- Project report – replacing a hinged dock leveller
Replacing a hinged dock leveller: from manual operation to hydraulics at a Frankfurt logistics centre
How 2 mechatronics technicians cut out two old manual ramps and welded in fully hydraulic Expresso hinged dock levellers in one day – mechanical, hydraulic and electrical work from a single source
For years the routine at this loading bay was: fold the ramp down by hand, for every lorry, in every weather. At a large logistics centre in Frankfurt we replaced two ageing, manually operated hinged dock levellers with fully electric, hydraulic hinged dock levellers from Expresso. Now a turn of the switch and a push of the button is all it takes: the leveller rises hydraulically, the lorry docks – and a firm, safe connection is formed between lorry and loading dock.
The best part: the complete replacement – cutting out the old levellers, welding in the new ones, hydraulics, control cabinets, wiring – took a single working day. With exactly two people. Because for a job like this our two mechatronics technicians need neither an additional electrician nor a welder: they are both.
Project profile
- Scope: Replacement of two manually operated hinged dock levellers with fully electric, hydraulic hinged dock levellers (Expresso) – dismantling of the old levellers with an angle grinder, moving in and positioning by forklift, welding to the building's existing steel structure, levelling and welding of the support feet, mechanical assembly, connection of hydraulics and hydraulic control cabinet, installation and wiring of two control cabinets inside the building including pulling the connecting cables
- Team: 2 mechatronics technicians from Omega Mounting
- Project duration: 1 working day
- Location: Large logistics centre in Frankfurt (end customer anonymous)
What is a hinged dock leveller?
A hinged dock leveller is a loading dock ramp that bridges the gap and the height difference between the loading dock and the lorry bed: for loading it is folded down onto the lorry bed, afterwards it is raised again. With old, manually operated models that means muscle power – the employee folds the heavy steel structure down and back up by hand for every lorry. That is strenuous, takes time and carries a risk of injury.
A hydraulic hinged dock leveller does this at the push of a button: a hydraulic power unit raises the leveller in a controlled manner and lowers it cleanly onto the lorry bed. A firm, load-bearing connection is formed between lorry and loading dock that holds throughout loading and unloading – safety for forklift drivers and goods, ergonomics for staff, speed for the handling process. Exactly this step from manual to hydraulic was on the agenda for this project – at two doors at once.
How do you replace a loading dock leveller?
In six steps – from the angle grinder to the last cable connection:
- Remove the old leveller: The old hinged dock levellers were cut away from their original steel frame with an angle grinder – after decades in service, the fastest and cleanest way.
- Position the new leveller: Using the forklift, we brought the new levellers exactly into position at the dock edge.
- Welding in using the MAG process: Each leveller was firmly welded to the building's existing steel structure using the MAG process (metal active gas). MAG is the first choice for structural steel of this kind: high deposition rate, fast weld build-up and strong joints – ideal for welding work directly on site. The new welds are clearly visible in the photos.
- Align the feet: The support feet were then aligned exactly and likewise welded firmly using the MAG process, so that the leveller stands permanently stress-free and secure.
- Mechanics and hydraulics: All mechanical components were assembled, the hydraulics connected and the hydraulic control cabinet installed.
- Electrics inside the building: Inside, we installed two control cabinets for the two levellers, wired them up, and pulled and connected the connecting cables between control cabinet and hinged dock leveller.
By the end of the day both doors were back in operation – with levellers that respond at the push of a button.
Why are mechatronics technicians worth their weight in gold here?
Because this job is three trades in one. Cutting and MAG welding – classic steel fitting work. Connecting hydraulics – machine engineering. Installing control cabinets, wiring, pulling cables – electrics. Anyone planning this with separate trades is coordinating three companies, three dates and three interfaces.
We send two mechatronics technicians who can do all of it: drive there, dismantle, weld, assemble, connect – customer happy. The customer does not have to think about "I need a mechanic, I need an electrician, I need a building services technician" – this job called for exactly the expertise of mechatronics technicians, and that is precisely why the double replacement was feasible in one day.
