Loading/Unloading Transloader

Transloaders are mobile units that transfer goods from one mode of transportation to another, such as from a truck to a railcar or vice versa. As a mobile platform, they can be outfitted with equipment for specific needs such as grounding protection, overfill monitoring, and metering for custody transfer. They are integral to the logistics of industries like rail, shipping, and freight by facilitating the movement of bulk materials, liquids, or other products between different transportation methods.

This transloader is equipped with a bottom loading hose for unloading tanker trucks and a loading arm that top loads railcar tanks. Operators can bulk transfer chemicals and liquids directly in the field, and safely access the top of vehicles. Transloading is especially valuable when goods must switch transport systems en route to their final destination.

SafeRack Gangways:

• Gangway 1: Installed on the transloader for accessing the top of the railcar. Easily lowering onto the top of the railcar with a 2-rail safety cage designed to sit securely on top of the railcar’s crash box, ensuring operator safety while accessing the top valves, hatches and fittings.
• Gangway 2: This gangway is configured for accessing the top of the tanker truck. It is equipped with a 4-rail safety cage, providing fall protection and a secure platform for operators to access the truck’s top hatch, which is necessary for venting during the unloading process.

Both gangways exceed OSHA standards, ensuring that Patriot Rail’s transloading operations meet stringent safety regulations.

Patriot Rail – An operations company for short line and regional freight railroads and rail services

Patriot Rail operates over 30 regional short line freight railroads and rail-related services companies, with more than 1,200 rail miles across the United States. Their service capabilities extend to freight and railcar storage, transloading, warehousing, industrial development, track access, and excursions. With the increase in international trade and the complexity of logistics, transloading has become a critical component of Patriot Rail’s operations, requiring reliable equipment that ensures both efficiency and safety.

Operational Benefits

• Enhanced Safety: The SafeRack gangways provide secure, OSHA-compliant access to both the railcar and tanker truck, minimizing the risk of falls and ensuring safe operational procedures.
• Efficiency: The dual-hose transloading system allows for quick and efficient transfer of chemicals, reducing downtime and improving overall throughput.
• Versatility: The ability to access both railcars and trucks with specialized gangways makes the transloader a versatile solution for Patriot Rail’s diverse transloading needs.

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Location	Mediterranean Sea
Customer	Energean Power
Product	25 ErectaStep Stairs and Platforms
Industry	Marine & Energy
Facility Type	Floating Production, Storage, Offloading) vessel

ErectaStep’s products are ideal for maritime environments due to their aluminum construction, which resists corrosion and rust.

Logistics and Coordination

The energy company’s procurement team in Greece managed the purchase and logistics, ensuring the smooth shipment of materials to Israel, where they were then transported to the vessel. Each of the 25 ErectaStep stair and access systems was configured to the specific requirements of the equipment and locations throughout the FPSO vessel. SafeRack streamlined the installation process by ‘spot packing’ the components, making them easy to identify and assemble on the vessel. SafeRack collaborated with the customer’s engineering contractor to ensure the correct placement and configuration for each platform and stair configuration. The modular, bolt-together design of ErectaStep components allowed for quick and efficient on-site assembly without the need for welding or heavy equipment. Any fitment issues were easily resolved by adjusting the modular components as needed, minimizing downtime and logistical challenges.

Installation Gallery

The ErectaStep products were utilized for various critical access points on the FPSO vessel, including:
Gas Turbines Access, Essential Generator Fuel Gas Valve Access, Rich Meg Filter Access, Flash Gas Compressor Access, Produced Water Skid Panel Access, Sales Gas Compressor AFT and Port-side Access, Distribution Meg Filter Access

ErectaStep’s modular design allowed for quick and efficient installation without the need for welding or heavy equipment.

Project Success:

The initial order comprised 25 platforms. Following the successful implementation, an additional order for 8 platforms was placed, signifying the project’s success and the reliability of ErectaStep products.

Key Product Features:

1. Durable Construction: Marine-grade aluminum ensures longevity and resistance to corrosion.
2. Modular Design: Allows for infinite configurations and easy on-site assembly.
3. Safety Compliance: All products meet OSHA standards for stairs, ladders, work platforms, and guardrails, ensuring safe work environments.
4. Ease of Installation: Prefabricated components that bolt together, eliminating the need for hot permits or welding.

The ErectaStep installations on the FPSO vessel demonstrate SafeRack’s capability to provide robust and adaptable access solutions for complex marine environments. These installations not only improve operational efficiency but also ensure safety and compliance with regulatory standards.

SafeRack Marine Loading Solutions

Marine Gangways

SafeRack’s MarinaStep barge access and ship access gangways are advanced, corrosion-resistant aluminum marine gangways that are designed for code-compliant worker safety, durability, and reliability in marine environments and are built to order to your required length and specifications that are built to last.

