Premium Boat Protection
  • Wahoo Docks™ has developed bumpers to uniquely succeed at achieving the main purpose of a dock – to protect your boat. The Category 5 comes standard with rubber bumpers to cover the top lip of the mainframe, as well as, a specially designed plastic bumper located on the roof supports. For even greater protection, our proprietary 12” mainframe bumper can be included to ensure that docking boats will always receive a soft reception.
    1. Durable
      Our bumpers have been designed to fit tightly around the shapes they cover. When fastened, they cannot easily be ripped off by a boat or other object.
    2. Long Lasting
      Our bumpers are made from long-lasting uv and mold resistant materials specifically identified for the purpose of being located in very moisture- rich environments.
    1. Off The Shelf Products
      Bumpers that provide adequate boat protection can add significant cost to a dock. As a result, many docks fall short of providing a complete complement of bumpers.
    2. Off The Shelf Products
      Standard bumpers can provide useful protection for a boat. Since they are not made for any particular dock, they have generic fastening mechanisms which are typically not as secure as custom molded products.
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Heavy Gauge 9” Mainframe
  • Our 9” mainframe extrusion is a full 34% heavier than the typical 8” c-channel mainframe used by our competitors. The extrusion is an intricate shape designed to provide redundant support for various complementary members within the frame of the dock. Moreover, the additional weight and height also provide substantially more stiffness to provide a stable feel and reduce stress on welded connections.
    1. Interlocking Design
      Our mainframe provides seat for cross bracing, stringers, and gussets so that bracing members may interlock into the mainframe as redundant support for welds.
    2. Heavier
      Being 34% heavier than the typical competitive mainframe components, our mainframe is significantly stronger and stiffer which increases stability and reduces weld fatigue.
    3. 9” Profile vs 8” Standard
      The additional height of the channel adds stiffness to the entire dock.
    1. Vulnerable Connections
      Our competitors typically butt-weld (weld one member to the face of another member) most or all structural components; therefore, relying entirely on the relatively weak welds inherent with aluminum.
    2. Low Grade Aluminum
      Wahoo Docks™ uses only 6061-T6 aluminum for its structural components which has the strongest weld strength of all marine grade aluminum types. Our competitors typically employ less expensive grades of 6005-T5 or 6063-T6 which exacerbates the problem of butt-welds.
    3. 8” Channel
      An 8” channel mainframe can be the foundation for a strong dock if properly designed. Regardless, a dock built on an 8” channel foundation will ultimately be less stiff and have a shorter lifespan than one built on our 9” mainframe.
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Noise Eliminating Bushings
  • To increase strength, the Category 5 dock incorporates numerous connection types depending on location and stresses including gussets, bolted connections and unique shapes. To maintain a perfectly comfortable, quiet dock, HDPE plastic bushings have been designed into the components to insulate metal to metal contact points so that our docks will never make uncomfortable noises.
    1. Pole Connections
      The connection between the roof poles and pole receivers is an inherently high stress location that requires the faces be insulated to ensure the high forces of metal on metal do not create any sounds.
    2. Hinge
      The piano hinge is insulated from the hinge pin in order to eliminate potential noises from often noisy hinges.
    1. Common Noises
      Lower quality floating docks are commonly assumed to make noise, a fact which dock owners have become accustomed. Lightweight structural members, poor connections, and loose hinges, among other reasons, contribute to docks that emit uncomfortable noises.
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Corner Bracket
  • Our corner bracket, a full 14 pounds per foot, is designed to strengthen the most vulnerable part of the frame - the outside corners of the dock. Moreover, the Corner Bracket secures the roof pole and acts as a stable base to transfer the stresses from the lower structure to the roof.
    1. Extrusion/Not a Casting
      The corner bracket is actually a 2-dimensional extrusion that is milled to create a 3-dimensional shape. Although a similar 3-dimensional shape could be achieved through a casting process, extrusions can be made much stronger and have a significantly better weld strength.
    2. Adds Strength Where Necessary
      The Corner Bracket has significantly greater wall thickness than similar amounts of mainframe which adds strength to the most critical area of the dock. Also, the unique shape reduces the weld-weakening inherent with a butt-welded corners and ties the entire perimeter of the mainframe together.
