How to Choose the Right Rail Dock Board for Your Facility

By Mike Nelson, Posted in Dock Boards

Choosing the right rail dock board starts with the application, not with a model number.

Two facilities can use similar forklifts and still need very different boards. Railcar type, dock-to-rail distance, door opening, lift-truck capacity, attachments, turning room, and whether the board will bridge dock-to-car or car-to-car all affect the final configuration.

That is why a rail dock board should be treated as site-specific railcar loading equipment. Before choosing a size or capacity, gather the measurements and equipment information that define the job.

Start With the Application: Dock-to-Car or Car-to-Car?

The first question is what the board needs to connect.

For dock-to-car loading, the board bridges a fixed loading dock and a railcar. Key measurements include the distance from the dock to the inside rail and the height from the top of the inside rail to the dock.

For car-to-car loading, the board bridges one railcar to another. That requires a different measurement: the distance from the inside rail of one track to the inside rail of the other.

These applications should not be treated as interchangeable. The geometry is different, so the board specification is different.

Railcar type matters as well. The Rail Dock Board Worksheet asks whether the application involves refrigerated, box, or flat cars before final dimensions are established.

Measure the Site, Not Just the Board

Width and length matter, but they are only part of the dimensional picture.

Important measurements include:

For dock-to-car applications, the worksheet calls for dock-to-inside-rail measurements throughout the operating area rather than relying on a single measurement.

The nominal board size is also not the whole dimensional picture. The worksheet accounts for overall width and relates board length to the measured dock-to-rail dimension. In other words, selecting a “96-inch board” from a table is not a substitute for measuring the actual site.

Common Rail Dock Boards include 96″, 102″, and 120″ widths, with lengths available up to 60″, but those dimensions are starting points for specification.

Choose Rail Dock Board Capacity Around the Equipment

Rail dock board capacity should reflect the equipment and load that will actually cross the board.

Do not look only at product weight.

The selection process should account for the largest lift truck used on the board, its load, and any forklift attachments. Attachments can change the equipment configuration and must be identified during specification.

Published rail board configurations include 15,000-, 25,000-, and 40,000-lbs. capacities, while heavy-duty steel rail boards can be built for capacities up to 100,000 lbs.

Capacity is also part of railcar loading safety. A dockboard must support the maximum intended load, so the correct capacity should come from the complete application rather than an estimate based on cargo alone.

Check Forklift Access and Turning Room

A board can have enough capacity and still be wrong for the loading path.

The forklift has to approach the board, cross it, pass through the railcar door, and maneuver at both ends. Forklift width, attachments, door width, and available turning room all affect that movement.

For tight approaches, rail boards can be configured with 10°, 20°, or 30° flares on the dock or car side.

That makes the real question more than:

Is the board wide enough?

It should also be:

Can the lift truck approach, cross, and exit the board through the available space?

Account for Railcar Positioning

Railcar positioning can change the usable gap and alignment.

Before finalizing a board, identify:

• where the railcar door will align with the dock;
• whether the dock-to-rail distance changes along the loading area;
• the narrowest railcar door that may be encountered;
• whether different railcar types will use the same location; and
• whether the board can be positioned consistently at each loading point.

A board designed for one set of site dimensions should not automatically be assumed to fit a different loading position.

Consider How Often the Board Will Be Used

Frequency of use does not determine capacity by itself, but it affects the service demands placed on the board.

Consider whether rail loading is occasional, takes place during one shift, or continues through multiple shifts.

More frequent use means more:

• loaded forklift crossings;
• positioning and removal of the board;
• lifting and handling;
• exposure to the facility environment; and
• need for routine inspection and maintenance.

Rail board manufacturers across the industry include use frequency in their specification process for this reason.

Our rail boards use heavy-duty steel construction with a box understructure, built-in lift loops, and D-rings for handling and secure positioning.

Why Steel for Rail Dock Board Applications?

Standard dock equipment may use steel or aluminum depending on the application. Rail loading has a different set of demands.

Our rail dock board line uses steel construction for rail-specific applications where powered equipment, substantial spans, and high-capacity requirements can all be part of the job.

That does not mean aluminum is unsuitable for every dock application. It means a railcar application should not be treated like a conventional trailer dock.

When Is a Standard Dock Board Not the Right Choice?

A standard truck dock board and a rail dock board solve related problems, but they are designed around different applications.

A standard board is not appropriate when the facility has car-to-car loading, unusual rail gaps, narrow railcar doors, high-capacity requirements, or tight turning conditions.

For conventional truck and trailer loading, compare the available Steel Dock Boards.

What Information Should You Have Before Ordering?

Before requesting a rail dock board, gather:

1. Railcar type or types
2. Dock-to-inside-rail distance
3. Rail-to-dock height
4. Car-to-car rail distance, if applicable
5. Narrowest railcar door
6. Narrowest warehouse opening
7. Capacity of the largest lift truck
8. How often the rail dock board will be used
9. Forklift attachments
10. Existing board dimensions, if replacing one
11. Turning constraints or flare requirements

The Right Rail Dock Board Starts With the Site

The right rail dock board is not selected from width or capacity alone.

Start with the application, then account for railcar type, site dimensions, forklift and attachments, required capacity, railcar positioning, turning room, and frequency of use.

That information allows the board to be specified around the facility instead of forcing the operation to work around a standard board.

Need help determining the right configuration? Contact our team with your railcar, dock, and lift-truck information.