The Challenge:
In high-throughput manufacturing environments, protecting workers during flatbed loading operations presents severe spatial and structural engineering challenges. Daktronics, a manufacturer of large-scale electronic scoreboards, digital billboards, and roadside LED displays, faced this exact crisis in their shipping departments. Operators had to climb onto flatbed trucks to secure massive, fragile electronic assemblies. This task exposed them to significant fall hazards.
Standard fall protection layouts were completely non-viable due to facility constraints. Traditional column-mounted tracks could not be deployed because existing building columns were misaligned with the loading bays. Conversely, standard free-standing systems were ruled out. Their massive support pillars required anchoring directly within high-traffic facility aisleways. This layout would create collision risks for forklifts and material handling equipment. Finally, in several key areas, facility slabs could not accommodate the deep excavation required for standard concrete footings. Daktronics needed an OSHA-compliant fallback system that required zero floor space and left transit lanes entirely unobstructed.
The Solution:
To overcome these structural limitations, Daktronics partnered with Technical Tool Products (TTP) to design a series of facility-specific, custom Gorbel Tether Track Fall Protection Systems. The Gorbel Tether Track line was selected for its rigid rail engineering, which drastically minimizes fall distance compared to traditional wire-rope lifelines by eliminating cable sag.
The deciding factor, however, was Gorbel's structural modularity. Instead of forcing expensive facility retrofits, Gorbel's engineering team adapted the rigid rail profiles to mount directly to existing overhead infrastructure. This approach bypassed the need for floor-anchored pillars entirely.
The Execution:
Visual analysis of the facility installations shows two distinct, highly creative engineering adaptations designed to maximize spatial efficiency:
The Overhead Runway Mast Mount: In shipping bays where floor space was unavailable and concrete footings were logistically impossible, engineers modified a heavy-duty mast-type crane structure. This system was engineered to interface directly with existing overhead building runways. By distributing the forces of a fall upward into the facility's structural steel skeleton, the team eliminated the need for new concrete work.
The Articulating Fold-Out Jib System: In ultra-tight shipping zones requiring absolute clearance for logistics vehicles, Gorbel utilized the bottom of existing overhead runway pairs to mount custom articulating jibs. This created a fold-out safety system. When a flatbed truck positions itself in the bay, the articulating arms swing smoothly out over the trailer. This action provides a rigid rail anchor point directly above the operator. Once the loading sequence is completed and the operator unhooks, the entire jib assembly folds back flat against the facility wall structure to keep the high-traffic shipping lanes entirely clear.
The Result:
The implementation of the custom Gorbel Tether Track systems delivered absolute safety compliance without compromising manufacturing velocity. By engineering around the existing footprint, Daktronics avoided the extensive costs, engineering approvals, and operational downtime associated with pouring new concrete footings or altering building columns.
Operators now execute loading procedures with complete structural protection and fluid, unhindered horizontal tracking. By adapting the fall protection to the workflow, rather than forcing the workflow to adapt to the safety gear, Gorbel and TTP successfully secured Daktronics' logistics chain while preserving 100% of their operational floor space.