Installing an overhead conveyor means working at height, inside a building that is often still in use. Good preparation shortens the schedule more than anything that happens on site.
Before installation
- Approved installation drawings and anchor or support details
- Structural check of roof or support steel for the conveyor loads
- Delivery schedule matched to the installation sequence
- Storage area for crates near the installation area
- Lifting equipment and access platforms booked
- Power, lighting and compressed air available for the team
- Site safety rules, permits and induction arranged
- Production areas that must stay running identified and protected
Installation steps
- Survey and set-out: mark conveyor centrelines and support points; check heights against drawings.
- Support steel: install headers, hangers and support structure.
- Track: hang and align straight sections, curves, switches and vertical curves.
- Drives and take-ups: install, align and anchor drive units and take-ups.
- Chain: pull in and connect the chain; set initial tension.
- Stations and lifts: install stops, drop sections, lifts and guards.
- Electrical: mount panels, run cables, install sensors and safety devices.
- Carriers: install trolleys, load bars and carriers.
- Mechanical checks: alignment, clearances, lubrication, guarding.
- Commissioning: I/O checks, dry runs, then runs with product.
Commissioning and ramp-up
Commissioning starts with each function on its own: drives, stops, switches, lifts and safety circuits. Then the line runs empty, then with test products, and finally with production. The site acceptance test confirms the agreed output. Prepare acceptance criteria in advance, as explained in our factory and site acceptance test guide.
Installation options
| Option | Pros | Watch out for |
|---|---|---|
| Manufacturer's team | One party responsible; experienced crew | Travel and visa planning; higher labour cost abroad |
| Local team, manufacturer supervision | Lower cost, local labour rules met | Clear split of responsibilities |
| Local team only | Lowest direct cost | Higher risk; quality depends on local experience |
What affects the schedule
- Conveyor length and number of switches, lifts and stations
- Working in a running plant: night and weekend shifts, protected zones
- Access height and space for lifting equipment
- Readiness of building, power supply and interfaces to other equipment
- Availability of the customer's production team for test runs
Retrofits
Installing in an existing line needs phasing and careful planning of shutdowns. See overhead conveyor retrofit and upgrade.
HITREE provides installation, supervision and commissioning worldwide; see our service offering or contact us.
Overhead conveyor installation checklist for the plant team
| Task | Typically prepared by |
|---|---|
| Structural approval of roof or support steel | Plant owner, with structural engineer |
| Utilities: power, air, network | Plant owner |
| Installation drawings and sequence | Conveyor supplier |
| Lifting equipment and access platforms | Agreed in the contract |
| Site safety induction and permits | Plant owner |
| Test products for commissioning | Plant owner |
Common causes of installation delays
- Building not ready: roof work, utilities or floors unfinished
- Crates delivered in the wrong order or without clear marking
- Clashes with pipes, ducts or cable trays not shown on drawings
- Late interface information from other equipment suppliers
- Production areas not released when planned
A short weekly meeting between the plant team and the installation supervisor keeps overhead conveyor installation on schedule.
