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Innovative Conveyor Crossovers for an Innovative Electric Auto Manufacturer

ErectaStep engineered a custom conveyor crossover for a cutting-edge electric automobile manufacturer, meeting OSHA standards while addressing challenges like a low ceiling and the need for lightweight, powder-coated components. Their solution, featuring modular, bolt-together design and customized elements, ensured safety and productivity in the plant without the need for on-site welding or heavy steel fabrication.

Conveyor Crossover-custom color engineering drawings

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By Dan Matz
Sep 23, 2019
Estimated 3 minute read

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 platforms, 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.

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

Conveyor Crossovers in Factory

Dan, our National Account Sales Manager since 2011, brings extensive expertise in mechanical and industrial engineering solutions, focusing on access and stair safety compliant with OSHA standards. He excels in strategic planning, customer engagement, and negotiation, ensuring clients receive tailored, effective access solutions for their needs.