A loading ramp acts as a pacemaker. If loading stalls, it's not just a truck that stops – the whole system stops. Your entire chain: goods receipt, warehouse, order picking, shipping. And yes: often it is The cause was trivial: a misaligned loading ramp, a defective lip, a Inappropriate controls – or maintenance that's just something we'll "do sometime".

The worst part is that many businesses only realize how expensive this is when the first damage occurs. But it's exactly the opposite: Whoever designs the loading bridge properly, operates it safely, and Regularly checking your finances saves you money quietly every month. No drama.

• Risk of accidents due to incorrect lip positioning or excessively steep inclination.
• Damage to forklifts caused by edges, gaps and hard transitions.
• Cargo damage due to a bumpy crossing or a sagging truck.
• Time lost due to "temporary solutions" (boards, sheets of metal, improvisation).
• Energy losses at the dock (drafts, cold, humidity, dust).

In short: A good loading bridge is not a gimmick – it is a profit and Safety lever.

• Control systems for loading technology (ramp controls & accessories)
• Gap seals for ramps and lifting platforms
• Expert advice & customer service (when you need it done quickly and cleanly)

Loading bridge / transshipment bridge

This is the bridge between the ramp and the truck. It compensates for differences in height and ensures that... so that forklifts, pallet trucks and personnel can drive over safely.

In everyday language you also hear: "dock leveler", "loading bridge" or "ramp bridge". This almost always refers to... It's always the same – only the design differs.

lip

The lip is the front support element that rests on the truck bed. It determines, whether the transition is smooth and safe – or whether it crashes, slips and goes wrong.

If the lip is too short, doesn't sit properly, or hangs "half in the air": immediate stress.

Feed lip vs. hinged wedge

Feed lip (telescoping): The lip extends actively and can be positioned more precisely.
Folding wedge (folding): The lip folds out – often robust, but less “fine” in its adjustment.

Which system is right for you depends on your dock, your vehicles, and your pace – not on gut feeling.

• Platform (the main sheet metal that bears the load)
• Lippe (cover on the truck)
• Hinge area (this is where the mechanism lives or dies)
• Lifting system (hydraulics / mechanics / air bellows)
• Safety features (maintenance stand, toe guards, emergency stop – depending on the system)
• Control (operation, logic, safety, and possibly signals)

• Clean, smooth crossing (no "kick" at the transition).
• The lip lies flat (not just at the edge).
• No dangerous gaps on the sides.
• The control system reacts clearly – without any "trick 17".

If you constantly have to improvise, either the interpretation or the condition is wrong.

Control systems are often the underestimated aspect. A good ramp control system ensures that... that the loading bridge works reproducibly – and not “differently” each time.

5.1 Approach & Docking

The truck starts moving, engages the buffer, is secured (depending on the concept: wheel chocks, Wheel blockers, signaling). Only then can you proceed.

Anyone who operates the gate and bridge first and only then "quickly" secures the area is creating a risk. And risk is always expensive at the ramp.

5.2 Gate, Bridge, Loading

In many docks, the order is crucial: open the gate, position the bridge, Carefully place the lip on the surface before releasing traffic.

Tip: If you use interlocks (gate/bridge coupled), the risk of incorrect operation decreases massively.

5.3 Departure & Return

After loading: Bridge back to its starting position, gate closed, safety release, departure. It sounds trivial – but it's exactly the point where many people "take shortcuts".

That's exactly where the damage occurs: lip still outside, truck drives away, crash. End of story.

Trucks are not always the same height. And their height changes when loading/unloading. In addition, there are different ramp heights, chassis, air suspension and load conditions.

The goal is simple: The crossing must be positioned so that vehicles can drive over it safely. without it becoming too steep or the lip "lifting off".

• Lift upwards (when the truck is higher)
• Lift downwards (if the truck is lower or sinks)
• Lip length & support (so that the transition remains sustainable)

Remember: If the truck sinks, the bridge must be able to move with it. Otherwise, a step will form – and that will destroy your equipment and your nerves.