More on SafeRack’s Marine Gangways

Marine Loading and Unloading Systems

A full range of products and services of Fluid Transfer Systems, Hose Handling Systems, Tandem Mooring Systems, Large Bore Flexible Hose Systems, Marine Coupling Systems, and Loading Platforms.

More on Marine Hose and Loading Arms

Energean Power FPSO Producing at Full Capacity

Vessel Details:

• IMO Number: 9889162
• Vessel Name: Energean Power
• Ship Type: Offshore Support Vessel
• Flag: Marshall Islands
• Gross Tonnage: 94,290
• Summer Deadweight: 148,089 tons
• Length Overall: 227 meters
• Beam: 50 meters
• Year of Build: 2022

Energean, an oil and gas company, has been a significant player in the energy sector. The Energean Power FPSO vessel, moored 80 kilometers west of Israel’s coast, has reached its maximum gas production capacity, supporting the Karish North and Karish fields. The vessel processes and exports gas to various power stations in Israel, enhancing energy security and supply stability in the region.

The post SafeRack’s ErectaStep Installations on a FPSO Vessel appeared first on SafeRack.

This SafeRack gangway installation for a new SOPREMA facility in Tongeren, Belgium. This gangway installation gives workers a safe way for workers to access the top hatches and silo valves and loading hoses for top-loading trucks

SafeRack Solution

SafeRack’s gangway solution ensures worker safety and operational efficiency in accessing the silo tops for loading trucks. The gangway facilitates safe access to the valves and top loading hoses, integral for SOPREMA’s daily operations.

• Product: SafeRack SAS Gangway
• Material: Aluminum with stainless steel hardware
• Features:
  • Self-Adjusting Stairs to accommodate varying vehicle heights
  • Slip-resistant walk surface
  • Safety cage with adjustable height for enhanced worker protection
  • Lightweight and corrosion-resistant design

Key Benefits

• Safety: The SAS Gangway ensures workers can safely reach the top valves and loading hoses without the risk of falls or accidents.
• Efficiency: The gangway design allows for quick and easy adjustment to different truck heights, speeding up the loading process.
• Durability: Built with robust materials, the gangway is designed to withstand harsh industrial environments and weather conditions, ensuring long-term reliability.
• Customization: The gangway was tailored to meet SOPREMA’s specific needs, ensuring optimal integration with the facility’s operations.

Facility Background

SOPREMA’s new plant emphasizes sustainability. It features a fossil-free, nearly zero-energy building with green roofs and Corten steel accents. This facility is designed to blend seamlessly into the landscape, reinforcing SOPREMA’s commitment to environmentally responsible construction and operations.

Implementation

The installation of the SafeRack gangway was seamlessly integrated into SOPREMA’s new facility, aligning with their sustainable and efficient operational goals. Thanks to effective collaboration between SafeRack, SOPREMA, and the involved construction teams, the project was completed within the tight schedule required for the production start.

SafeRack’s gangway solution is crucial to SOPREMA’s new eco-friendly production plant, enhancing worker safety and operational efficiency. This installation reflects our commitment to delivering innovative and reliable access solutions tailored to the specific needs of global industrial clients.

XPS Insulation: Everything You Need to Know

What is XPS?

XPS (extruded polystyrene) is a popular thermal insulation material known for its high performance and durability. At SOPREMA’s XPS factory in Belgium, new XPS insulation boards are manufactured using recycled materials, including cutting waste from XPS panels and expanded polystyrene (EPS).

Pros and Cons of XPS

Pros:

• Excellent Lambda Value: Provides superior thermal insulation.
• High Compressive Strength: Suitable for heavy loads.
• Water Repellent: Ideal for use in humid environments.
• Lightweight: Easy to handle and install.
• Limited Thickness: Offers effective insulation without bulk.
• Rot Resistance: Long-lasting performance.
• Long Lifespan and Reliability: Durable over time.
• 100% Recyclable: Supports circular construction projects.

Cons:

• Fire Classification: XPS has a Euroclass E rating for fire resistance, which is not its strongest feature.

Applications: What Can XPS Be Used For?

• Underground Insulation: Ideal for foundation walls.
• Inverted Roofs: Combined with DUOFLEX for effective roofing solutions.

XPS versus Other Insulation Materials

1. XPS vs. EPS:
   • Cell Density: XPS has higher cell density, providing better compressive strength.
   • Water Vapor Resistance: XPS is less permeable to moisture compared to EPS.
2. XPS vs. PIR/PUR:
   • Material Composition: PIR/PUR are chemical-based, while XPS is polystyrene-based.
   • Thermal Performance: PIR/PUR offers better lambda values, but XPS has superior compressive strength.
   • Moisture Resistance: XPS excels in humid environments, unlike PIR and PUR.

