Up, Over, and Around Warehouse Conveyors – Choosing the Safest Warehouse Solutions

Much like a city grid, a warehouse must safely and efficiently accommodate pedestrian, vehicle, and equipment traffic. Added to that challenge is the presence of conveyor systems winding around your facility. To get the most out of your team and equipment while keeping everyone safe, there are a variety of solutions that allow your team to maneuver safely around warehouse conveyors while maintaining productivity and adherence to OSHA standards. Storage Solutions, Inc (WOI) has the experience that uniquely positions us to help you cross that bridge most effectively. Here are some tailor-made solutions that we recommend.

Conveyor Crossovers, Gates & Walkways 

Conveyor systems can be floor-mounted, suspended, or both requiring careful consideration for safe vehicle and pedestrian movement around them. Whether you have a single push conveyor system or miles of automated your best solutions will likely involve a combination of these types of products. Each product has standard sizes but can also be customized to meet your unique warehouse needs.

• Conveyor crossovers – allow pedestrians to climb up and over stationary conveyor lines at safe, designed cross zones.
• Conveyor lift gates – allow pedestrian traffic to cross through conveyor lines to optimize workflow and ensure quick and safe exit, if necessary. 
• Industrial catwalks & elevated walkways – walkways created to safely navigate around areas of conveyor.

Let’s take a close look at each solution:

Conveyor Crossovers

As the name indicates these modular configurations provide a way for workers to climb up and over individual lines of warehouse conveyors. Crossovers require additional space around the conveyor line vs lift gates for example, but the crossover does not require an interruption of the conveyor line.

Modular designs bolt together for quick, easy installation and relocation if warehouse traffic routes change. Welded designs are available where a higher load capacity is required. Conveyor crossovers come in standard sizes but can also be customized for capacities, widths, and vertical clearances.

Conveyor crossovers come with handrails and can be equipped with additional safety features such as diamond plate or safety grating for slip resistance. Typically painted bright yellow, the crossovers can be custom painted if necessary.

Conveyor Lift Gates

Installing crossing points through long conveyor lines reduces worker travel time and increases productivity. However, while lift gates will briefly interrupt product flow, they avert the temptation to hop over or under conveyor lines which increases warehouse safety for personnel. 

These products are available in a large variety of lengths and widths to design just the solution you need.

Types of Lift Gates

• Manual lift gates
• Power lift gates

Manual lift gates installed within gravity conveyor lines can be constructed from rollers or skate wheel flow products. In the down position, gates are secured with a safety latch that must be released to lift the gate and allow pass through. There are optional features available to help workers open and close them without strain. 

Power lift gates will accumulate product while open in the open position. When workers raise the gate, a limit switch sends a signal to hold product flow by stopping the conveyor rollers. Once the gate is closed, the rollers are reactivated and the product flow continues. 

Industrial Catwalks & Elevated Walkways

Catwalks and elevated walkways allow safe passage over, above, and around warehouse conveyors,  production lines, and obstructions. Depending on load capacity and use, customers can choose from durable aluminum, thick-gauge steel, and even fiberglass grating catwalks to best suit their needs.

• Aluminum -lightweight & easy to assemble
• Steel – capable to handle machinery & equipment
• Fiberglass – maintenance free & corrosion resistant

Catwalks can be suspended from the warehouse ceiling or supported from the floor. Adjacent structures such as pallet racking can also provide support for the walkway.

The modular components are designed for quick bolt-together installation. There is a large variety of standard sizes and shapes available through custom components that can also be manufactured. Catwalks are finished with accessories such as safety railings and gates, where necessary.

The WOI team is ready to assist you in defining the most effective warehouse traffic routes and supplying you with the solutions to implement the best plan. Our 5-Step Total Satisfaction Experience™ guarantees that we will listen and execute your project to your expectation. We promise to:

1. Pay special attention to your particular application
2. Thoroughly review your application with you
3. Provide agreed-to project development & installation timelines
4. Conduct a safety analysis
5. Ensure a pleasant appearance of the finished product

We will walk you through each stage of the process and offer expert customer service and peace of mind along the way. Contact a member of our team today and set up a chat or Zoom, or call us at (865) 540-4004 for a prompt response. We proudly serve customers in Tennessee, Alabama, and throughout the Southeast.