• What is the height difference between the ramp and a typical truck?
• Which vehicles are actually coming? (7.5t, semi-trailer truck, swap body)
• What's your firing rate? (occasional vs. continuous)

Load capacity is not just about "how heavy the forklift is". What's crucial is how the load is distributed. It moves dynamically over the transition. Peaks form at the edge. And peaks are what It kills components.

Therefore, the following applies: If you save money on the loading bridge, you will pay for it later through repairs. Downtime and damaged goods.

• Vehicle type (electric pallet truck, forklift, reach truck, etc.)
• Max. load + dead weight
• Driving speed on the ramp (yes, that makes a difference)
• Wheel loads / axle loads
• Width of the crossing (single lane/double lane)

The loading bridge is a safety component. If you undersize it, It won't just be uncomfortable – it will be dangerous.

And yes: That's precisely why a professional check is worthwhile. Laying it properly once is cheaper than patching it three times.

There are various ways to move a loading bridge. Each method has its advantages. However, each option also has typical sources of error. Knowing these will help you make a better decision.

Important: "Low-maintenance" does not mean "maintenance-free". There's no free lunch at the loading dock.

In high-frequency docks you often see hydraulic systems with clear control and clean Signaling. Because it's predictable. And predictable means: less stress.

9.1 Feed lip (telescoping)

The feed lip extends actively and can be positioned more precisely on the truck. This is great if you have many different vehicle heights or want to work more precisely.

• More precise adjustment to varying truck heights
• Often a very clean transition with good settings
• Ideal for high-frequency operations and varying vehicle types.

9.2 Folding wedge / folding lip

The folding wedge unfolds. It's simple and robust, but less "precise" than a feed lip. In some environments, this is exactly an advantage: less "fine-tuning", more "just working".

• Robust design
• Proven in standard vehicle fleets
• Less “complexity” in the movement

If you tell us which vehicles are coming and how your dock is set up, we'll tell you what makes sense – without marketing fluff.

For both systems, the appropriate ramp control is key. The control determines, how smoothly the bridge moves, how reliably it returns to its starting position, and how you integrate safety.

Working on loading bridges is not a hobby project. When it comes to electrics, hydraulics, or... Load-bearing components can only be worked on with experts, manufacturer specifications, and proper safeguarding.

A misaligned lip isn't just "annoying". It's a potential accident hazard.

If operators have to "know the ropes," that's not a good sign. Good technology is like that. It's designed to work reproducibly. And that's exactly what a ramp control is for: Clear processes, clear conditions, clear feedback.

In practice, controls are often the point that turns "it sort of works" into "it runs smoothly".

• Clear operating logic (up, down, lip, reset)
• Clear signaling (operating status, fault, release)
• Interlock options (e.g., gate/bridge coupled)
• Robust design for industrial environments
• Serviceability (diagnostics, replacement, clear wiring)

In our "Controls for Loading Technology" section you will find solutions for various applications. Bridge types – including variants for feed lip and hinged wedge.

The ramp is a danger point: crushing, falling, running over, driving away, slipping. You don't need to dramatize it – you just need to secure it properly.

Many accidents don't happen because people are "stupid," but because of processes and technology. Allowing user error. And that's exactly what you shouldn't allow.

• Safety strut/maintenance support for service work
• Side covers/protection against pinch points
• Emergency stop or safe shutdown (depending on the system)
• Signaling (traffic light/display) for driver and warehouse
• Wheel blockers or clear organizational security measures

If you still have boards lying around as "compensation": That's not a solution. That's a Random number generator. One wrong move, and you're in trouble.

Clean height adjustment + clear operation = less risk, more speed.

A loading bridge is only as good as its surroundings. If the pit is poorly prepared, If water is standing, edges are breaking off, or the power supply has been "somehow" disconnected, then It's never quiet.

Good planning means: dimensions fit, loads fit, water doesn't play tricks on you, and service is possible. without dismantling half the dock.

