Stair crossovers
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System overview
A stair crossover is a raised bridge with stairs at each end that carries foot traffic over an obstruction instead of around it. The KC300 spans ducts, conveyors and machinery in aluminium modules from 1.0m to 6.0m, carries a working load limit of 2.5kPa, and is designed to AS 1657:2018.
Stair heights adjust on site to suit the bridge height you need, so one system covers a low duct run and a high conveyor line without a new fabrication drawing. Because the whole system is aluminium, an 80 extrusion weighs 2.6kg per metre and a 600mm aluminium mesh deck 4.2kg per square metre, which is what makes a crossover viable on plant structures and mezzanine floors that will not take a fabricated steel bridge.
Working load limit 2.5kPa, designed to AS 1657:2018
Bridge modules from 1.0m to 6.0m, stair heights adjustable on site
High-grade structural aluminium with stainless steel brackets and T-bolts
Flat-packed and assembled with basic tools, no welding and no cutting on site
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Key Features
Create your stair, platform and crossover designs in minutes with Builda
Kattsafe's Builda configurator lets you design in real time with compliance guidance built in, and gives you full technical drawings and component lists at the end of it.
Design modular access to suit your site, with the ability to:
Add existing structures such as walls, floors and equipment, then design the crossover around them
Design with the full range of step ladders, rung ladders, platforms and crossovers
Get full technical drawings and component lists to bring your designs to life
Check your system against Australian Standard AS 1657:2018 as you design
How to use the modular access Builda
This two-minute walkthrough covers how to customise a modular access system, price it in real time and order it. Register using the form in this tab and you can start your first design straight away.
Register for access
Fill out the form to gain access to the Builda configurator. Once approved, you'll receive your login details by email.
Frequently asked questions about stair crossovers
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How we know a KC300 will hold
Kattsafe platform and stair components are designed to AS 1657:2018 and load tested against AS 1657:2018 and AS/NZS 1170 under live load conditions, which is where the 2.5kPa working load limit comes from. Compliance rules are built into the Builda configurator, so a system designed in Builda is checked against the standard as it is drawn. Kattsafe recommends inspection and certification every three years by a competent person.
When do you need a stair crossover?
You need a crossover when people cross an obstruction on foot often enough that walking around it is not realistic, and there is headroom to go over it. Ducts, conveyor lines, pipe runs, cable trays and machinery are the usual cases.
Crossover, walkway or platform?
Stair crossover (KC300). Up, across, down. Use it when the obstruction is in the way of a route people already walk, and the crossing point is short. Modules run 1.0m to 6.0m.
Elevated walkway (KC500). A continuous raised route supported from below. Use it when the run is long and there is floor to stand supports on.
Suspended walkway (KC600). The same continuous route, hung from the structure above. Use it when there is nothing below to support it.
Access platform (KC200). A place to stand and work, not a route through. Use it when the job is at the obstruction rather than past it.
Access stairs (KC100). When you need to get up to a level, not across an obstruction.
What the standard requires
AS 1657:2018 Fixed platforms, walkways, stairways and ladders: Design, construction and installation sets the design, construction and installation requirements for fixed access in Australian workplaces, including when a stairway is appropriate rather than a ladder or ramp.
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Built for the obstruction you actually have
Bridge modules run from 1.0m to 6.0m and stair heights adjust on site, so one system covers a low duct run and a high conveyor line without a new fabrication drawing. Where there is nothing adjacent to fix to, bracing and spreader trusses let the crossover stand on its own.
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Load tested, not just rated
Kattsafe platform and stair components and base configurations are designed and load tested against Australian Standards AS 1657:2018 and AS/NZS 1170, and the Builda configurator checks a design against AS 1657:2018 as you draw it. The result is a 2.5kPa working load limit you can put in front of an engineer.
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Installed without hot works
Systems arrive flat-packed and partially assembled, and go together with basic hand tools and M10 T-bolts: no welding, no cutting, no special equipment. On live sites that means no hot works permit and no shutdown, which is usually the reason a crossover gets specified in aluminium rather than fabricated in steel.
Tools and resources
Download the Revit files or design your crossover in Builda. If you want a hand sizing a system, our team is happy to help.
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The 3D configurator in full, if you would rather design outside this page. Draw the crossover, check it against AS 1657:2018 as you go, and get the drawings and component list at the end.
Kattsafe Autodesk Revit files carry native geometry and Australian Code compliant defaults, so a crossover drops into your model without rebuilding the geometry.
Work out the exact angle and spacing for each tread so treads sit level and comply with Australian Standards, with less measuring on site. Useful for a single crossover or a stair-only install.
Godfrey Hirst Carpets, Geelong VIC
Australasia's largest carpet manufacturer needed access around complex conveyor machinery with almost no floor space to give up. Kattsafe modular platforms and stairs were adjusted on site and tied into the existing platforms and walls, with no pre-measuring and no welded fabrication, giving access to areas the team previously could not reach safely.
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