Conclusion

SafeRack’s gangway solution is crucial to SOPREMA’s new eco-friendly production plant, enhancing worker safety and operational efficiency. This installation reflects our commitment to delivering innovative and reliable access solutions tailored to the specific needs of global industrial clients. Additionally, SOPREMA’s use of XPS insulation demonstrates their dedication to sustainable building practices, ensuring long-term energy efficiency and environmental responsibility. For more information on SafeRack’s products and solutions, visit SafeRack.com.

The post Project Profile: SafeRack Gangway Installation for SOPREMA, Belgium appeared first on SafeRack.

This ErectaStep installation achieved full ROI in under 1.5 years, delivering substantial cost savings while improving safety too!

Saves Money

Comparing traditional scaffolding rentals with ErectaStep modular platforms reveals significant long-term financial benefits. While renting scaffolding might seem less expensive initially, costs quickly add up with the rental fees, frequent inspections and certification, and the need for skilled labor for assembly and disassembly. Scaffolding also requires regular maintenance, incurring additional costs. In contrast, ErectaStep’s modular stair design eliminates these recurring costs, offering a significant long-term saving. Constructed from marine-grade aluminum, ErectaStep systems are designed for durability and long-term use, significantly reducing maintenance expenses without requiring repetitive, costly re-certification.

Benefits of ErectaStep over Traditional Scaffolding

Improved Safety and Compliance

ErectaStep’s stairs are designed to meet OSHA standards, ensuring a safe working environment for all personnel involved in maintenance and inspection tasks. The stairs’ construction, made from industrial-grade aluminum, eliminates the risks associated with using scaffolding, such as instability and potential for collapse.

Durability and Low Maintenance

Constructed from 100% industrial-grade aluminum, ErectaStep stairs are resistant to rust, warping, and rotting. This ensures a long lifecycle and minimal maintenance, which is particularly important in the harsh conditions often found in industrial environments like nitrogen manufacturing facilities​​​​.

Modular Design for Versatile Applications

ErectaStep’s modular design allows for infinite configurations, making it possible to configure the stairs to any height and specific site requirements without custom fabrication and the costs and extended timelines that come with custom fabrication.

Quick Installation

One of the significant advantages of ErectaStep stairs over scaffolding is the ease and speed of installation. The prefabricated components bolt together on-site without the need for welding, enabling a rapid setup that minimizes downtime and disruption to facility operations​​​​.

Improved Operational Efficiency

By replacing scaffolding with ErectaStep’s permanent stairs, the facility has streamlined its maintenance and inspection processes. The stairs provide reliable, consistent access to valves, allowing for quicker and more efficient task completion. This improvement in operational efficiency helps reduce overall turnaround times, critical for maintaining production schedules in the manufacturing sector​​​​.

Specific Features of the Installation

• Material: 100% industrial-grade aluminum, ensuring durability and resistance to corrosion.
• Compliance: Fully meets OSHA standards, enhancing workplace safety.
• Configurability: Modular design allows customization to any required height and site-specific needs.
• Installation: Prefabricated and bolted together on-site, requiring no welding and ensuring a quick setup​​​​​​.

The post ErectaStep Stair Installation Replaces Scaffolding at Arizona Chemical Manufacturing Facility appeared first on SafeRack.

Georgia Pacific needed a solution to protect non-employee truck drivers who were required to climb atop their log trailers to manually unbuckle or unstrap timber loads.

Project Details

SafeRack’s engineering team designed an OSHA-compliant horizontal trolley beam fall arrest system with an access platform and a SafeRack gangway for operators to reach the top of their load on the log trailer. The design meets the facility’s requirements of providing a safe way for truck operators to prepare their load quickly for unloading for improved throughput.

Log Trailer Unloading Station Overview:

The fall arrest system and access platform was installed at the Georgia Pacific paper mill in Big Island, VA. The double-sided configuration improves the facility efficiency and increases throughput by allowing multiple log trailers to be processed simultaneously, while providing a safe working environment for truck operators as they prepare their loads for off-loading.

System Benefits:

• Provides OSHA-compliant fall protection for non-employee truck operators
• Adaptable to various log trailer lengths and heights
• Allows truck operators to safely access the top of their loads when necessary
• Arrests falls by keeping operators upright in a harness, preventing ground impact
• Enhances overall facility safety and reduces liability risks

Installation Elements

Trolley Beam Fall Arrest System

• Double-sided configuration
• Horizontal I-beam design for maximum coverage
• Compatible with self-retracting lifelines
• Meets or exceeds OSHA and ANSI standards
• Allows attachment anywhere along the beam, including midpoints
• Reduces fall distances during loading and unstrapping operations

SafeRack Gangway

• Installed on both sides of the access platform
• Self-leveling and articulating design to accommodate varying vehicle heights
• One-piece stair construction for enhanced durability and reduced weld failures
• Spring counterbalance for ease of use

SafeRack’s custom-engineered fall arrest solution effectively addresses the unique safety challenges presented by log trailer unloading operations at Georgia Pacific’s Big Island facility. By combining a trolley beam fall arrest system with accessible gangways, the installation ensures compliance with safety regulations while maintaining operational efficiency and improving throughput… safely.