    3. Incorporates Roof Pole
      By incorporating the roof pole receiver into the corner bracket, the roof becomes securely integrated into the mainframe.
    1. Vulnerable Connections
      Our competitors typically butt-weld two mitered corners of c-channel together to form a corner which creates an inherently weak connection. The strength in this arrangement comes almost entirely from butt-welded gussets which creates an even greater weld-weakened area in a critical location on a dock.
    2. Cast Corners
      Although castings can be uniquely shaped and are inexpensive, they are brittle relative to extrusions. Also, the impurities in castings make their weld strength very weak. Wahoo Docks™ uses no castings in areas requiring structural strength.
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Gusset Reinforcements
  • Gusset reinforcement is critical with aluminum structures primarily because welding in this metal weakens the surrounding area. However, by incorporating gusset reinforcements, the resulting connection can be made incredibly strong. As a result, we incorporate gussets freely throughout the dock structure. In fact, each cross brace on the Category 5 dock utilizes gusset reinforcements which fit securely into a seat which further strengthens the dock.
    1. More Gussets
      We utilize more gusset reinforcements than any competitive dock builder. Doing so, adds tremendous strength and longevity to a dock by reducing the stress on individual welds.
    2. Gusset Reinforced Roof Pole Receivers
      Each pole receiver is reinforced by a pair of gussets that tie the mainframe, gusset, cross bracing, and roof together.
    3. Corner Bracket Gusset
      The most critical connections on the lower structure are the corners of the dock. Our docks utilize a 14 pound per foot extrusion to reinforce the corners which is then strengthened with traditional gussets.
    4. Interlocking Seat
      The structural components of the dock are shaped to provide a seat onto which the gussets are welded, providing even more strength for each support.
    1. Sparing Use of Gussets
      A lack of appreciation of the mechanical properties of aluminum induces competitive dock builders to use gussets sporadically throughout the dock, often in the corners only.
    2. Lightly Welded Connections
      The weakest point of gusset bracing is the connection to the mainframe. Unfortunately, competitive dock builders often incorporate only small strip welds to attach their gusset reinforcement.
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Proprietary Decking
  • Wahoo Docks™ offers only long lasting, maintenance-free decking on its docks. Over a decade ago, we engineered AridDek™ aluminum decking as the perfect compliment to our maintenance-free boat dock. Our decking is long lasting, maintenance-free, and maintains its new appearance for many years. Further, AridDek’s proprietary tongue and groove design interlocks to create a seamless, waterproof surface, eliminating the need for a waterproof substructure on upper deck applications. More recently, we developed a parallel product to AridDek™ made from cellular PVC that similarly has a waterproof design and is long lasting (shipments will begin in late Spring ’07).
    1. Very Stable
      AridDek™ does not materially degrade for many years even with extensive exposure to sunlight and water.
    2. Maintenance Free
      The powder coated, non-skid finish will never require painting, sealing, staining, or waterproofing.
    3. Lightweight
      The lightweight of AridDek™ is ideal for upper deck applications to keep the center of gravity of the dock very low.
    4. Long Lasting
      AridDek™ is impervious to insect damage, rot, and other types of decay common with materials that are composed of organic material.
    5. Cool to the Touch
      The high thermal conductivity of aluminum and light color offerings create a surface that naturally stays cooler than composite, concrete, or wood and all other decking materials.
    6. Easy to Clean
      AridDek™ is non-porous relative to other decking materials and easy to clean.
    7. Attractive
      The seamless design (up to 32’ length) and hidden fastener system creates a neat, clean look.
    1. Short Lived
      Organic decking materials and typical composites (polyethylene-based composites) exposed to a marine environment are susceptible to insect damage, rot, and other types of decay.
    2. Heat Absorption
      Most competitive decking products, specifically composites such as wood and concrete, can become very hot to the touch when exposed to direct sunlight.
