Overhead Gantry

Drawing Number: AD-2439-2024-01-2



The automotive client required an effective solution for managing and presenting charging cables ergonomically during electric vehicle battery testing. The primary concern was that cables running on the floor created significant health and safety hazards. Employees could trip over the cables, leading to potential injuries, and the untidy arrangement could result in operational inefficiencies. Additionally, there was a risk that cables could come into contact with the cars’ bodywork, possibly causing scratches or other types of damage. Therefore, the client sought a method to keep the cables organised and elevated, ensuring both the safety of their staff and the protection of the vehicles being serviced.



Acres provided an overhead gantry capable of supporting various types of charging cables on either side of the electric vehicle. This gantry locks securely in position and includes a tool balancer to bear the weight of the cables, reducing risk to the operator and improving ergonomic efficiency during electric vehicle battery testing.

The design process included simulations to minimise the weight of the gantry, ensuring the structure remains compact while providing robust support for the gantry arm. This consideration was crucial to maintain a small footprint and avoid unnecessary bulk. The gantry is highly versatile, designed to be multi-configurable and easily mountable to an existing workstation. This flexibility allows it to be positioned on either side of the workstation, accommodating different operational setups and workspace constraints.

Additionally, the center of gravity was meticulously considered during the design phase to ensure that the gantry does not compromise the stability of the workstation. This attention to detail helps in preventing any tipping or imbalance that could pose safety risks or operational inefficiencies.

To ensure the solution’s reliability and safety, the gantry was subjected to rigorous load testing, achieving Safe Working Load (SWL) certification. This certification confirms that the gantry can safely handle the required loads, providing peace of mind regarding its durability and performance in a real-world automotive workshop setting.



Project REF: AD-2439-2024-01-2 / 12506-P1


A gantry is a framework or structure, typically consisting of one or two side supports connected by a horizontal beam or girders, used to span an area and support equipment or materials. In various applications, gantries serve different purposes:

  1. Construction and Engineering: Gantries are used to support and move heavy materials. For example, gantry cranes lift and transport heavy items in construction sites and shipyards.
  2. Manufacturing and Industrial: In factories, gantries support machinery or tools that need to be positioned over a work area, allowing for precise movement and operation.
  3. Automotive: In the context of automotive workshops, a gantry can be used to support charging cables, tools, or equipment overhead, keeping the workspace organised and reducing trip hazards.
  4. Medical and Laboratory: Gantries in medical settings can support imaging equipment such as CT or MRI scanners, ensuring stable and precise operation.
  5. Transportation and Infrastructure: Highway gantries are used to support signage, cameras, and other equipment over roads and highways.


Using a gantry in manufacturing offers several benefits, enhancing efficiency, safety, and productivity. Here are the key advantages:

  1. Increased Safety: Gantries keep cables, tools, and equipment off the floor, reducing trip hazards and potential accidents. This organised setup minimises the risk of injuries to workers.
  2. Improved Ergonomics: By supporting heavy tools and cables, gantries reduce the physical strain on operators. Tool balancers and overhead support systems can alleviate the weight burden, making tasks less physically demanding and reducing the risk of repetitive strain injuries.
  3. Enhanced Organisation: Gantries help maintain a clean and organised workspace by providing a dedicated structure for cables and tools. This organisation improves workflow efficiency and makes it easier to locate and use equipment when needed.
  4. Space Optimisation: Overhead gantries maximise the use of vertical space, freeing up floor space for other operations. This is particularly beneficial in manufacturing environments where floor space is at a premium.
  5. Flexibility and Adaptability: Many gantry systems are modular and adjustable, allowing them to be configured to suit different tasks and workspace layouts. This flexibility makes it easy to adapt the manufacturing setup for various projects and processes.
  6. Load-Bearing Capacity: Gantries are designed to support significant weights, making them suitable for holding heavy tools and equipment. This capability ensures that all necessary tools are within easy reach without compromising safety or stability.
  7. Efficiency and Productivity: With tools and equipment readily accessible and properly supported, workers can perform their tasks more efficiently. This streamlined workflow reduces downtime and increases overall productivity.
  8. Durability and Reliability: Gantries are typically built to withstand the demands of industrial environments, offering long-term durability and reliability. This robust construction ensures consistent performance and reduces the need for frequent maintenance.



Acres have a range of standard products but also support clients with custom machinery and medium-high volume products such as trolleys, stillages etc. 

We have manufactured lots of different tables / workstations / workbenches for various industries.

We also manufacture access platformsjigs and fixtures and many other types of production support solutions / products. 

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Manufactured in the UK from our Headquarters in Derbyshire, England.

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