A log trailer, logging trailer or timber trailer, is a specialized type of semi-trailer designed for transporting raw logs from forests to processing facilities. Log trailers are typically 40 to 53 feet long with sturdy side stakes or bunks to contain and support the load. They often feature a skeletal frame design to minimize weight while maximizing payload capacity.

Flatbed Trailer Types

The post Log Trailer Fall Arrest System – Georgia Pacific Facility appeared first on SafeRack.

A North American automotive assembly plant located in the Mid-West reached out to SafeRack late last year to find a safer alternative to their operators climbing up the sides of tank trucks. This complex not only assembled vehicles but also had a paint department where they prepped, primed, and painted various components.

Project Challenge

The customer was bottom unloading approximately 3 to 5 trailers per day of acrylic polyurethane “enamel” and clear topcoat resins via hoses. However, they still needed to access the tops of trailers to check seals and take samples. The existing method of operators climbing up the sides of tank trucks posed significant safety risks and inefficiencies.

SafeRack’s Solution

SafeRack’s ultimate solution included a platform and stair unit, an SAS self-adjusting stair access gangway, and a fall prevention safety cage. This solution provided the following benefits:

• Platform & Stair Unit: Ensured stable and secure access to the tops of the trailers.
• SAS Self-Adjusting Stair Access Gangway: Allowed operators to safely and easily reach the trailer tops.
• Fall Prevention Safety Cage: Provided an extra layer of safety, fully encapsulating the worker and preventing falls.

Impact on Operations

“A paint shop is one of the most critical and often most expensive stages in the assembly process. It is the one area where you can’t afford any downtime. A vehicle’s paint is often the first thing a customer notices and must look flawless.”

SafeRack’s solution not only enhanced the safety of the operators but also ensured the paint shop could maintain continuous operation without the risk of accidents or delays due to unsafe access methods. This allowed the automotive assembly plant to uphold the highest standards of quality and efficiency in their paint department.

The post Bulk Paint Unloading at an Automotive Assembly Plant in the Mid-West appeared first on SafeRack.

Previously, Amtrak employees at the Los Angeles maintenance shed had to use extension ladders to perform maintenance in and on locomotives, a method fraught with safety risks and inefficiencies. SafeRack was awarded the contract to design and build a state-of-the-art, two-story access platform, enabling the maintenance crew to work more efficiently in a fully OSHA-compliant, safe environment.

Project Overview

The SafeRack team designed and engineered a hot-dipped galvanized steel construction platform, complete with stair units, towers, gangway track, and carriage, all fully encased in handrails. This two-story platform is designed to provide safe and easy access for maintenance tasks on Amtrak’s locomotives, addressing previous challenges and enhancing overall safety. Each level includes a SafeRack gangway for workers to access the locomotive. The gangways are raised as the railcar pulls into the shed and can be lowered into position, providing workers an easy and safe way to work on the locomotive.

Gangway Solutions

Fall Protection Specialist

“As subject matter expert, I’ll leverage my years of experience as your personal consultant throughout the project to ensure you get a world-class solution.”

Ray Evans

 – 

Bulk Chemical Market Specialist

Contract#  47QSAWA19D0085  

Enhanced Safety and Efficiency

The post Railcar Maintenance Access Platform appeared first on SafeRack.

Location	Sulphur, Louisiana
Project	Replacing Temporary Scaffolding
Client	Citgo
Materials/Product	Petroleum
Facility	Petrochemical Refinery

JODY ASHWORTH
Regional Manager | Safety Consultant | OSHA Compliant | Advanced Technology | Fall Protection & Loading Solutions | Louisiana
Follow Jody on LinkedIn

Solution: The refinery reached out to ErectaStep for a permanent stair solution. Utilizing ErectaStep’s modular design and advanced CPQ (Configure, Price, Quote) software, a suitable stair configuration was quickly devised using readily available components. This approach eliminated the need for costly and time-consuming custom fabrication.

Installation: The project commenced with the removal of the old scaffolding and was followed by a week of site preparations and concrete work. The installation of the new ErectaStep stairs was completed in just one day, thanks to the bolt-together design that required no welding, special equipment, or tools.

Results: The new ErectaStep installation led to significant cost savings by eliminating ongoing rental and maintenance expenses associated with the temporary scaffolding. The more durable and efficient stair solution not only reduced costs but also enhanced operational efficiency and safety. The refinery has since planned to replace all temporary scaffolding across the facility, with the new stairs expected to pay for themselves in under two years.

Conclusion: The transition to ErectaStep’s permanent stair solutions marks a strategic improvement in the refinery’s maintenance and safety management. This project exemplifies the economic and safety benefits of choosing durable, prefabricated solutions in demanding industrial environments. For more details on how ErectaStep can improve your facility’s safety and efficiency, contact us today.

