cushions may not be pressed-in more than 50 mm. Therefore
it is important that the depth of the buffer has the right proportion to the depth of the
cushions. With the help of support brackets, the difference can be simply bridged.
DFH
Dock seal with fixed side
All dimensions in mm
Colours
Top and side flaps DFH DFC
Graphite black, similar to
● ●
RAL 9011
Marker stripes
White ● ●
Yellow ● ●
Orange ● ●
Red ● ● 49
Hörmann industrial doors
The complete programme for your logistics
50
Hörmann practical application tip
High-speed doors are suitable not only as individual doors, but also in combination
with sectional or rolling shutters to quickly close the opening after the forklift
has passed through.
High-speed doors
Hörmann high-speed doors are used both inside
and as exterior doors to optimise traffic flow,
improve room air conditions and save energy.
Your advantage: SoftEdge technology with
built-in crash-protection makes high-speed doors
extremely safe and economical.
SICHERHEITS-LICHTGITTER
HÖCHSTE KRATZFESTIGKEIT · serienmäßig ·
Industrie -Sectionaltore
Torausführung Parcel / ParcelWalk
Rolltore und Rollgitter
Ansichtsgleiche Nebentür NT 60
Schnelllauftore
Spiraltore und Speed-Sectionaltore
mit 42 / 67 mm thermisch getrennten Lamellen
Further information
can be found
in the Hörmann brochures
51
Buffers
Buffers protect the ramp and the building from damage. They absorb the dynamic
forces of the lorry during docking and are both sturdy and flexible. Depending on
the requirements, different mounting plates and mounting brackets are available.
52
Hörmann practical application tip
A mounting plate allows the simple replacement of the buffers.
Buffers in various
sizes and shapes
Flexible bumpers
Flexible bumpers follow the up and down
movements of the lorry during loading
and unloading. In addition, height-adjustable
versions offer the opportunity of driving Flexible bumpers
the bumper up to 250 mm upwards and lock follow the movement
it there. They are indispensable for the DOBO of the lorry during
system. Flexible bumpers are available as rubber, loading and unloading
PU or steel buffers.
Mounting plates
and mounting brackets
Mounting plates
For particularly secure fitting of the buffer
to the building. For renovation, when the building
structure is already damaged, mounting plates
are indispensable in most cases. Mounting plates /
mounting brackets
Mounting brackets for safe and flexible
With the help of mounting brackets, a buffer fitting
can be placed above the pedestal level
or be given more depth, for example with tail lifts
or for the protection of cushion dock seals.
To fit mounting plates by welding, we recommend
a steel bracket at the ramp edge.
Advantages at a glance:
• Reliable transmission due to short distance between
the reader and transponder Automatic recording of goods movements, simply while crossing
• The RFID reader is securely fitted underneath the dock the dock leveller.
The delivery note with the information on the goods and the linked
transponder number is displayed. The completely loaded goods
are then marked (Fig.).
54
Accessories
Safety equipment and external control for loading houses
Wheel chock
A wheel chock prevents the lorry from leaving
the safe docking position during the loading process,
e.g. by braking of the forklift when driving in or out
55
Accessories
Wheel guides
Docklight
Docklights provide a safe
and bright work environment and
good illumination of the loading
area. The energy-efficient LED
docklight is recommended
above all in addition to the
halogen version DL 1300. With
30 W power input, it ensures
uniform, good illumination.
Button DT 1
In most cases mounted to the ramp, button DT 1
is used for functions such as driver registration.
In this way, the driver is first ordered to check
the docking position, in order to then put the dock
leveller into operation at the press of a button.
56
Accessories
Wheel guides, protection bollards
Light guide
The LED lights attached to both sides of the dock leveller
help guide the lorry driver, even in the dark or if visibility
is impaired due to heavy precipitation.
There is no hindrance to cleaning vehicles or snowploughs.
Wheel guides
Wheel guides are used to support the driver in docking.
At the same time, they guide the lorry straight into
the loading bay or dock seal/shelter. This prevents
damage to vehicles, ramps and dock shelters
and ensures efficient sealing. Wheel guides are available
in straight and curved versions.
Protection bollards
Protection bollards are a useful investment indoors
and outdoors.
Outdoors they prevent expensive collision damage
to driveway dock shelters or to buildings.
Indoors they protect door tracks from collision damage
during loading by forklifts.
57
Hörmann Product Range
Everything from a single source for your construction project
58
Quick service with testing,
maintenance and repairs
Our extensive service network
means that we are always nearby
and at your service around the clock.
Sectional doors
Rolling shutters
and rolling grilles
High-speed doors
Loading technology
Visibility window
59
Hörmann: Quality without Compromise
Hörmann KG Amshausen, Germany Hörmann KG Antriebstechnik, Germany Hörmann KG Brandis, Germany Hörmann KG Brockhagen, Germany
Hörmann KG Dissen, Germany Hörmann KG Eckelhausen, Germany Hörmann KG Freisen, Germany Hörmann KG Ichtershausen, Germany
Hörmann KG Werne, Germany Hörmann Alkmaar B.V., Netherlands Hörmann Legnica Sp. z o.o., Poland Hörmann Beijing, China
Hörmann Tianjin, China Hörmann LLC, Montgomery IL, USA Hörmann Flexon LLC, Burgettstown PA, USA Shakti Hörmann Pvt. Ltd., India
Hörmann is the only manufacturer worldwide that offers you GARAGE DOORS
a complete range of all major building products from one source. OPERATORS
We manufacture in highly-specialised factories using the latest
INDUSTRIAL DOORS
production technologies. The close-meshed network of sales
www.hoermann.com
LOADING EQUIPMENT
and service companies throughout Europe, and activities in the
USA and Asia, make Hörmann your strong partner for first-class HINGED DOORS
Issue 12.2016 / Print 03.2017 / HF 86278 EN / PDF