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Redundant Interconnections
  • The Category 5 is composed of over 35 proprietary, fully engineered components unique only to Wahoo Docks™. Each part has been uniquely designed to interlock with other structural members to create an interlocking framework that incorporates redundant support in critical areas. This framework distributes the forces placed on the dock throughout the entire structure and increases the stiffness of the dock.
    1. Strong Framework
      The interconnections among the components in the Category 5 create a uniquely strong dock, stiff dock. Each component rests on a “seat” provided by other components.
    2. Strong Connections
      The strength of the Category 5 is derived from the structural relationship among the components. The welds primarily act to keep the components in place, not bear loads – this is the ideal connection scenario.
    3. Ideal Design
      Unlike steel, unique shapes for aluminum can be procured by mid-sized manufacturers. As the largest manufacturer of aluminum docks in the U.S., Wahoo Docks™ has created a perfectly-tailored dock without regard to the standard tubing, channel, and i-beam shapes used by competitive steel, wood, and aluminum dock companies.
    1. Weak Connections
      By using standard shapes, competitive docks typically butt-weld many connections. A butt-weld occurs when the end of one component is welded to the face of another. This is the weakest type of connection possible on an aluminum structure.
    2. Standard Shapes
      By using off-the-shelf shapes, a dock cannot be ideally designed to maximize strength, aesthetics, and low-maintenance cost most efficiently.
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Intelligent Gangway Design
  • Our gangways are designed using proven finite element structural analysis and are the most cost-efficient design used to achieve maximum strength. Our weld locations, bracing placement, and material choice create the strongest gangways possible.
    1. Material Choice
      Gangways inherently require a large number of welded connections. In no place is the use of high-weld strength 6061-T6 aluminum more important than in gangways where each component of the truss is reliant on the others.
    2. Bracing
      The bracing throughout the gangway is calculated to provide strength in necessary areas. Our gangways are rated significantly below their theoretical carrying capacity in order to ensure we never have a structural failure.
    1. Copycat Gangways
      Over the years, competitors have universally copied our gangways. However, even slight differences can reduce the strength of a gangway significantly. The weld locations, use of lower weld strength 6005-T5 aluminum, bracing placement, and the attachment of the truss diagonals to the vertical members are all ways in which competitors save time and money.
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Heavy Duty Hinge
  • The hinge between a dock and a gangway is the most common failure point on docks. Wahoo Docks™ developed a heavy-duty, self-aligning hinge that provides a connection with unparalleled strength. Moreover, the fluted design on the walking surface provides an attractive, non-skid plane; and, the tight tolerance provides safe passage that will not pinch toes or fingers.
    1. Strong Hinge
      The hinge is three times heavier than traditional hinges made from aluminum pipe. The design reduces weld weakening on the most critical stress areas. Further, the proprietary shape securely receives the hinge pin with very tight tolerances to reduce slack and increase longevity.
    2. Quiet
      The hinge is designed to receive an HDPE plastic insulating bushing between the piano hinge and the hinge pin to eliminate noise.
    1. Loose Tolerances
      Hinges that employ loose tolerances create an inherently weak connection. This can be a result of hinge design or from using off-the-shelf components that do not fit together appropriately.
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Finished Design
  • Our docks are uniquely complete. In addition to the structural considerations, Wahoo Docks™ has invested considerable time and resources to make the dock as refined as possible. As the nation’s largest manufacturer of residential docks, we are able to amortize the cost of trim pieces and other finishing components over a large number of docks. The end result is a uniquely flawless dock that cannot economically be produced by any other dock company.
    1. Pole Feet
      Each Category 5 roof pole has a footing at its base to cover unsightly flooring cuts.
    2. Bumpers
      Our bumpers are custom made to fit around our various structural components.
    3. Railing
      The railing is composed of 13 custom parts which hide all seams that would otherwise require problematic touch-up paint.
    4. Fluted Faces
      The face of each of our exposed structural shapes have a fluted or ribbed pattern for aesthetic purposes. Over time, the use of ribbed faces & premium grade aluminum decreases and obscures the natural white oxidation that occurs on aluminum and is especially noticeable on flat surfaces.