Project Profile – RollaStep as a Scaffolding Alternative

A large tire manufacturing plant had to regularly access their heat exchangers, a piece of equipment that is used in transferring heat between a solid object and a fluid, or between two or more fluids. Workers needed a work platform to access these heat exchangers for maintenance every 4-6 weeks throughout the year. Each time scaffolding was rented and union contractors were brought in to set-up and break down the units at an expense of $2,400 each time. Additionally, you can see from the photos that the scaffolding was cumbersome, difficult to move from each heat exchanger and wasn’t OSHA compliant.

See full project profile

The post SafeRack Replaces Temporary Scaffolding with Permanent Stairs at Refinery appeared first on SafeRack.

In both industrial and non-industrial environments, the requirement for a step, stair, or ramp is required when there is a break in elevation of 19 inches (48 cm) or more to be OSHA compliant.

Here’s an example of two different industrial facilities with a 1-step ErectaStep unit installed to be OSHA compliant and, as importantly, provide safe access points for workers to navigate around the plant. Because ErectaStep’s metal stairs are modular with parts always in stock, these units could be shipped and installed the next day. No engineering or fabrication is needed; they are just anchored to the cement without special tools.

Ray Evans, who has been with SafeRack since 2003 and currently serves as a Market Specialist, offers insights into the impact of material choices on safety, productivity, and overall business success, particularly regarding stairs and access solutions.
Contact Ray or follow him on LinkedIn

ErectaStep’s Easy Solutions – Both Compliance and Safety

ErectaStep’s pre-engineered, modular, and fully compliant metal stairs, platforms, and crossovers are easy to meet OSHA standards. Our modular stairs not only save time and are cost-efficient, but they’re also adaptable to various industrial and commercial environments. The modularity of ErectaStep’s products ensures that they can fit the specific needs of any site, helping to prevent common workplace incidents such as trips, slips, and falls by providing reliable access solutions​​​​.

Key Benefits of ErectaStep Stair Units

• OSHA Compliant: All ErectaStep stair and access platforms meet the critical safety standards set by OSHA, ensuring that they help maintain a safe working environment​​.
• Modularity and Customization: The modular design allows for quick assembly and easy adaptation to various heights and configurations, making them ideal for virtually any application​​.
• Durability: Constructed from industrial-grade materials, ErectaStep’s products are designed to withstand harsh environments without succumbing to rust or degradation​​.
• Ease of Installation: ErectaStep’s products are prefabricated and designed for easy onsite assembly, requiring no welding and minimal tools​​.

Practical Application in Industrial Settings

ErectaStep’s solutions are prominently used where quick and safe access is needed over obstacles such as pipes, spill containment dike walls, or uneven ground. Our product range, from simple one-step units to complex multi-level stair systems, allows facilities to implement safety measures without engineering, welding, or custom fabrication.

Conclusion

Understanding when a step is required to maintain safety standards in any facility is important. By integrating ErectaStep’s compliant and customizable stair solutions, businesses can enhance the safety and accessibility of their operations, ensuring that they not only meet regulatory requirements but also protect their employees from potential hazards. For more detailed information on implementing these solutions in your facility, consider contacting ErectaStep for a consultation or a demonstration of their products​​.

The post When is a Step Required? appeared first on SafeRack.

A prominent public transportation authority in the Bay Area sought an upgrade from their cheap and inefficient mobile stairs, which were cumbersome and had to be moved from place to place by maintenance workers as needed. Their needs included:

• Safer, more efficient access for maintenance crews
• Greater productivity for workers

Location	San Francisco Bay Area
Industry	Public Transportation
Product	ErectaStep Modular Stair Platform

DEREK ROSE
The Compliance and Safety Expert on this project

Challenge

The customer sought a more effective solution to ensure easy, safe access to passenger train cars for their crew. The challenge was to replace inefficient and unsafe mobile stairs with a more stable, durable, and efficient solution.

Outcome

The reconfigured application works beautifully. Installation was straightforward and easily implemented using our installation manual and a few simple tools. The safety and efficiency of the maintenance crew’s operations have been significantly enhanced. The ErectaStep system provides a stable and reliable solution in its current configuration while offering versatility as the facility’s needs change over time.

The ErectaStep installation at this San Francisco Bay Area public transportation facility highlights its versatility and adaptability, demonstrating its value in enhancing operational safety and efficiency in the public transportation industry.

The post Access Solution for San Francisco Public Transportation Maintenance appeared first on SafeRack.

ErectaStep’s stair and access platform installation at a Cla-Val Valve Test Stand, illustrates a blend of safety, efficiency, and modular design in a tight space.

Kinley Construction, a general contractor specializing in industrial construction in North America, spearheaded the construction of a valve Test Stand In the heart of Costa Mesa, CA, at the Cla-Val Global Headquarters. This project is a testament to Kinley Construction‘s expertise and highlights the power of ErectaStep’s modular 5-component design in industrial efficiency and safety.

