The Challenge: Overcoming ergonomic hazards in plastics fabrication
A major municipal transportation authority recently transitioned its fleet to fuel-efficient hybrid buses to reduce emissions and fuel costs. These vehicles represent a win for environmental sustainability. However, they introduced a significant maintenance challenge. Unlike traditional buses, these hybrid models feature electric battery packs mounted on the roof. This design improves airflow, reduces corrosion, and enhances heat dissipation.
When maintenance staff needed to access these roof-mounted battery units, they had no fall protection. The facility was equipped with ladders for roof access, but there was no active fall arrest system to prevent serious injuries if a worker slipped or lost balance. The authority needed a safe, reliable solution. They compared traditional wire rope anchoring systems against rigid rail solutions. They ultimately rejected wire rope for two reasons. First, the facility lacked the necessary space for additional support beams. Second, the existing ceiling height provided insufficient clearance to prevent a worker from hitting the floor during a fall.
The Solution: Precision lifting with Gorbel work station bridge cranes
To address these technical hurdles, the authority chose the Gorbel Tether Track™ Ceiling Mounted Monorail System. This rigid rail system provided safety and utility without requiring structural modifications or excessive vertical clearance. The installation consisted of four identical, 39-foot-long dual-trussed monorails. These were equipped with Miller self-retracting lanyards with 20 feet of line. Management specifically selected the dual-trussed design because it allows multiple workers to work on the roof simultaneously. Employees gain the flexibility to pass one another safely without needing to disconnect from the track.
The Execution: Streamlined material flow
The installation process utilized the facility's existing structural steel. This choice avoided the need for expensive, space-consuming floor-mounted supports. During maintenance, a worker simply pulls the lanyard down using a hook and attaches it to their full-body harness. This step provides continuous fall protection from the moment they step onto the ladder until they return safely to the ground. The enclosed track design, which features a 2-degree taper on the running flange, ensures the trolley follows the worker effortlessly. This design prevents the sticking common in older systems.
The Result: Enhanced safety and efficiency
The implementation succeeded. It improved workplace safety while maintaining the efficiency required by a busy transportation hub. The Supervisor noted that the system integrates into their workflow. Workers can access the rear of the bus, hook up, and complete essential maintenance in a safe, secure environment.