    5. Octagonal Roof Supports
      Our 4” octagonal poles are an attractive alternative to historically common square poles. Additionally, our poles can be powder coat painted from the mill to provide a more serene look.
    6. Cleats
      Our custom 8” aluminum cleats offer smooth surfaces and are heftier than those found on most competing docks.
    1. Makeshift Parts
      Competitive docks often offer none of the finishing pieces found on a Wahoo Dock. If they are offered, they are jury-rigged replicas that do not provide equal utility or aesthetic benefits.
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Flexible Appearance
  • One can achieve a variety of looks with a Wahoo™ dock depending on color and option selection - from a crisp, clean appearance of natural aluminum to a rustic summer cottage. In short, by proper selection of frame, roof support, roof metal, decking, and railing choices, new dock owners can create a maintenance free dock uniquely their own.
    1. Roof Supports
      Roof supports come with either a natural aluminum look, can be wrapped with Ironwood or powder coated in either an Oiled Bronze or Hunter Green finish.
    2. Frame
      Lower frames come with a natural aluminum look, covered by our proprietary 12” mainframe bumper, “wrapped” with Ironwood, or built using composite boards to provide a rustic wood look with the typical strength and maintenance- free properties of a Wahoo™ dock. Similarly, the roof banding can be wrapped to further create the wood dock impression.
    3. Decking
      The choice of decking plays into the final appearance and feel of a dock – from the clean feel of AridDek™ to the warm feel of Ironwood.
    4. Railing
      Railing color is typically selected to best blend with other color choices of decking and roofing.
    5. Roofing
      With 19 color options available, dock owners have flexibility to find a color to suit their style.
    1. Low Flexibility
      Smaller and less progressive competitors cannot match the Category 5 dock in terms of color and material options. Typically, this is because some of the options require innovative manufacturing practices and others require high inventory demands.
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The Little Things
  • There are many subtle aspects to a dock that are often overlooked, but can be sorely missed. To this end, every dock builder has their personal preferences as to what they achieve with their designs that others do not. We believe Wahoo Docks™ offers a wide variety of significant features that make our dock even more special than the other reasons provided in this section.
    1. Custom Mainframe Bracing
      Each and every dock is designed from a clean sheet of paper to ensure all aspects of a dock are ideally suited for the layout. To this end, each roof support is dissected by a cross-member that strengthens the mainframe and reduces torque at the roof pole location.
    2. Appropriate Floatation
      Every dock is analyzed using a proprietary floatation analysis program, the only such program in the dock industry, to ensure that every dock is adequately and appropriately floated in a level manner.
    3. Bird/Pest Resistant
      We attempt to design each dock such that birds and other animals find it unsuitable as a habitat. Small things, such as closing open ends of purlins, go a long way toward achieving a more comfortable dock experience.
       
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Material Science
  • The key to a long lasting, maintenance-free dock is an understanding and appreciation for the structural, mechanical and chemical properties of the component parts. Simply, our docks contain no components that will rust or deteriorate over time. Further, our docks are designed around the mechanical properties of each component to ensure that we maximize durability most efficiently. We have invested heavily in custom components such as unique extrusions and castings, bumpers, fasteners, decking, trim, etc. These proprietary materials are comprised of aluminum, stainless steel, or plastic which allows us to create a dock that is uniquely durable and has a finished appearance like no other.
    1. Structural Strength
      Wahoo Docks™ uses 6061-T6 marine grade aluminum which is more durable. It is similar in tensile strength to steel and welds 20% stronger than all other marine-grade aluminum.
    2. Maintenance Free
      6061-T6 aluminum will not rust and needs no protective coatings such as routine paint, stain or primer needed for steel or wood docks. A Wahoo™ dock will never need sanding, sealing, staining, or painting. Further, we use only premium types of decking that last for long periods and require no upkeep.
    3. Longevity
      The hardware used by Wahoo Docks™ from cable anchoring to the decking fasteners, are made of stainless steel ensuring that even the smallest components will not become an eyesore or rust to the point of structural degradation.
    4. Rust Resistant
      6061-T6 marine grade aluminum demonstrates excellent weathering characteristics and will not experience structural degradation even after many years in a marine environment.
    1. Cheaper Aluminum
      Almost universally, competitive aluminum dock builders build their docks with either 6063-T6 or 6005-T5 series aluminum which is less expensive but welds 20% weaker than the 6061-T6 used by Wahoo Docks™.
    2. Steel Rusts
      Regardless of how it is coated, steel docks rust and deteriorate over time; therefore, reducing their strength and visual aesthetics. Further, steel docks frequently do not use stainless steel fasteners which reduces the structural integrity of the dock over time.
    3. Design Inadequacies
      Dock design is an art and a science. The vast majority of dock manufacturers have no scientific foundation behind their designs; therefore, they produce docks that simply do not maintain their integrity when it’s needed most.
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Premium Components
  • Wahoo Docks™ uses maintenance-free, long lasting components on its docks. From the finest floats, to 2,800# lb marine winches, our hardware and components cannot be matched for their longevity.
    1. Perma-Float Floatation
      Permafloat provides the most durable, long lasting floatation available.
    2. Winches
      When winches are needed, our 2-speed, 2,800# commercial marine winch is stronger, larger and unlike most residential docks it is cantilevered or strategically placed so no recreational space is wasted.
    3. Roofing
      We use 26-gauge R-panel sheet metal.
    4. Bumpers
      We incorporate proprietary, form-fitted bumpers throughout the dock.
    5. Decking
      Our decking options all offer low maintenance with long term durability.
    6. Railing
      AridDek™ railing is a premier railing brand that will not deteriorate like any competitive dock railing product.
    7. Cleats
      Our proprietary 8” aluminum cleats are heavier than most generic 8” cleats and offer smooth, non-fraying surfaces.
    1. Cost Saving Components
      The components on a dock can be up to 50% or more of the cost of manufacturing a dock and are typically where manufacturers reduce their costs to offer a lower-priced dock.
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MIG Welding: Metal Inert Gas Welding
  • Because aluminum extrusions are heat treated (tempered), the heat affected area of a welded aluminum connection is weaker than the base metal. As a result, aluminum welding inherently requires special skill and equipment. 100% of the welding on a Wahoo™ dock is performed in a controlled environment by skilled professionals using the latest Metal Inert Gas (MIG) welding equipment. Because MIG welding requires a gas shielding, wind and moisture greatly degrade the process creating a weak weld which is why no welding is performed ‘in the field’ and is performed only in the protected environment of our manufacturing facility.
    1. Design Features
      Because the weld affected area of an aluminum connection is weaker than the base metal, Wahoo Docks™ designs its docks to reduce the reliance on welds in the most critical areas. This is achieved through 1) the redundant interlocking of components so that welds are intended to keep components in place rather bear loads, 2) using fasteners rather than welds in areas that experience fatigue, and 3) supporting welds with gusset reinforcements at all critical locations.
    2. Superior Welding
      Each weld serves a particular function and contributes its individual weld strength as a determining factor towards the dock’s structural stability. Wahoo Docks™ employs the most modern welding equipment and techniques.
    3. Welder Apprenticeship
      All welding is performed by skilled professionals who participate in a several month apprenticeship program.
    1. Poor Weld Conditions
      Frequently, dock builders manufacture both aluminum and steel docks in the same facility. Because steel fabrication produces particulates that contaminate nearby aluminum shapes, it is practically impossible to produce strong aluminum welds in this environment.
    2. Design Features
      Docks designed without a thorough understanding of the properties of aluminum commonly use welded connections in areas that would be better suited by a different connection type. Specifically, roof pole connections, which are inherently heavily stressed, are frequently stabilized with welds by competitive dock builders, a location where strength is vital.
    3. Field Welding
      Some aluminum dock manufacturers weld portions of their dock at the site, or ‘in the field.’ exposure to weather elements creates an environment which is impossible to create proper, penetrating welds.
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Thru-Bolted Roof Supports
  • Wahoo Docks™ uses stainless steel bolts and locknut pairs to secure its roof poles into the custom pockets. This is the most definitive method to attach roof poles on an aluminum dock and one that will not loosen over time.
