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Industrial Crossover Bridges for Pennsylvania Distribution Facility
How can industrial crossover bridges improve material flow between warehouse pick modules?
Industrial crossover bridges can create direct connections between elevated pick modules, work platforms, and other warehouse structures, reducing unnecessary travel while improving the movement of materials and personnel. For this Pennsylvania distribution facility, FCP engineered, fabricated, and installed two custom steel crossover bridges connecting existing pick modules at Levels 2 and 4. The bridges span an active aisle and allow pallet loads to move directly between modules, providing a shorter, more efficient route while integrating with the facility’s existing rack system.
Industry
Distribution Facility
Category
Crossover Bridges
Client
Raymond West
End User
Nordstrom
Location
Pennsylvania
Project Overview
Industrial Crossover Bridges for Pennsylvania Distribution Facility
FCP Mezzanine was contracted by Raymond West to design, build, and install two industrial crossover bridges at a Nordstrom distribution facility in Pennsylvania.
The facility’s existing pick modules were separated by an aisle, requiring materials and operators to take longer routes to move between the structures. The project called for two elevated steel bridges connecting the modules at Levels 2 and 4.
Rather than altering the overall warehouse layout, FCP developed a custom crossover solution that worked within the existing material handling infrastructure.
Project Details
- Application: Pick Module Crossover Bridges
- Structures: Two custom steel crossover bridges
- Levels Connected: Levels 2 and 4
- FCP Scope: Engineering, fabrication, and installation
The Challenge: Connecting Existing Pick Modules
Unlike a crossover bridge incorporated into a new facility design, these structures had to be integrated into an existing rack-supported pick module system.
That created an important engineering challenge: FCP couldn’t simply design an independent bridge without considering how its loads and connections would interact with the existing rack structure.
FCP worked closely with Raymond West and the rack manufacturer to develop the connection details and coordinate the engineering required to integrate the new crossover bridges with the existing system.
The resulting design had to fit the current configuration while minimizing disruption to the facility and maintaining the function of the aisle below.
The Solution: Custom-Engineered Steel Crossover Bridges
FCP designed two steel crossover bridges spanning the aisle between the existing pick modules—one connecting Level 2 and another connecting Level 4.
The completed bridges provide direct elevated routes between the modules while maintaining the open aisle beneath them.
By creating these connections, pallet loads can move more directly between the pick modules instead of following a longer route through the facility. Operators also gain a shorter, more direct path between work areas.
The project demonstrates how a custom industrial crossover bridge can be engineered around an existing warehouse or distribution system rather than requiring the facility to adapt to a standard, off-the-shelf crossover.
Designed Around Existing Warehouse Infrastructure
Existing distribution and manufacturing facilities frequently present more complex engineering challenges than new construction. Rack systems, conveyors, pick modules, mezzanines, equipment, aisles, and building structures may already occupy the available space.
FCP’s approach is to engineer the steel structure around those conditions. For this project, close coordination with the existing rack manufacturer was essential to developing an engineered connection between the crossover bridges and pick modules. That collaboration allowed the new structures to become part of the existing material handling layout while preserving the operation and clearance of the aisle below.
Industrial Crossover Bridges Built for the Application
FCP designs and manufactures custom steel crossover bridges and access structures for warehouses, distribution centers, manufacturing facilities, processing operations, and other industrial environments.
Depending on the application, crossover structures can be designed to connect mezzanines, pick modules, work platforms, equipment platforms, rack-supported structures, and other elevated work areas or to provide access across conveyors, equipment, piping, aisles, and other obstacles.
Each crossover is engineered around the facility’s specific dimensions, loads, clearances, access requirements, and existing infrastructure.
Dedicated Support for Custom-Engineered Solutions
Complex retrofit projects require more than a standard steel structure. FCP’s engineering and project teams work directly with customers, contractors, equipment suppliers, and other project partners to develop solutions around real-world site conditions.
For this crossover bridge project, that meant coordinating closely with Raymond West and the existing rack manufacturer to resolve connection and engineering challenges. From initial design and detailing through fabrication and installation, FCP provided dedicated support to help ensure the new crossover
Built for B2B Project Partnerships
FCP works directly with general contractors, material handling integrators, construction professionals, facility managers, warehouse and distribution teams, manufacturers, and design professionals to solve complex industrial steel and access challenges. Whether FCP is supporting a new facility, expanding an existing operation, or integrating a custom structure into existing equipment and infrastructure, our team works collaboratively from engineering through fabrication and installation.
