Conveyor repairs at elevation inside an active fulfillment centre require more than mechanical skill — they demand careful hazard planning, fall protection, and precise execution under operational pressure. In May 2024, Horizon Industrial completed a head pulley replacement on an elevated conveyor system at a major Calgary e-commerce facility, restoring the system to full operation safely and efficiently.
Project Overview
Horizon Industrial was contracted to perform a complete conveyor repair at a high-volume e-commerce fulfillment centre in Calgary. The scope involved replacing a failed head pulley on an elevated conveyor system operating approximately 15 feet above the facility floor — requiring both mechanical expertise and a comprehensive fall protection plan.
Safety Planning
Prior to mobilization, Horizon Industrial completed a full Job Hazard Analysis and Safe Work Plan for the repair scope. Working at elevation of approximately 15 feet on an active conveyor system was identified as the primary hazard. A site-specific Fall Protection Plan was prepared and reviewed by all crew members before work commenced, in compliance with the facility’s contractor safety requirements.
The Repair
Horizon’s millwrights completed the head pulley replacement on the elevated conveyor, following all manufacturer specifications and facility safety protocols. The repair was completed with the conveyor system isolated and locked out, with fall protection in place throughout. Following replacement, the system was inspected, tested, and returned to operational status.
Results
The conveyor system was restored to full operation with the head pulley replaced to specification. All safety documentation was completed, and the facility’s operations were able to resume normal throughput without extended downtime.
Horizon came in, handled the fall protection, did the repair right, and had us back up the same day.
Project Photos