    1. Longevity
      3/8” stainless steel bolts and locknuts simply do not loosen over time.
    2. Tight Fit
      A bolt/locknut combination will immobilize the connection and since we incorporate bushings around the poles, will never make a sound.
    1. Tech Screws Loosen
      Many competitors that use bolted roof pole connections, fasten the poles with lightweight tech screws. These invariably loosen over time and cause the dock to loose stability, weaken and make noise from the roof pole joints.
    2. Welded Connections Weakens Joint
      The alternative to bolting a roof pole connections is to weld the roof pole to a stub or the frame. This is inherently a poor location for welding on the dock since the weld-affected area of aluminum is weaker than the base metal.
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Upper Deck System
  • Creating a deck system that is aesthetically attractive, strong, safe, long lasting, and maintenance-free is not easy. In fact, it took us several years of refinement to produce the upper decks we offer today that exhibit the features noted above. It has taken great effort and expense, requiring seven unique castings and ten unique extrusions to produce the only truly finished looking upper deck on the market, and we are proud of it!
    1. Finished Appearance
      Our upper deck areas appear completely finished, with no sharp edges, field painted touch-up areas, makeshift components or low- grade materials. A Wahoo Docks™ upper deck is comprised of our proprietary AridDek™ decking and railing system that is entirely maintenance-free and provides a neat, clean look for many years.
    2. Durable
      AridDek™ decking and railing have proven their durability in extreme environments and makes them the ideal choice for longevity.
    3. Cool to the Touch
      AridDek™ decking and railing are the coolest options available for upper deck applications. In short, their light color and high thermal conductivity of aluminum combine to make the products perfectly comfortable to the touch – even on the hottest days.
    4. AridDek™ Decking
      AridDek™ decking is ideal for upper deck applications because it is cool to the touch, durable and easy to clean. Because it creates a waterproof barrier itself, no additional waterproof barrier is required (typically, this barrier is a rust prone galvanized pan).
    5. AridDek™ Railing
      AridDek™ railing is comprised of seven proprietary castings and six extrusions to create a perfectly complete, solid railing system that will last for the lifetime of the dock.
    6. Perfectly Leak-proof
      Our docks are perfectly waterproof. We mount our railing poles to the top of our waterproof decking and then secure these through the decking directly to the roof structure. Each railing mount is secured with four bolts, each one of which has an independent washer to ensure no water passage.
    1. Low Life Expectancy
      Second level decks have extreme environmental exposure and most materials decay rapidly with such direct contact with the weather and sunlight.
    2. Application Specific Problems
      Many top-mounted rail systems use silicone or other caulking methods to plug the holes created by their poles or screws which is often applied inadequately in the field leaving gaps for water to pass.
    3. Unfinished Look
      Many rail systems use unpainted or field painted railing to save money. The aesthetic disparity of these railing systems is clear.
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Reinforced Roof Support Pockets
  • The roof support pocket is the most vulnerable location on the dock. Because of this, the Category 5 incorporates proprietary heavy weight components that are captured by several supporting members and are gusseted to create very strong junction.
    1. Lower Pocket
      Each lower frame roof support pocket sits on a shelf designed into the frame, is inset into the mainframe, joined to a 6” cross brace, and gusseted. In short, it is solidly captured into the mainframe of the dock itself.
    2. Upper Pocket
      Each upper level roof support pocket is designed to capture each lip of the upper rafter and welded into place. Like its lower frame partner, the upper pocket is tied intrinsically to the structure in which it sits.
    3. Smart Weld Locations
      The roof support pockets are designed to accept our 4” poles and bushings and receive 3/8” stainless steel bolts for securing the roof supports to the pockets. As a result, we are uniquely able to anchor our poles without weakening the most vulnerable connections.
    1. Butt-Welded Connections
      Most competitive steel and aluminum docks have simple butt-welded connections to join the roof supports to the frames (in other words, the roof pole or stub is welded directly to the top lip of the mainframe or roof beam). Although this is an especially poor arrangement for aluminum docks because of the welded properties of aluminum, it is an inherently weak connection in a very important area of the dock.
    2. Poor Force Distribution