For more than four decades, FCP has helped project teams turn plans and operational challenges into practical, buildable steel solutions. Our goal is to serve as an extension of your project team—providing responsive engineering, experienced project support, and custom steel structures designed around the requirements of the facility.
A Thank You From FCP
FCP would like to thank the Raymond West team for trusting us to engineer, fabricate, and install these custom crossover bridges. Projects that integrate new steel structures into existing material handling systems require close communication, creative engineering, and strong coordination between everyone involved.
We’re proud to have worked alongside Raymond West and the rack manufacturer to overcome the connection challenges and develop a solution that integrated with the existing pick modules while improving material flow throughout the facility.
Thank you to Raymond West for the partnership and for choosing FCP.
Frequently Asked Questions (FAQ’s)
What is an industrial crossover bridge?
An industrial crossover bridge is an elevated steel structure that creates a direct route between work areas or across obstacles within a facility. Crossover bridges can connect mezzanines, pick modules, work platforms, and other elevated structures or span warehouse aisles, conveyors, equipment, piping, and production areas.
What are crossover bridges used for in warehouses and distribution centers?
Crossover bridges can improve the movement of people and materials by creating more direct routes between work areas. In warehouses and distribution centers, they may connect pick modules, mezzanines, work platforms, or material handling systems while maintaining clearance for aisles, equipment, or operations below.
Can a crossover bridge connect existing warehouse pick modules?
Yes. Custom steel crossover bridges can be engineered to connect existing pick modules when the supporting structures, loads, connection points, clearances, and other site conditions are properly evaluated. Projects involving rack-supported pick modules may also require coordination with the rack manufacturer.
Can FCP engineer crossover bridges for existing rack systems?
Yes. FCP can design custom crossover bridges around existing warehouse and material handling infrastructure. When a crossover connects to an existing rack system, FCP can coordinate with the customer, rack manufacturer, and other project partners to develop the appropriate connection and integration solution.
What is the difference between a crossover bridge and crossover stairs?
A crossover bridge typically connects two elevated areas at or near the same level, creating a direct route across an aisle, equipment, or other obstruction. Crossover stairs generally use stairs and an elevated platform or walkway to allow personnel to travel up and over conveyors, piping, equipment, or other obstacles before returning to floor level. Both can be custom engineered around the facility’s layout, required clearances, and access needs.
Are industrial crossover bridges custom engineered?
They can be. FCP’s crossover bridges are engineered around the requirements of each application, including span, loads, dimensions, elevations, clearances, connection points, access requirements, and existing facility infrastructure. This allows the structure to be designed for the facility rather than requiring the facility to accommodate a standard crossover.
Does FCP provide fabrication and installation for crossover bridges?
Yes. FCP provides engineering and fabrication for custom industrial crossover bridges and can provide installation as part of the project scope. This integrated approach helps coordinate the crossover from initial design and connection details through fabrication and field installation.
What industries use steel crossover bridges?
Steel crossover bridges are used in warehouses, distribution and fulfillment centers, manufacturing plants, processing facilities, material handling operations, and other industrial environments where elevated access or a direct connection between work areas is needed.
Need An Industrial Crossover Bridge?
From individual crossover bridges to complete industrial access and material handling structures, FCP engineers and manufactures custom steel solutions for warehouses, distribution centers, manufacturing plants, processing facilities, and other demanding industrial environments.
FCP capabilities include steel crossover bridges, crossover stairs, catwalks, industrial stairs, work platforms, equipment platforms, pick module structures, and complete mezzanine systems—all engineered around your facility, equipment, loads, clearances, and operational requirements.
Whether you need to connect existing pick modules, span an active aisle or conveyor, or solve a complex access challenge, put more than four decades of FCP engineering and steel manufacturing experience to work on your next project.
GET A FREE PROJECT PROPOSAL
Have plans, specifications, or an operational challenge that needs a custom solution? Send FCP your project requirements. Our team can review your application and develop a competitive proposal for a custom crossover bridge, crossover stairs, platform, mezzanine, or complete industrial access system built around your facility and project requirements.
Industrial Crossover Bridges – PA Distribution Facility
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