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Home / Industries / Bulk Chemical Loading / Ammonia Loading and UnloadingAmmonia (NH3) Handling Design, Loading, and Installation Experts
Although no two Ammonia Loading solutions will be identical, the product itself determines much of the critical design criteria that will ensure that optimum safety and productivity can work together in harmony.
What is Ammonia? Ammonia is a colorless gas with a distinct odor composed of nitrogen and hydrogen atoms. It is produced naturally in the human body and in nature, in water, soil and air, even in tiny bacteria molecules.
In the United States, ammonia is typically a “tight-fill” (closed-loop) loading operation and is loaded into trucks or rail cars via chemical hoses, by-pass arms, or stainless steel arms. Ammonia, if not handled properly can be fatal and Personal Protective Equipment (PPE) is required. Additionally, because operators are on top of the vehicles during the loading process, fall prevention is essential, not only for safety but increases throughput. Ammonia is typically transported in 33,500-gallon non-insulated, thermally protected tank cars. The rails cars themselves are 9′ outside diameter with an overall length of ~65′, with a 6’ x 8′ centered crash box opening.
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Typically, as a starting point, we will need to know answers to these questions for your project
- The Railcar connection locations need flexibility – Do you know what the breadbasket connections look like?
- Are you using liquid and vapor arms/hose as two separate devices or a piggyback arm?
- Is the loading station indoors or outdoors?
- Is the loading area temperature controlled?
- How are you going to spot your railcars
Our highly trained technical sales team will undertake a detailed site survey prior to undertaking any work to check and clarify all dimensions, obstructions, access issues and other salient points. Our challenge is to provide the safest working environment – protecting operators and the equipment – while simultaneously enabling you to improve throughput and productivity.
Your Project Needs
Whether you are looking for a turn-key installation, on-site supervision or a maintenance program, SafeRack is positioned to assist you. We can do as little or as much as you need. Our project management and supervision team is the best in the business at supporting your company’s needs.
- Collaborative Design – Our loading platform specialists will work with you one on one, if you design to design the best loading solution for your specific needs
- Contract review – drawings and associated documents relating to the contract prior to site arrival
- Risk Assessment – Undertaking a site risk assessment
- Shipment Inspection – Detection of any shipping damage or abnormalities
- Material Receiving – Supervised off-loading and transport at site
- Installation Management – Supervised Installations and Coordination
- Start-up & Commissioning – On-site training for both users and maintenance personnel
Loading Arms
Generally speaking, SafeRack recommends rigid pipe loading arms where possible for the following reasons:
- Balanced throughout their movement envelope
- Designed not to hit the ground – protecting the asset and the operator
- Ergonomic – one man operation
- Fitted with manual or actuated valves.
- Fitted with optional purge/vent facilities
- Can be moved into position with ease and left hanging in the air while the operator prepares the tanker connection
- Parked neatly
Hoses require:
- Annual pressure test
- Are difficult to stow neatly when not in use
- Can be dropped
- Can be driven over
- Are very heavy to use if fitted with a valve at the tanker connection point
- Cannot be easily heated or have vent/purge valves fitted to it
- Prone to catastrophic failure
Typical Ammonia Loading Platform
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Below are some of the loading and unloading solutions for illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs.
Ammonia Loading Arms
Ammonia is typically loaded into railcars via chemical hoses, by-pass arms, or 3” stainless steel loading arms. The current best loading practice includes loading arm or chemical hose, with quick-acting coupling, often in the form of Hammer Unions with stabber pipe. The hose will have a top inlet with a control valve to ensure that it is self-draining after use and is supported along the length of a mechanical loading arm to improve handling; this is known as a by-pass arm. You can install one liquid and one vapor arm, or mount both the liquid and vapor hoses on one by-pass arm. Depending on the (un)loading temperature and pressure, gaskets and seal material could be PTFE, EPDM or Low-Temp Viton.
Break-away couplings can be fitted near the inlet of the hose for additional safety in the event of a drive-off
Although some sites use PTFE lined loading arms, our experience has been that these can be cost-prohibitive to maintain and challenging to keep a leak-tight seal across each arm section.
Loading Gangways and Safety Cages
A wider access gangway (36″- 48″ is preferable) as it helps improve access and egress to and from the vessel. In addition, a wider gangway will reduce the risk of the operator’s PPE getting caught, torn or damaged, and will improve productivity and safety. Powered gangway solutions are also an option, with both hydraulic and pneumatic solutions being commonly used. Each gangway will be fitted with a two-rail safety cage for the railcar crash box. This will be a centered 6’x8’ safety cage to sit directly over the cashbox. This will provide a safe, secure work environment for your operator when connected to their breathing apparatus
SafeRack’s GX SAS gangways use Retractalok power-assist technology allowing operators to raise or lower effortlessly, light as a feather to lift, and solid as a rock. Tested in the most critical applications, this revolutionary new gangway outperforms all others. Available in multiple lengths and widths.
Learn MoreMAXRack Elevating Safety Cage
As an alternative to our two and four-rail safety cages, some customers prefer our MAXRack elevating safety cages. The ultimate fall prevention solution engineered to keep operators safe and productive. Designed for both trucks or railcars, and available in multiple cage lengths and widths. Safe, durable, and easy to use. MAXRack is built rock-solid with galvanized steel column supports and lifting arms (cages can be Aluminum, Galvanized, or Stainless Steel depending on application) Available in two power options – Pneumatic Air Drive and Electric Drive (Explosion and Non-Explosion Proof).
Learn MoreAmmonia Eye Wash/Drench Showers
ANSI guidelines state that an Eye Wash/Drench Showers need to be located 10 seconds or 55’ (16.8m) from contaminants or hazardous materials. Eyewash stations need to be on the same horizontal plane with no obstructions.
Therefore, we would propose the installation of a standard combination Drench Shower/Eyewash Unit, which will save limited space and fit easily into any work environment.
Ammonia Spill Containment
Spill containment pans will be provided at the point of loading operations and is an essential piece of equipment in overall site safety and environmental protection Ammonia Grounding
While not highly flammable, high airborne concentrations can be ignited and pose a significant fire and explosion hazard, especially in confined spaces. Steel containers or vessels of ammonia may also explode when subject to excessive heat or high temperatures. Industry best practice includes the grounding of all vessels prior to starting the (un)loading process. - Vehicle grounding and bonding — ensure true grounding before product flow is permitted
- Explosion-proof enclosures — meet or exceed UL, CSA and Ex requirements
Safety Gates Ammonia Loading Applications
Safety Gates will be installed at the top of stairs and any other openings to ensure operator safety at all times. YellowGate Safety Gates
SafeRack’s line of industrial safety gates is the most flexible product on the market with the ability span openings between 16” and 36” and is field adjustable with nothing more than a wrench. Learn More
Ammonia Loading Platform Options
- Lighting – Lighting both over and under the platform will be provided. For overcast days or second shift, lighting is essential for improved safety and improved productivity.
- Platform & Canopies – Full platform canopies reduce exposure to the elements and improve the safe and productive loading operation from the operator’s perspective.
- Operator Shelter – Depending on your site requirements, consideration should be given to the requirement of an operator or guard building on the loading platform. This can be customized to meet specific site requirements
- Wheel Chocks – Railcar Wheel Chocks provide fast blocking of all types of railcars and meet OSHA regulations to safely prevent railroad cars from moving during loading or unloading operations. This is a requirement by the Department of Homeland Security
Personal Protective Equipment PPE Requirements
Eye/Face Protection: Wear chemical safety goggles. A face shield (with safety goggles) may also be necessary.
Skin Protection: Wear chemical protective clothing e.g. gloves, aprons, boots. Coveralls or long sleeve shirts and pants in some operations. Wear a chemical protective, full-body encapsulating suit, and self-contained breathing apparatus (SCBA). Suitable materials include: butyl rubber, neoprene rubber, Viton®, Viton®/butyl rubber, Barrier® – PE/PA/PE, Silver Shield® – PE/EVAL/PE, Trellchem® HPS, Trellchem® VPS, Saranex®™, Tychem® BR/LV, Tychem® Responder® CSM, Tychem® TK. The following materials should NOT be used: natural rubber, polyvinyl chloride. Recommendations are NOT valid for very thin neoprene rubber gloves (0.3 mm or less).