• Clarify vehicle mix and timetable
• Measure ramp/dock height and level differences
• Check pit dimensions and installation situation
• Plan power supply & protection (industrial environment!)
• Consider drainage / moisture / corrosion
• Consider gate and dock sealing (energy loss is real)

Send us some photos of the dock, its dimensions, and your vehicle mix. We'll tell you clearly, what makes sense – and which parts you can get directly in the shop.

13.1 Before opening: Secure the truck

Secure first, then move. Period. Depending on your plan, this means: Wheel chocks, wheel chocks, organizational approval, signaling.

“He’s not going anywhere” is not a strategy.

13.2 Open the gate, position the bridge

Open the gate, position the platform, and place the lip cleanly on top. A flat contact surface is mandatory. A lip that hangs "on the edge" is a problem – not a condition.

If you notice that operators are constantly readjusting: check the causes (wear and tear, control system, incorrect design).

13.3 During loading: do not overload, do not speed

It sounds like an old-fashioned saying, but it's pure physics: speed + edge = peak load. And peak load = wear and tear + damage.

Pro tip: A smooth transition saves you forklift tires and repairs. Every month.

13.4 After loading: Reset

The bridge must be returned to its original position before the truck is allowed to proceed. If the Lippe still hanging in the truck while the driver is driving – that's the classic scenario that gets expensive.

13.5 Shift change: brief visual inspection

A quick look can save you a major breakdown. If oil is leaking, the lip is "catching," or the If the platform appears crooked, don't ignore it. It's better to react early.

Small glitch + quick fix > major outage + chaos.

• Lip only makes contact at a single point → incorrect positioning or wear.
• Lip doesn't move/fold properly → Check drive/mechanics/control.
• Cracking/knocking sound when driving over → transition too hard, setting or dimensions.
• Side gap “open as a barn door” → missing/defective side protection solutions.

• Platform sinks away → Leakage, valve, cylinder (expert check).
• Jerky movement → air in the system, valves, contamination, maintenance issue.
• Slow reaction → oil condition, filter, unit, temperature.

• "You have to press twice" → Contacts, logic, control panel, wiring.
• Fault after rain/moisture → Sealing, housing, junction boxes, environment.
• Unclear states (no one knows if it's free) → signaling/interlock is missing.
• Emergency stop/shutdown is triggered → find the cause, do not bypass it.

Once a problem occurs repeatedly, it is no longer a "coincidence". It is a pattern. And patterns can be solved cleanly – with photos, a short description, and a professional check.

If control/operation is the topic: Look in “Controls for loading technology”. This is often the quickest way to reduce operator errors and stabilize processes.

Maintenance isn't sexy. But downtime is even less sexy. And on the ramp, the following applies: If it breaks down, it breaks down at the exact moment you need it least.

Good maintenance is a mix of visual inspection, cleaning, functional check and Plannable testing. Not rocket science – if you take it seriously.

Note: The specific intervals depend on usage, environment, and risk assessment.

Many problems arise because controllers are "old", contacts are damaged, or the logic is flawed. better suited to the intended use. A suitable ramp control system helps to make loading clearer and safer.

When the loading bridge malfunctions, people often press buttons, switch gears, and try things out without a plan. Result: wasted time and frustration. Better: systematic approach.

You don't need an engineering thesis. You need a clear sequence.

• Visual inspection: Oil? Damage? Loose parts? Unusual position?
• Operation: What exactly happens when you press the button? What is the reaction?
• Environmental factors: humidity, dirt, temperature, mechanical obstruction?
• Electricity: Fuse, power supply, plug connections (qualified professional required!)
• Documentation: Photo/video is more helpful than 10 phone calls

Send us 3 things: a photo of the nameplate/system, a short video of the fault, and a sentence: "What should she do, what does she do instead?"

A loading dock is a huge leak if it's not sealed. Drafts, Cold, dust, moisture – everything finds its way in. This costs energy and makes goods susceptible to damage. and creates an unpleasant working environment.

Good sealing is not just a "nice to have". In many businesses, it's a real ROI driver.

