The Challenge: Resolving the Conflict Between Safety and Heavy Lifting
A Midwest heavy equipment manufacturer faced a conflict between safety and productivity while building massive track trenching and surface mining machines. These units are immense. They weigh nearly 200 tons when fully assembled. The grinding surfaces reach nearly 10 feet in height, and the treads stand as tall as an average man.
The assembly process takes about 8 weeks. It requires overhead bridge cranes to move 40-ton components. Workers quickly rise above the 4-foot threshold during the build, triggering OSHA fall protection requirements. Standard fixed rail or wire rope systems created a ceiling that obstructed the overhead cranes. The facility needed a solution to protect multiple workers without stopping the movement of heavy materials.
The Solution: Deployable Protection on Demand
The facility installed four Gorbel Tether Track™ Fold Away Systems to resolve interference between the bridge cranes and safety infrastructure.
Engineers selected these units for their ability to retract from the crane's path. The installation included:
- Dual Track Rails: These enable two workers to operate simultaneously on a single system.
- Extended Coverage: Two systems span 100 feet and two span 150 feet. Wall cantilever jibs support them every 50 feet.
- Motorized Articulation: One jib per system is motorized. This allows it to position anywhere within a 180-degree coverage area or fold flat against the wall.
The Execution: A "Pass-Through" Workflow
The Fold Away system created a workflow that allows safety equipment and cranes to share the same space. As observed in the project footage, the deployment follows a specific sequence:
- Component Positioning: The overhead bridge crane hoists the heavy component into position while the Tether Track system rests folded against the wall.
- System Deployment: Once the part is near, the motorized jibs deploy the fall arrest track and swing it over the assembly area.
- Hoist Integration: The crane operator drops the hoist cable through the rectangle formed by the deployed jibs and runs.
- Active Assembly: Operators tie off and assemble the suspended component while the crane holds it.
- Retraction: Workers unhook upon completion. The system folds back against the wall to clear the bay for the next lift.
The Result: Maximum Manpower, Zero Obstructions
This installation resolved the conflict between heavy manufacturing and safety compliance. The dual-track design allows the facility to put "four operators up onto a machine and have them all tethered". This capability lets the team throw "maximum manpower" at the build to meet tight deadlines.
- Safety Compliance: The setup adheres to OSHA guidelines for work above 4 feet.
- Operational Efficiency: Productivity remains high because the system folds out of the way of overhead cranes.
- Flexibility: Opposing walls support full rectangular coverage beneath the bridge cranes.