Improving Bike Workshop Safety and Efficiency with a Custom Electric Lifting Solution for Decathlon

Meeting the Demands of Heavier Electric and Cargo Bikes in Modern Workshops

As e mobility continues to reshape how people travel, it is also transforming the realities of bicycle maintenance. Electric bike workshops are increasingly required to service heavier, more complex bikes - from electric models to large cargo bikes - placing new demands on equipment, processes and technicians.

When Decathlon, the world’s largest sporting goods retailer, set out to upgrade its workshop environments, the brief was clear: improve safety, support operational efficiency and create a solution that could be deployed consistently across a global network.

This case study explores how we worked alongside Decathlon to develop a custom cargo bike lifting solution designed specifically for the evolving demands of modern bike workshops.

The Challenge: Manual Handling Risks from Heavy Electric and Cargo Bikes

The average bicycle has changed significantly in recent years. While a traditional road bike might weigh under 10kg, modern electric and cargo bikes can exceed 55kg, making manual handling both impractical and potentially hazardous. Industry guidance recommends assistance for loads above 15kg to reduce the risk of musculoskeletal disorders and workplace injuries. Decathlon found that existing market solutions were not fit for purpose. Standard workshop accessories struggled to securely grip the wider frames and unconventional geometries of cargo bikes, increasing safety risks for technicians. To maintain high service standards while protecting staff, Decathlon needed a lifting solution that could safely handle heavier loads, adapt to non‑standard frames and integrate seamlessly into busy workshop environments.

The Solution: A Custom Electric Bike Lift Designed for Heavy Cargo Bikes

Working closely with Decathlon’s teams, we adopted a collaborative development approach focused on understanding real‑world workshop conditions. Over a nine‑month design and testing programme, engineers refined a custom solution based on standard IMI Bahr Bike lift technology. Rather than relying on off‑the‑shelf equipment, the lift was engineered specifically for the geometry and weight of heavy cargo bikes. A modular accessory system allows technicians to switch quickly between different configurations, enabling a single workstation to service everything from lightweight e‑scooters to heavy‑duty cargo bikes.

Key features of the solution include:

• High load capacity: Designed to safely lift bikes weighing over 55kg

• Enhanced safety: Secure gripping mechanisms tailored to non standard frames

• Operational quietness: A low noise motor supporting more comfortable working environments

• Modular design: Faster setup and consistent use across multiple workshop locations.

This configurable approach reduces the need for multiple specialist tools, supporting faster rollout and simpler adoption across Decathlon’s global workshop network.

Delivering value at scale

For Decathlon, success depended not only on design performance but also on scalability. Rolling out a consistent solution across many workshops required a partner capable of supporting global deployment without disruption.

Our industrial production capability enabled the solution to be manufactured and delivered at scale, ensuring consistent performance and safety standards across regions. This reduced operational risk for Decathlon while supporting standardised workshop processes and training.

The result is a solution that aligns with Decathlon’s long‑term operational goals, supporting safe, efficient maintenance as workshop demands continue to evolve.

The results: safer, quieter and more efficient electric bike workshops

The introduction of the custom electric lift has significantly improved day‑to‑day working conditions for Decathlon technicians.

• Improved safety: Electric assistance removes the physical strain associated with lifting heavy e bikes and cargo bikes, supporting technician wellbeing

• Greater versatility: A single workstation can now accommodate a wide range of mobility devices, improving productivity and flexibility

• Enhanced working environment: Quiet operation and maintenance free tooling contribute to more comfortable, sustainable workshop spaces

By reducing physical strain, noise and maintenance requirements, the solution supports healthier working environments and more efficient, sustainable workshop operations.

Engineering a scalable solution together

By combining Decathlon’s deep understanding of workshop needs with our engineering expertise in material handling and light mobility applications, the teams developed a solution that addresses today’s challenges while preparing for future growth. This project demonstrates the value of close customer collaboration and configurable engineering, delivering practical innovation that improves safety, efficiency and operational resilience across a global network.

Ready to improve bike workshop safety and efficiency with a custom electric lifting solution?

Our engineers partner with customers across mobility, material handling and industrial applications to design configurable, high‑performance solutions tailored to real‑world challenges.