• Gap seals on ramps/transitions
• Floor profiles & seals at gates and transitions
• Clean edge solutions instead of "open gaps"

Relevant sections in the shop:

• Gap seals, loading technology
• Floor profiles & seals

A customer once said: "We have a draft." After the sealing, it wasn't just warmer – The goods stayed cleaner, the gate areas drier, and the team celebrated. These are the kinds of improvements you notice every day – and yet they often go unaddressed.

Many docks have an industrial gate (often a sectional door) directly at the loading point. If the gate is malfunctioning, slow, or "acting up", the entire process is delayed: Longer downtimes, more hectic activity, more mistakes.

And then the usual thing happens: people want to make up for lost time – and that's exactly where the risks increase.

• Rough running (worn road wheels)
• Misalignment / jerky guidance
• Defective hinges/roller holders
• Bottom seal "finished" → Drafts & dirt at the dock

• Ball-bearing rollers (sectional doors)
• Roller holders & hinges (sectional doors)
• Gap seals for sectional doors

Rollers and roller holders are classic wear parts. When the rollers are worn out, The gate runs more heavily, loudly, and often erratically. And erratically means: more stress on everything, what's attached to it.

You notice it immediately at the dock: The gate takes longer to open, operators press the button more often, processes become hectic. It is not the “biggest” problem – but it triggers many small subsequent problems.

• The gate suddenly becomes louder or jerky.
• The reels have play or are visibly malfunctioning.
• Hinges/roller holders appear warped or loose
• The gate is "stuck" or no longer moves cleanly into its final position.

If it starts at the gate, the loading point will eventually suffer as well. It's a chain reaction.

• Ball-bearing rollers
• Roll holders & hinges

Most people only consider the purchase price when it comes to loading equipment. What's rarely factored in is: Downtime costs, delays, damages, complaints, energy loss. And that's exactly what it is. The point at which good loading technology pays off brutally quickly.

• How much does it cost to be idle for one hour at the dock?
• How often per week is there improvisation or reenactment?
• How much damage was caused at the border crossing last year?
• How much energy do you draw through open/leaky docking points?

Once you answer that honestly, the investment suddenly no longer seems "expensive".

In many cases, the right control system + a clean seal is the fastest step. because it reduces user errors and makes the dock more stable – without having to completely rebuild everything.

• Control systems for loading technology
• Gap seals, loading technology

21.1 High-speed logistics hall

Many truck types, frequent changes, high pressure. Solution: clear processes + reliable control. plus sealing, so that the dock area does not become an energy drain.

• Ramp control suitable for the bridge design
• Clear signaling/logic – fewer operating errors
• Gap sealing at the dock improves the working environment

21.2 Food / Hygiene sensitive

Control is key here: drafts, dust, humidity – everything is a concern. The loading area It must be sealed and clean, otherwise quality and audits will suffer.

• Consistent sealing at transitions
• Regular cleaning and maintenance routine
• Clear “Do’s & Don’ts” for operators

21.3 Medium-sized businesses with "already running" dock

Classic scenario: outdated technology, many makeshift solutions, no one feels responsible. Solution: one-off. Take inventory, identify critical points, and draw up a maintenance plan.

• Modernize the control system (stabilize operation)
• Replace gate parts (rollers/hinges)
• Retrofit sealing

It's almost never "one big thing". It's five small things that suddenly happen together. a clean loading area. And that's exactly where we excel: sorting quickly, Highly recommend, deliver reliably.

• Photos of the dock (ramp, bridge, gate, operations)
• Which vehicles come regularly?
• What type of loads will be driving over it (pallet truck/forklift type)?
• What is the most annoying problem right now?

• Check/retrofit sealing (drafts, dirt, moisture)
• Stabilize operation/control (clear processes)
• Check gate movement (rollers, roller brackets, hinges)

• Control systems for loading technology
• Gap seals, loading technology
• Ball-bearing rollers
• Roll holders & hinges

If you want things to run really smoothly: We'll look at your situation and tell you, what you can resolve directly in the shop – and where service makes sense.

We don't sell you anything "on a hunch". We want your dock to run reliably.