Safe Installation of 11,000 lb Conveyors Using Deco’s Custom Self-Propelled Lift Cart

Jan 28

Installing heavy components into large industrial machines is always a high-risk operation—but when those components weigh 11,000 pounds and must be positioned with precision inside road milling machines, the safety and ergonomic challenges multiply. Several of Deco Manufacturing’s customers needed a safer, more efficient, and more controlled way to handle these conveyor installations.

Deco’s engineering team designed a fully customized, self-propelled lift system that dramatically increased workplace safety while simplifying a previously difficult and dangerous task.

The Challenge: Installing Heavy Conveyors Without Risk to Workers

The traditional installation process was slow, labor-intensive, and inherently unsafe. Customers faced several obstacles:

Manual or partially manual lifting methods created unnecessary risk for operators.
11,000 lb conveyor assemblies required ultra-stable handling and precise positioning.
Tight machine tolerances meant the conveyor must be tilted, leveled, and aligned with great accuracy.
ES&H concerns were rising due to repetitive strain, pinch points, and unstable lifting practices.
Different conveyor models meant the solution had to be adaptable without time-consuming changeovers.

Customers needed a single, robust, mobile system that could lift, tilt, position, and safely maneuver massive conveyor assemblies with minimal operator effort.

The Deco Solution: A Custom Self-Propelled Lift & Tilt Cart

After on-site process analysis, time studies, and consulting with operators and Environmental Safety & Health teams, Deco engineered a turnkey mobile lift cart designed specifically for installing heavy conveyors into road milling machines.

Key System Features

✔️ Self-Contained 24VDC Battery-Powered System
No external power sources required. Includes its own onboard charger for maximum uptime.

✔️ Self-Propelled Mobility
Operators can move 11,000 lb conveyors with confidence, stability, and smooth control.

✔️ Lift & Tilt Capabilities
Fine-tuned vertical and angular adjustments allow precise alignment during installation—reducing strain, guesswork, and risk.

✔️ Quick-Change Lightweight Aluminum Cradles
Easily swap cradle configurations to accommodate multiple conveyor models without heavy lifting or extended downtime.

✔️ Safety-Forward Design
Includes strobe lights and audible alerts during movement to increase jobsite awareness and reduce hazards.

✔️ Multiple Control Options

Wired handheld pendant for lift/tilt operations
Redundant fixed controls
Operator's driver station for intuitive motion commands

This ensures complete operator control and versatility in a variety of installation scenarios.

Impact: A Safer, Faster, More Repeatable Conveyor Installation Process

After implementing Deco’s custom solution, customers reported significant improvements:

Major reduction in workplace risk and injury potential
Faster, more predictable conveyor installation cycles
Reduced worker fatigue thanks to powered mobility and controlled movement
Consistent, accurate positioning of 11,000 lb conveyors
Universal system adaptability across conveyor models

The lift cart transformed a challenging high-risk task into a safe, efficient, and repeatable process.

Why Manufacturers Choose Deco for Heavy-Duty Handling & Safety Solutions

Deco Manufacturing specializes in solving the toughest material-handling and installation challenges in heavy industry. When off-the-shelf equipment can’t meet your safety, precision, or workflow requirements, Deco provides: