Conveyor Crossover-custom color engineering drawings

Innovative Conveyor Crossovers for an Innovative Electric Auto Manufacturer

The Challenge – Create an OSHA compliant custom conveyor crossover in an area with a low ceiling. The client didn’t want heavy steel, on site welding and required all parts to be powder coated with a custom color theme. 


ErectaStep, a brand known for top quality industrial stairs, work platforms, ladders, recently designed and built a custom conveyor crossover system for one of the world’s most innovative electric automobile manufacturer’s factories. The manufacturer needed a unique industrial solution to crossover a conveyor, but required it to meet unique specifications, while providing OSHA compliance and ultimately to aid in productivity. They needed a quality solution with a high-aesthetic value, one that would be entirely powder coated and match their organization’s colors. The restricted environment in which the conveyor crossover system was being installed had a lowered ceiling and other challenges. ErectaStep was called upon to create a solution that would meet the needs of the environment, the manufacturer, and maintain OSHA compliance. Because of the lowered ceiling, a standard 6 inch thick platform would cut it too close for most workers to properly do their job safely. ErectaStep could provide a cost effective solution while meeting all requirements and needs.

Conveyor Crossover Custom Color

An additional restriction was that they wanted lightweight materials and not heavy steel. Additionally it had to be assembled on-site without welding, and ErectaStep’s modular lightweight aluminum components, and bolt-together design became the perfect solution! We eliminated the need for custom fabrication and the weeks of estimates, drawings, edits and installation time typical to custom fabrication solutions. The ErectaStep system gave them the ability to have pre-fabricated components created in advance to prevent any factory downtime during assembly and installation.


Along with some customized components, ErectaStep’s lightweight aluminum components, and modular, bolt-together design was the perfect solution!


ErectaStep provided a solution that utilized platforms that were 3 inches less than the standard size, but were as sturdy as the 6-inch variety and stayed within compliance. Along with the custom platform height, the automobile manufacturer also wanted color specific powder coating of the entire crossover stairs, platform, and handrails. Each crossover included handrails , stair stringers, work platform, and stair treads . We also added non-slip tape on the stair treads and leading edges based on a preference of the organization. To ensure safety and stability on the reduced work platform height, single handrail sections were used to span across the platform and stairs.

Tim Boyle - Account Manager - Great Plains Region“These conveyor crossover applications presented some unique engineering challenges, and I’m proud our team could quickly deliver a solution that supported both the customer and their automation partner.”

Tim Boyle
Account Manager – Great Plains Region

Discuss your project with Tim

The vehicle manufacturer is very pleased with the system and believes that it was the right choice for the specific situation.

Custom Conveyor Crossovers in the plant
Custom Conveyor Crossovers in the plant, being QC’d and getting ready to ship

Conveyor Crossovers in Factory