Whole life cost, operational efficiency and safety drive
developments in loading bay technology and warehouse
design. Hörmann and Prologis have been working together
to meet the future needs of customers

Consultation with logistics operators and
key customers has been established to
determine occupiers’ evolving needs so
that warehouse designs are, as far as possible,
future proofed. This work lays the foundations
for new product development at Hörmann,
which continues to focus its research and
development effort to deliver the right
equipment to meet operational and energy
efficiency demands, while improving safety.

The focus is not just on products but also
on how the two companies can provide the
best possible service. From this Prologis has
introduced the build-to-suit five year lease,
where in exchange for a five year lease
commitment, Prologis will build a high quality,
sustainable distribution centre to meet a
customer’s exact needs. The short-term nature
of the lease means Prologis needs to design the
buildings to be flexible and adaptable in order
to maximise the value of its investment.

Service and maintenance forms an
important element in ensuring the optimised
building operates at maximum efficiency. For
doors and loading systems this has the added
benefit of extending their working life cycle,
reducing their overall environmental impact
and minimising the risk of a breakdown
leading to any costly downtime.

Increased demand for service contracts
has not only prompted Hörmann to invest
even more in its service provision but has led
to new initiatives inspired by the
consultation process. New pre-winter checks
have been introduced to meet a concern that
downtime in winter months can be more
costly particularly if a door sticks in the open
position. The purpose of the checks is to
ensure maintenance and service programmes
are working efficiently and that any remedial
action is carried out quickly to prevent costly
interruptions, particularly during the
traditionally busy pre-Christmas period.

As loading systems become more flexible
and adaptable, safety and energy efficiency
demands are becoming more stringent. To
this end there is increasing integration of
loading bay components, which in turn calls
for service and maintenance programmes
that ensure the equipment operates reliably
and to its peak potential at all times.

The consultation process has thrown up
some anomalies in current warehouse
design. Traditionally dock heights in the UK
were set at around 4ft (just over 1200mm);
however the standard deck height for most
trailers is around 1300mm. By adopting this
new height as a standard for new
developments and installing longer 3.5m
dock levellers, a greater range of vehicles can
be accepted at an individual loading bay.

This instant flexibility has a benefit in the
construction phase, as standard size dock
shelters and dock houses can be installed
without modification, speeding up the build.

These changes are adding to the benefits
that can be achieved, and with supply chains
targeted as an area where savings can be
made, there is now greater scrutiny of
operating costs than ever before.

Mark Moore, service manager for
Hörmann in the UK is seeing this change first
hand, as he explains: “The days of open door
policies for some loading areas and the
attitude of ‘we’ll fix it when it breaks’ are long
gone. Service contracts with extended
warranties are becoming the norm as our
customers are ensuring they get the
maximum out of their equipment, to run
streamlined operations. It is all about quality
and service with preventative maintenance
recognised as a cost saver by most operators.

The best way to describe the changes we are
seeing is to compare our equipment to cars
and trucks. When it comes to vehicles the
owners adhere to the manufacturers’
recommended servicing schedule to
maintain warranties, the same is quickly
becoming standard for our products.”
Responding to customers’ needs has
developed flexibility in terms of the services
provided and the future proofing of designs
and in the way projects are approached. A
specification is built that can satisfy a number
of criteria, from the immediate needs of
today to the predicted needs of the future.

Hörmann and Prologis have completed a
number of projects where the design has been
strongly influenced by the need to adapt to
potential future requirements. At the BMW
distribution centre in Prologis Park Pineham
(pictured), ‘knock through’ pre-cast concrete
door panels have been placed between the
current loading bays so that additional bays
could be easily installed should BMW’s needs
change. This also adds to the long term use of
the building which could readily be modified
for any future tenants. At Prologis Park
Bradford, an alternative solution was
employed and manual, insulated, sectional
doors fitted, instead of ‘knock through’ panels,
to a section of a building that was designed to
accommodate additional bays should they be
required. In both these examples, the
flexibility to expand with minimal
environmental impact