Site & Obstacle Survey
We start with the obstacle dimensions, clearance requirements and operator traffic. Site conditions dictate the design, not the catalogue.
CUSTOM ACCESS SOLUTIONS
Custom Crossover Solutions
Engineered crossover platforms tailored to span pipes, conveyors and plant equipment, built around your site obstacle clearance and operator traffic.
Custom Crossover Engineering
Bridges over the
Bridges over the
obstacles in your way.
Custom crossover platforms designed to safely bridge fixed obstacles, pipes, cable trays, conveyors, plant equipment and any other site feature that interrupts operator movement. Two access geometries are available across the standard range (67° step and 44° stair), and every custom build engineers around your specific clearance, deck length and traffic profile.
The boom arm hinges open for access and closes once the operator is on the platform, maintaining continuous edge protection throughout use. Anti-slip checker-plate deck, safety yellow powder-coated handrails, and integrated compliance plate certifying conformity to Australian Standards, every crossover ships ready for WHS sign-off.
Whether you need a one-off span at a fuel terminal or fleet quantities for a national rollout, the same in-house team designs, fabricates and dispatches the build from our Carrum Downs, VIC facility. Backed by a Lifetime Structural Warranty.
How We Engineer Your Crossover
Five steps from site brief to handover.
Access Geometry
Selection between 67° step access (compact, single-operator) and 44° stair access (heavier traffic, tool loads). Custom geometries available for non-standard heights.
Engineered Drawings
Detailed engineering drawings issued for review before fabrication, with load calculations and compliance references documented.
In-house Fabrication
All fabrication takes place in our Carrum Downs, VIC facility under an ISO 9001:2015 quality management system. Compliance plate fitted before dispatch.
Delivery & Site Support
Flat-pack delivery to keep freight cost manageable. On-site installation support available, with installation guides and engineering certificates included.
Frequently Asked Questions
What types of obstacles can a custom crossover platform span?
Custom crossover platforms are designed to span any fixed site obstacle that interrupts pedestrian movement, pipes, cable trays, conveyor systems, plant equipment footings, drainage channels and structural beams. The design is driven by the obstacle clearance height, width and operator traffic frequency rather than a standard catalogue.
What load rating do custom crossover platforms carry?
Standard configurations are rated to 450 kg. Custom load ratings are available where site conditions require a higher capacity for tool loads, two-operator access or equipment movement. Load requirements are documented during the design phase and reflected in the compliance plate fitted before dispatch.
What is the difference between 67-degree step access and 44-degree stair access?
The 67-degree step geometry is more compact and suited to single-operator access at lower traffic frequencies. The 44-degree stair geometry is more gradual, suited to higher traffic and heavier tool loads. Custom geometries are available for non-standard obstacle heights that fall outside both standard configurations.
How long does a custom crossover project take from brief to delivery?
Lead time depends on complexity and fabrication queue. After the initial site survey and design approval, fabrication typically takes two to four weeks for standard configurations. Complex multi-span builds or projects requiring additional compliance certification take longer. Contact Star Aluminium with your timeline requirement at the brief stage.
What compliance documentation is provided with a custom crossover platform?
Every custom crossover ships with a compliance plate, engineering drawings, load calculation documentation and a Lifetime Structural Warranty covering structural integrity under the design load parameters. ISO 9001:2015 applies throughout the design and fabrication process.