The Project: Cla-Val Test Stand

Designed by Argus Consulting, the Cla-Val Test Stand serves as a specialized facility for rigorously testing valves produced by Cla-Val. Employing mineral spirits as the testing medium, ErectaStep’s stairs and platforms provide access during the valve testing operations. This testing process is pivotal in guaranteeing that each valve adheres to Cla-Val’s standards of quality and reliability.

The Role of ErectaStep

ErectaStep, known for its modular and versatile access solutions, even in challenging, tight spaces, was installed to facilitate easy and safe navigation throughout the testing facility. This installation is not just about accessibility; it’s about enhancing operational efficiency and ensuring the safety of Cla-Val personnel.

Features of ErectaStep in the Cla-Val Project

• Modularity and Customization: ErectaStep’s modular design allows for easy customization to fit the specific needs of the Cla-Val Test Stand. This adaptability is crucial in a facility where precision and efficiency are paramount.
• Durability and Safety: Made from high-grade aluminum materials, ErectaStep platforms won’t rust and ensure durability and safety.
• Ease of Maintenance: The ErectaStep system is designed not only for easy access but also for ease of maintenance. This feature is particularly beneficial for the Cla-Val Test Stand, where regular maintenance of valves, filter separators, micron filters, and other components is essential.
• Efficient Operations: By providing quick and safe access to various parts of the testing facility, ErectaStep platforms significantly enhance the efficiency of operations. This efficiency is critical for Cla-Val, where time and precision are of the essence.
• Modular Design: ErectaStep’s modular, bolt-together design eliminates the need for custom fabrication and welding, offering unparalleled flexibility and adaptability to meet the evolving requirements and updates of the Cla-Val valve test stand, ensuring a future-proof solution for their dynamic testing environment.

The installation of ErectaStep at the Cla-Val Test Stand is a perfect example of how innovative solutions can transform industrial operations. It underscores ErectaStep’s commitment to providing safe, efficient, and customizable access solutions in challenging industrial environments. As the Cla-Val Test Stand moves towards completion, it stands as a testament to the collaboration between Kinley Construction, Argus Consulting, and ErectaStep, all working together to set new standards in industrial efficiency and safety.

The post Test Stand Access Platform Installation appeared first on SafeRack.

Project Profile – Replaced 12 Marine Loading Arms on 3 docks

• Replace end-of-life marine loading arms with long lead times for replacement parts and expensive and time-consuming maintenance requirements.
• Enhance safety features beyond existing loading systems.
• Significantly reduce wind load on the docks.
• Improved flow rate – Achieve the same or better flow rate with reduced loading diameter without pressure drop.
• Eliminates the challenge of pushing products up 30-50 feet with traditional loading arms.
• Adapt to a hazardous environment (A Class 1, Division 2) 

Installation and Operation

The installation of all 12 DockReels was completed successfully, marking it the first of its kind in the U.S. for marine loading. The new system is now fully operational, and its effectiveness has led the company to recognize it as a “Best Practice” in marine loading, instructing other locations to strongly consider replacing loading arms with DockReel loading systems.

Location	Beaumont, TX
Industry	Chemical
Key Products	DockReel systems
Project Partners	SafeRack, Techflow Marine

Brian Dieffenderfer

YOUR MARINE
MARKET SPECIALIST

Get a Quote

Challenges and Solutions

The project faced several challenges, including unexpected delays due to supply chain issues persisting from the Covid-19 pandemic, staffing changes, and complex logistics. However, the team, including personnel from SafeRack and Techflow Marine, demonstrated exceptional commitment and problem-solving skills, overcoming these hurdles effectively.

Customer Feedback

Direct quotes from key personnel at the chemical company highlight the successful collaboration and innovative nature of the project. Appreciation was expressed for the engagement and support from collaborating partners, with hopes for future collaborations.

Recognition was also made of the technology as a groundbreaking application in the industry, setting a precedent in the U.S. Praise was offered for the teamwork and partnership formed during the project’s execution.

Customer Quotes

Company and Customer name redacted per company policy

Onshore and Nearshore Loading Equipment

Marine Loading and Unloading Systems

A full range of products and services of Fluid Transfer Systems, Hose Handling Systems, Tandem Mooring Systems, Large Bore Flexible Hose Systems, Marine Coupling Systems, and Loading Platforms.

DockReel – A New and Efficient Marine Loading Arm Alternative

Gone are the days of inefficient, heavy, and maintenance-prone marine loading arms. Welcome to the new world where flexibility, lower operating expense, and advanced safety features are at your fingertips. Couple that with local support, available spare parts, and the world leaders in loading and unloading technologies, and you’ve got a solution that will serve you and your customers long into the future.