Respiratory Protection: Up to 5 ppm:
(APF = 10) Any chemical cartridge respirator with cartridge(s) providing protection against ammonia*; or Any supplied-air respirator*.
*Reported to cause eye irritation or damage; may require eye protection.
APF = Assigned Protection Factor
Recommendations apply only to National Institute for Occupational Safety and Health (NIOSH) approved respirators. Refer to the NIOSH pocket guide to chemical hazards for more information.
Use a local exhaust ventilation and enclosure, if necessary, to control the amount in the air. Consider using a corrosion-resistant exhaust ventilation system separate from other ventilation systems. It may be necessary to use stringent control measures such as process enclosure to prevent product release into the workplace. Use backup controls (e.g. double mechanical pump seals) to prevent the release of this material due to equipment failure. * For illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs Major Ammonia Producers where we have successfully executed Ammonia Loading Projects
Ammonia 101
Things to know about Ammonia
Chemical formula: NH3
Appearance: Clear, colorless, gas. Clear, colorless liquid under pressure.
Physical State: Liquid
Ammonia is a clear colorless gas, or a clear colorless liquid under pressure. Ammonia refers to solutions that are 50% ammonia or greater. In a concentrated form (gas or liquid) ammonia is corrosive to human soft tissue upon contact, and exposure in sufficient quantities can be fatal.
Ammonia is used in the manufacture of plastics, explosives, textiles, pesticides and other chemicals. Other derivatives of ammonia include: ammonia nitrate, ammonium nitrate and chloride.
Anhydrous ammonia used to make fertilizers is a highly toxic, volatile chemical that can severely injure or kill an operator if safety precautions are not properly adhered to. Anhydrous ammonia does not play well with oxygen; therefore, tanks or vessels must be purged with nitrogen before transport or storage.
Aqua ammonia transfer methods vary by site. Depending on the type of transfer method loading arms could be either tight fill or splash fill. It’s extremely important to ask your customer questions regarding their loading/unloading process.
OSHA Permissible Exposure Limit (PEL) @ .05 parts per million
Ammonia is both caustic and hazardous in its concentrated form, classified as extremely hazardous and is subject to strict reporting requirements by facilities that produce, store, or use it in significant quantities. Ammonia boils at −33.34 °C (−28.012 °F) at a pressure of one atmosphere, so the liquid must be stored under pressure or at low temperature.
When released to the open air, the vapors initially move close to the ground, causing greater risk for exposure.
Anhydrous ammonia (Anhydrous means without water) used to make fertilizers is a highly toxic, volatile chemical that can severely injure or cause death if safety precautions are not taken. Anhydrous ammonia does not play well with oxygen; therefore, tanks or vessels must be purged with nitrogen before transport or storage.
Customer Reviews
5 5Compact size, light weight for moving by service people.Adjustable height and moving direction for type of service. Compact size, light weight for moving by service people.
By Bong Soo Kim from Kolon Industries on 10/9/144 5SafeRack is our sole provider of railcar pans.Phyllis was, and always has been, very easy to work with and makes ordering your products a real pleasure. Cost, quality, and reliability will definitely make SafeRack our sole provider of railcar pans.
By Jeff Hughes from A&B Welding on 5/7/135 5Delivery was exactly met as quoted.John Edwards was very responsive and delivery was exactly met as quoted.
By Jamie Lynch from Armstrong Industries on 12/27/115 5Addressed all my safety concerns.Very good quality and very adaptable to my project, with the pre-engineered modular design. It is a superior product, and exceeded in covering all my safety concerns.
By David Eicher from Sentinel Transportation LLC on 4/22/135 5The product was of good quality and installation was easy.The product was of good quality and installation was easy. We received the product on time as promised. John Baste was a pleasure to deal with, answered all my questions and worked with me on the purchase. HIGH FIVE
By Sue Martin from The County of Santa Clara on 6/1/125 5Existing parts that we had is worn that need changed.The sales team at SafeRack was very helpful and responsive.
By Carmelito Lao from Lafarge C/O Financial Services Center on 8/5/19Is your plant or facility compliant with ANSI, OSHA, and local safety codes? We can help!
