# Sheet Metal Fabrication for Material Handling

https://kdisplay.com/industries/material-handling

K-Display fabricates conveyor guards and brackets, transfer chutes, line-side racks and dunnage, bins, carts, and packing workstations in Chicago from operator, integrator, and equipment-maker drawings. Parts are cut, formed, welded, and powder coated, with hardware installed and each zone packed as one delivery.

## Overview
K-Display supplies conveyor guards and brackets, transfer chutes, line-side racks with dunnage, bins, carts, and packing workstations. They are cut, formed, and welded from carbon steel, powder coated, and fitted with casters, handles, and hardware, and delivered welded or knock-down. OSHA 29 CFR 1910.219 requires a horizontal belt with both runs 42 inches or less from the floor to be fully enclosed. In material handling sheet metal fabrication, that makes the guard for a low horizontal belt drive a full enclosure.

## Process
- Cut and weld the frames: We laser cut and press-brake form the guards, covers, brackets, and chutes, then MIG and TIG weld the rack, cart, and workstation frames.
- Hardware in, then powder coat: We press in self-clinching nuts and studs before powder coat and mask the caster-plate holes and threads, so caster plates and rack bolts seat on bare metal.
- Fit, label, and deliver by zone: We fit casters and handles after the coat, label each conveyor section, aisle, or cell, kit its hardware, and pack it as one delivery for its zone.

## Typical parts
- Conveyor guards and mounting brackets: Drive covers, side covers, and guard panels made to each conveyor section's frame and bolt pattern, with the brackets that hold them, cut and formed in sets per run.
- Chutes and transfer slides: Formed chutes and slides cut to the drop height and package size between two conveyor runs.
- Line-side racks and dunnage: Uprights, shelves, and dunnage frames sized to the tote or part they hold, for line-side storage and staging.
- Bins and totes: Formed metal containers with dividers and stacking features sized to the part and to the shelf or cart they ride on.
- Carts and dollies: Welded frames with decks, shelves, push handles, and caster plates for the payload and the aisle width.
- Packing and picking workstations: Bench frames, metal tops, shelves, and monitor and scanner mounts arranged to the operator's task and the tote flow.

## Requirements
- Loads per shelf, deck, and caster: Load figures for the racks, carts, and workstations at each shelf, deck, and caster.
- Package-contact faces: The faces packages slide against on chutes, bins, and cart decks, marked for deburred edges, dressed welds, and a continuous finish.
- Guarding standard and dimensions: The safety standard the guard is built to, such as ASME B20.1 for conveyors, with guard heights, opening sizes, and fastener type.
- Floor-duty finish: Powder coat color, such as safety yellow or OSHA orange, and a texture for the edges forklifts and carts bump.
- Layout dimensions: Conveyor section lengths, frame widths, and bolt patterns, with rack elevations and cart drawings.
- Zones and install phases: The zone or phase each delivery serves, with the parts and quantities in each, so guards, racks, and carts arrive when that stretch of the line is installed.

## Related pages
- [MIG & TIG Welding](https://kdisplay.com/capabilities/welding/mig-tig-welding)
- [Powder Coating](https://kdisplay.com/capabilities/finishing/powder-coating)
- [Assembly & Value-Added Services](https://kdisplay.com/capabilities/finishing/assembly)
- [Custom Conveyor Guards, Covers & Brackets](https://kdisplay.com/products/panels-covers/conveyor-guards-covers-brackets)
- [Custom Hoppers, Chutes & Troughs](https://kdisplay.com/products/panels-covers/hoppers-chutes-troughs)
- [Custom Parts Racks & Shelving](https://kdisplay.com/products/carts-racks-bins/racks-shelving)
- [Custom Metal Bins & Parts Containers](https://kdisplay.com/products/carts-racks-bins/bins-containers)
- [Custom Industrial Carts & Dollies](https://kdisplay.com/products/carts-racks-bins/industrial-carts-dollies)
- [Custom Workstations & Work Benches](https://kdisplay.com/products/carts-racks-bins/workstations-stands)