View Marine Hose and Loading Arms

Results and Future Prospects

The successful installation has not only optimized the loading process but also set a high standard for future marine loading endeavors. The company is now planning to expand its use of DockReel systems, with an immediate order for additional units.  One unexpected benefit found was that the system is so quiet that the operators had to confirm with the control team that product was flowing, and they were able to reduce the valve positions from 25% to 8% while still retaining the same flow rate, proving the superior flow characteristics of the DockReel over traditional Marine Loading Arm systems.

Conclusion

This pioneering project in Beaumont, TX, has demonstrated the feasibility and advantages of the DockReel system in a challenging industrial environment. It stands as a testament to innovative technology and effective collaboration, paving the way for future advancements in marine loading solutions.  Surpassing the safety features of traditional loading technologies and providing superior benefits of dock load reductions, smaller dock footprint, reduced infrastructure requirements, 

The post Innovative Marine Loading Dock Installation at a Chemical Plant in Beaumont, TX appeared first on SafeRack.

In the dynamic and demanding world of logistics and material handling, importance is placed on the safety of operators engaged in the loading and tarping of flatbed trailers. Our customer, a manufacturer in the steel industry, excels in producing high-quality steel pipes and tubes. The customer’s commitment to safety is paramount, especially when handling and transporting these substantial steel components. Recognizing the inherent risks in their operations, they sought a reliable solution to enhance the safety of their truck operators during the loading and tarping of flatbed trailers.

The Challenge: Safe Tarping for Steel Pipes and Tubes

The primary challenge faced by the client was ensuring the safety of operators tasked with loading steel pipes and tubes onto flatbed trailers and securing them with tarps. This process is crucial for protecting the steel from environmental elements during transportation. However, it involves significant risks, as operators work at heights and navigate over uneven and potentially unstable loads. The need for an effective and compliant fall protection system was critical, aligning with OSHA’s regulations for work at heights exceeding four feet.

The Solution: RollaStep MP Mobile Platform

Two 52′ RollaStep MP (Mobile Platform) units emerged as the ideal solution. Designed for versatility and compliance with OSHA standards, the mobile platforms can be easily rolled up to the flatbed trailer to provide a safe and stable workspace adjacent to flatbed trailers. Made from industrial-grade aluminum, the unit is easy to roll and position next the trailer. The RollaStep MP is equipped with comprehensive fall protection on both sides of the platform, ensuring maximum safety for operators during the tarping process.

Implementation and Impact

Following the implementation of the RollaStep MP, the client reported immediate positive feedback from their truck operators. The platform was praised for its effectiveness in enhancing safety and operational efficiency. Operators experienced a significant reduction in the risks associated with loading and tarping steel pipes and tubes, leading to an overall improvement in workplace safety and morale.

Conclusion

The adoption of the RollaStep MP Mobile Platform by this leading steel pipe and tube manufacturer highlights the importance of innovative safety solutions in industrial settings. This project demonstrates how targeted safety interventions can significantly improve working conditions in sectors like modular construction, where handling heavy and unwieldy materials is a daily task. The RollaStep MP stands as a beacon of commitment to worker safety and operational excellence in challenging industrial environments.

The post Advanced Flatbed Fall Protection for a Leading Steel Pipe and Tube Manufacturer appeared first on SafeRack.

Client’s Challenge

The primary challenge faced by the client involved enhancing operator safety while working at heights on aging platforms. These platforms were not initially designed to support the weight of additional safety equipment. Recognizing the critical need for a safer working environment, the client reached out to SafeRack for a solution.

SafeRack’s Solution

SafeRack’s engineering design team engaged in a collaborative effort with the client, providing essential guidance on reinforcing the existing structures. The team’s expertise was instrumental in identifying the necessary support steel to accommodate the new equipment’s load and reaction forces.

The ultimate solution crafted by SafeRack involved the installation of ten (10) modified mount GX gangways, equipped with 6’ x 4’ elongated fall prevention safety cages. These gangways, detailed on SafeRack’s Gangway Product Page, are the best in class, known for their durability, ease of use, and safety features. The GX Self-Adjusting Stair (SAS) Gangways are specifically designed to provide operators with safe and easy access to a variety of vehicle heights. Constructed with high-quality aluminum and featuring a self-leveling tread, these gangways ensure a safe, even walking surface for operators.

Project Impact

The installation of these customized gangways significantly enhanced the safety and efficiency of the client’s operations. The elongated safety cages provided additional protection for operators, ensuring a secure environment while handling hazardous materials. This project not only addressed the immediate safety concerns but also demonstrated SafeRack’s commitment to delivering tailored solutions that meet the unique needs of their clients.

Client Satisfaction

The collaboration between SafeRack and the client was a resounding success, with the client expressing elation over the project’s outcome. The project stands as a testament to SafeRack’s ability to overcome challenges through innovative engineering and customer-centric solutions.