One example of the flexibility required: on the client's side there was not yet a final power connection at the doors. Instead of waiting, we worked with a power distribution unit and handed over the systems fully functional – the building's own electrical contractor reconnected the final supply afterwards. Properly coordinated, with no downtime for the customer.
Why Omega Mounting?
- Loading dock technology experience: From 18 loading dock levellers in 3 days to a wheel chock roll-out at more than 50 sites – loading bays are our speciality.
- Mechatronics technicians instead of three trades: Welding, hydraulics, electrics – one team, one date, one handover.
- Working during ongoing operations: We replace levellers in a way that keeps the logistics centre running – two doors in one day.
- Manufacturers' partner: We install loading dock equipment from renowned manufacturers such as Expresso – professionally to specification, including commissioning.
- Pragmatic solutions: No site power? Power distribution unit, hand over, have it properly reconnected later – what matters is that the customer can work.
- Rooted in the region: From Rodgau we are quickly on site in Frankfurt, Offenbach and the entire Rhine-Main region – and we work throughout Germany.
Conclusion
Two old manual ramps out, two hydraulic Expresso hinged dock levellers in – cut out, welded in, aligned, hydraulics and electrics connected, all in one day with two mechatronics technicians. For the staff of the logistics centre this means from now on: a push of a button instead of a feat of strength, a firm connection instead of a wobbly one. If your loading dock equipment is getting on in years, get in touch with us – we replace it before something fails.
Request a callback for your project now – Omega Mounting GmbH, Rodgau. As an installation company from the Offenbach district, we are quickly on site in Frankfurt, Offenbach, Hanau and the entire Rhine-Main region – and work throughout Germany.
We bundle maintenance and repair within the city of Frankfurt under Maintenance and servicing Frankfurt.
Photo gallery of the job
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About the author
Tobias Schott
Managing director of Omega Mounting GmbH, Rodgau · more than 20 years of hands-on experience in installation and maintenance
A trained mechatronics technician, at home in maintenance, servicing and industrial installation since 2004 – first alongside his father, and since 2012 with Omega Mounting: from the overhead conveyor in Frankfurt to the crane system in a new-build hall. As appointed person for lifting operations, he plans and leads lifting operations in data centers and on industrial sites in the Rhine-Main region, is an instructor and examiner for cranes, aerial work platforms and telehandlers, and a safety officer. On assignments abroad he is known as the "German Troubleshooter" – the one you call when things get stuck on site. He did not learn what quality means from a manual, but from his father: Made in Germany as a standard for his own work, not as a label. That is why quality comes first at Omega Mounting – before speed and before price. The project diary shows the jobs his team has planned and carried out – without customer names, but with everything that can be learned from them.
Frequently asked questions
With a manual ramp, the employee folds the heavy steel ramp over by hand for every lorry – strenuous and, in the long run, an ergonomic and safety risk. The hydraulic hinged dock leveller rises with a turn of the switch and a push of the button, lowers itself in a controlled manner onto the lorry bed and forms a firm, safe connection between lorry and loading dock.
Cut the old leveller from the steel structure with an angle grinder, position the new leveller by forklift, weld it to the existing steel structure using the MAG process, align and weld the feet, assemble the mechanics, connect the hydraulics and hydraulic control cabinet, install and wire the control cabinets in the building.
On this project: two levellers in a single working day – with two mechatronics technicians, including welding work, hydraulics and the complete electrical installation. Good preparation and a team that masters all trades make the difference.
Yes – our mechatronics technicians install the control cabinets, wire them up and pull the connecting cables to the leveller. Mechanical, hydraulic and electrical work come from a single source; site-specific particularities (such as the final connection still missing here) are solved pragmatically in coordination with the building services team.
Less physical strain, faster lorry turnaround, a defined firm connection for every loading operation – and thus a lower risk of accidents and downtime. Especially at busy doors, the conversion pays for itself quickly.
Yes – this project took place at a large logistics centre in Frankfurt. From Rodgau we are quickly on site throughout the Rhine-Main region, from Frankfurt and Offenbach to Hanau and Darmstadt – and throughout Germany on request.
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