The Challenge
An e-commerce fulfillment center that delivers millions of packages per day faced ongoing challenges caused by its telescoping conveyor belt system. While essential to loading operations, the conveyors extended deep into the workspace, limiting foot traffic between dock lanes. The layout forced staff to walk long distances to navigate around equipment—slowing movement, complicating communication, and affecting overall productivity.
As the facility prepared for its busiest season, these inefficiencies threatened to impact on-time fulfillment. Leadership needed a solution to restore efficient foot traffic while maintaining safety standards without interrupting operations.
- 15-Day Turnaround: Project completed within 15 business days of order.
- Rapid Installation: Onsite assembly finished in just five days.
- Seamless Flexibility: Managed two reconfigurations without delays.
- OSHA Compliance: Installed safe, efficient stairs for staff operations.
Improving facility flow and operational efficiency through modular access solutions
The Solution
ErectaStep, in partnership with Banks Industrial Group, developed and installed modular crossover platforms that enabled workers to cross and navigate around the conveyor system safely. The design included three ErectaStep stair and platform assemblies, each spanning approximately 70 feet and configured for seamless integration into the existing workspace.
Illustration right: Actual design configuration drawing of conveyor crossover bridge.
Working from the fulfillment center’s engineering drawings, Banks and ErectaStep rapidly defined the project scope and finalized layouts within days. From order to delivery, the modular components were fabricated, packaged, and shipped in under a week—minimizing floor space requirements and allowing installation to proceed without interrupting operations.
Once onsite, Banks’ installation team completed assembly in just five days, adapting the configuration as needed to address access refinements and minor drawing inconsistencies. The quick adjustments demonstrated both the precision and flexibility of ErectaStep’s prefabricated system.
The Results
The fulfillment center gained immediate improvements in accessibility, workflow, and safety:
- Streamlined foot traffic: Workers can now cross directly over conveyor lanes, reducing unnecessary travel time.
- Faster response and communication: Supervisors and loading teams can move freely between docks during peak operations.
- Minimal operational downtime: Installation was completed within the facility’s demanding schedule without disrupting shipping activities.
- OSHA-compliant access: The stair systems and platforms meet all relevant safety standards for industrial use.
A Partnership in Performance
ErectaStep and Banks Industrial Group share a commitment to providing rapid, effective solutions that keep industrial facilities productive and safe. Through close coordination, clear communication, and proven modular design, the project was completed from purchase order to finished installation in just 15 business days—including two onsite system reconfigurations and a refund for unused materials.
Conclusion
This project highlights the value of ErectaStep’s prefabricated stairs, work platforms, and access systems for logistics and fulfillment environments where efficiency, safety, and adaptability are vital. By working closely with trusted partners like Banks Industrial Group, ErectaStep continues to help operations nationwide optimize facility layouts and maintain peak performance—no matter the season.
Colorado Springs Distribution Center Conveyor Crossover Project
This modular stair and crossover system allowed for quick installation and assembly without the need for custom engineering or specialized tools.
