Dock levellers with swivelling lip

Dock levellers are delivered with sheets for

CAMPICAST dock leveller is delivered with preassembled electro-hydraulic powering system underneath the leveller (unless the dock leveller was ordered with multifunction console). It was designed for direct installation in a concrete without the need for constructing special loading station; it is sufficient to prepare the edge and floor slab on which leveller will be placed. After placing leveller on the floor slab and securing it in position to prevent movement during pouring of concrete, concrete is poured and pavement is constructed. Sides of the leveller are equipped with profiles which fix the leveller in the concrete floor slab.
Delivery: truck trailer can accommodate 5 dock levellers arranged in stacks 550mm x 5 = 2750mm. The truck must be not covered and then trailer must be on the level not larger than 1200mm. For transport purposes total length of the leveller with closed lip (swivelling lip) and main hinge as 300mm large then the length of ramp itself. plus 150mm should be adopted.

Fixing of side profiles:
Particularly important here is the innovative and patented mounting system of two edges which are embedded into concrete poured into large openings in metal. Head, which is the most strained part during loading, is equipped with strong buckles which are firmly attached to mesh located below head and above head.

Technical specifications:

Leveller dock: covered with steel non-slip surface, equipped with machine welded supports. Leveller dock is delivered with metal sheets for covering of concrete fixing. Dock leveller must be attached to the floor slab by means of screws and plugs and then attached to the edge prior pouring concrete.

Swivelling lip: standard length is 360mm, optional 430mm (at each size the total length is extending over the dock edge).

Load bearing with concentrated load is according to EN 1398: 6000kg – 9000kg (10000kg – 15000kg with uniformly distributed load – but not on ramp scope).

Self supporting structure: CAMPISACAST system with vertical reinforcements.
Finishing: galvanised metal sheets, ramp surface after degreasing and phosphorescing is painted with two-component epoxy anti-corrosion primer coat and two-component top coat of RAL 7005 and coat oven dried. Lip is painted with RAL 2000.

Operation: lifting is done with hydraulic cylinder equipped with safety valve according to standard EN 1398; opening of lip is hydraulic, forced hydraulic closing (not by gravitation). Command for one full cycle issued by single push button (lifting – lip opening – automatic lowering after releasing button – closing of lip and rising the ramp by releasing button prior ramp reaching its highest position, automatic lowering to the resting position.

Side adjusting: during loading the dock levellers are adjusting to vehicle inclination in lateral plane in the range specified in standard EN 1398

Maximum tilt: + 640 – 350 mm.

Maximum working inclination: maximum inclination allowed by standard EU 1398 is 12,5%, however vehicles slide at this inclination. The largest inclination which transport means can conquer is 8% for forklifts and 4% for pallet jacks.

Power supply and control:

• electro-hydraulic three-phase 380-400V power supply system installed under ramp, control of one full cycle with one press button.
• wall mount, single phase, 230V electro-hydraulic console enabling safe, easy and economical maintenance, one command control or operation of several functions.

Optional equipment:

• side flaps: for ramp 2200mm wide – 2 flaps 180mm as standard, for 2000mm long ramp – 2 optional flaps 180mm
• wind seals: main hinge equipped with this protection as standard. Side sealing available as optional equipment
• rubber bumpers: bumpers of SUPER type constitute a part of readymade equipment. Bumpers need to be ordered for traditional docks for installation on plates by means of wall plugs.

Alternative for ordering:

• rubber bumpers of SUPER type with dimensions 150 x 140 x 400 mm height with patented sleeves which are placed in cement fastening.

Rubber bumpers ordered with dock levellers fixed by sleeves.

Preparation for fixing into cement:

Leveller shall be placed on cement floor slab, aligned to the front edge, levelled and then 2 corner buckles at front corners should be opened at 45° angle. The leveller must be then fixed to the floor slab using the openings drilled in the beam to prevent its movement during pouring of cement (see the instructions). Cement should be levelled from three sides: firstly the base layer, approx. 15-20 cm from the floor level; next the floor level with two mesh reinforcements, one bellow the main buckles and the second one above them. Floor must completely cover the side profiles – they must be embedded in concrete to gain the maximum support. The protective cover should not be removed before works completion.

Arrangement of edge and the plate:

CAMPISACAST dock leveller must be placed on plate located on the height of 570mm (minimum 550mm for structures of strict tolerances) from finished floor level, it must be levelled and attached to the plate before pouring cement (see picture IR000689).

The leveller 2000mm wide : opening “A” should be:
2440mm with SUPER bumpers

The leveller 2200mm wide : opening “A” should be
2640mm with SUPER bumpers

Length “B”: approx. 500mm larger than the length of the leveller

Width “F”:
approx. 600mm larger than the width of the leveller
2600mm (for leveller 2000mm wide)
2800mm (for leveller 2200mm wide)

Dimension “D”: fixing of lifting cylinder
1615mm (for leveller 2500mm wide)
1830mm (for leveller 3000mm wide)

Width “E”: 180 larger than the width of dock leveller 2180mm (for leveller of width 2000mm), 2380mm (for leveller of width 2200mm). Width “G”: 300mm larger than the length of leveller 2800mm (for leveller of 2500mm long) and 3300mm (for the leveller 3000mm long).