EMERGENCY EYEWASHES / SHOWER EQUIPMENT AND THE ANSI/ISEA Z358.1 – 2014 STANDARD
Following eye contact, you must start washing with water immediately to prevent permanent damage. In the event of skin contact, you must start washing with water immediately to prevent slow-healing chemical burns.
Are you aware that ANSI guidelines state that Eye Wash/Drench Showers need to be located 10 seconds or 55′ from contaminates or hazardous materials and located on the same horizontal plane, with no obstructions? If bottom loading/unloading, an additional shower should be located at grade as well. SafeRack provides the above equipment plus much more needed to keep employees safe and expedite bulk chemical loading and unloading.
OSHA Regulation Experts – Does your existing chemical safety equipment or chemical loading systems meet OSHA’s latest requirements? SafeRack’s professional technical sales consultants are available to meet with your team to make recommendations to keep your facility in front of OSHA’s ever-changing country and region-specific standards and regulations, including lifeline and trolley beam fall arrest systems, metal stairs, and access platforms.
Why SafeRack?
The SafeRack approach is a collaborative one. Let’s call it The SafeRack Way. We have, over many years amassed a great deal of experience and understanding of the safety aspects involved in loading road tankers and railcars, as well as the behavioral habits of the operators.
Experts In Chemical Loading
- Acetic Acid
- Acetic Anhydride
- Acetonitrile
- Acrolein
- Acrylic Acid
- Acrylonitrile
- Aluminum Chloride
- Aluminum Sulfate
- Ammonia
- Ammonium Hydroxide
- Ammonium Nitrate
- Aniline
- Benzene
- Benzyl Chloride
- Bromotrifluoromethane
- Butadiene
- Carbon Dioxide
- Caustic
- Chlorine
- Chloroform
- Chlorosulfonic Acid
- DEF (Diesel Exhaust Fluid)
- Diethylene Glycol
- Dimethylformamide
- Dodecylbenzene Sulfonic Acid
- Ethanol
- Ethyl Acetate
- Ethyl Chloride
- Ethylene
- Ethylene Dichloride
- Ethylene Glycol
- Ethylene Oxide
- Ferric Chloride
- Ferrous Chloride
- Hexane
- Hydrochloric Acid
- Hydrofluoric Acid
- Hydrofluorosilicic Acid
- Hydrogen Cyanide
- Hydrogen Peroxide
- Hydrofluoric Acid
- Hypochlorous Acid
- Isopropyl Acetate
- Liquid Argon
- Liquid Nitrogen
- Liquid Oxygen
- Maleic Anhydride
- MDI
- Methanol
- Methyl Chloride
- Methyl Ethyl Ketone
- Methyl Methacrylate
- Methyl Isocyanate
- Molten Sulphur
- Nitric Acid
- Oleum
- Phenol
- Phosphoric Acid
- Phosphorus Oxychloride
- Phosphorus Trichloride
- Polypropylene
- Renewable Diesel
- Sodium Cyanide
- Sodium Hydroxide
- Sodium Hypochlorite
- Styrene Monomer
- Sulfuric Acid
- Sulfur Dioxide
- Titanium Tetrachloride
- Toluene
- Toluene Diisocyanate
- Turpenitne
- UAN (Urea Ammonium Nitrate)
- UREA
- Vinyl Acetate
- Vinyl Chloride
- Xylene
- Zinc Chloride
- Agro-Chemical
- Specialty Chemical
- Petrochemical
North America’s largest loading terminal
World-leading designer, manufacturer, and installer of truck and railcar loading platforms
As one of the primary railcar loading points, Hardisty is one of the major crude oil hubs in North America and a major origination point of pipelines that export to the United States. SCS was asked to supply and construct a SafeRack crude oil loadout terminal spanning nearly half a mile. The USD Hardisty terminal can load up to two 120-railcar unit trains per day and consists of a fixed loading rack with 62 railcar loading positions enclosed, separate control, operator, and mechanical buildings, as well as a unit train staging area and loop tracks capable of holding multiple unit trains simultaneously. SCS also supplied and installed boom-supported loading arms with supply and vapor management systems.


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