Conclusion

This project highlights SafeRack’s dedication to enhancing workplace safety and operational efficiency. By addressing the specific needs of the specialty chemical company and providing a customized solution, SafeRack has reinforced its position as a leader in the field of industrial safety and access solutions.

The post Customized Gangways Installation at a Mississippi Specialty Chemical Company appeared first on SafeRack.

Project Overview The core of this project was the installation of three SafeRack tracking gangways, each equipped with a pivoting safety cage. These track-mounted gangways move horizontally to position each gangway to align over the railcar’s crash box, eliminating time-consuming “spotting” or positioning the railcars. This also ensures the safety cage is positioned correctly over the crash box for fall prevention by eliminating hazardous gaps when workers are trying to access top railcar hatches.

A pivotal aspect of the project’s design was the integration of three 20-foot Ultratech railcar spill containment track pans and a sump containment trench. Track pans are placed at each unloading spot to capture and channel any accidental spills during the unloading process. The captured material is then directed into a large containment trench or sump, a specially designed low-lying area that safely collects liquids. This system mitigates the environmental impact of potential spills and allows for the recovery of spilled materials, thereby reducing waste and preserving resources. Including this spill containment system is a testament to SafeRack’s dedication to providing both environmentally responsible and economically beneficial solutions, ensuring that our client’s operations are safe, sustainable, and efficient.

The SafeRack team also installed an elevated access structure, incorporating our innovative ErectaRack prefabricated pipe rack system. This addition not only streamlined the installation process but also provided a robust and reliable framework for the entire unloading terminal.

Photos (left to right, top to bottom)
Spill containment track pan | elevated access platform
pipe rack | spill containment sump | track-mounted gangway with pivoting safety cage

Spill Containment and Environmental Considerations A standout feature of this installation is the inclusion of three 20-foot Ultratech railcar spill containment track pans. These track pans play a vital role in environmental protection and product recovery, capturing and channeling any spilled material into a large containment trench or sump. This feature underscores our commitment to environmental safety and operational efficiency.

Project Execution and Impact The installation process was a testament to SafeRack’s efficiency and expertise, taking a mere four days to complete. This swift execution minimized downtime and allowed the client to resume their critical operations promptly. The client, known for their automotive maintenance services, including the manufacturing and distributing professional-use additives, cleaners, specialty lubricants, and precision tools, found immense value in this installation.

The project facilitated the safe and efficient unloading of products and contributed to the client’s overall productivity and profitability. By improving operational efficiency and ensuring environmental safety, SafeRack’s solutions have become integral to the client’s success.

This project in El Dorado, Kansas, is a shining example of SafeRack’s ability to deliver tailored, efficient, and safe industrial solutions. Our expertise in elevated access structures and spill containment systems, combined with our commitment to environmental safety and operational efficiency, positions us as a leader in the industry. We are proud to have contributed to the success of our client, a leader in the automotive maintenance industry, and look forward to future collaborations that drive innovation and excellence.

The post Railcar Unloading Terminal Installation in El Dorado, Kansas appeared first on SafeRack.

SafeRack, known for its innovative safety solutions, completed a critical fall protection project at a food manufacturing facility. This project was distinguished by the need to engineer and install a system in a remarkably tight space, presenting unique challenges.

The Challenge: The client, an established food manufacturing facility, required an effective fall protection system for offloading three railcars. The significant hurdle in this project was the extremely limited space available, constrained by a nearby property line and an adjacent process building. This scenario demanded ingenuity and precision in design and implementation.

This project required a trolley beam L-style system commonly used in railcar, mass transit, and truck applications and is suited for fall arrest applications. rail support columns require smaller foundations and minimize fall distance and deflection while easily accommodating multiple users, making them ideal for outdoor fall protection applications. With the fall protection system overhead, a worker’s fall can be arrested before striking equipment or falling to the ground.

Innovative Solution in Tight Space: SafeRack, through detailed planning and hands-on engineering, developed a specialized trolley beam design to fit this confined space, which included integrating two of the trolley column supports inside the building and through the roof. The solution included:

• Ingeniously integrating fall protection supports with the existing building structure and extending them to the external area, despite the spatial limitations.
• Engineering and structural steel tailored for confined space fall protection.
• A customized fall protection trolley beam.
• Three designed trolley/harness systems, complete with all necessary hardware.

Installation and Collaboration in Constrained Area: The installation involved intricate work to accommodate the limited space, including:

• Establishing new external foundations in a confined area.
• Roof penetration and internal civil modifications.
• Comprehensive system use training, emphasizing safety in tight spaces.

This project showcased the collaborative excellence of SafeRack’s engineering and manufacturing teams and the customer’s operations team, all working together in a challenging environment.

About SafeRack’s Trolley Beam Fall Protection System:

• Adaptability in Confined Spaces: Specifically designed for use in restricted areas, enhancing safety without compromising on space.
• Functionality and Compliance: Ideal for workers near exposed I Beams, meeting or exceeding OSHA & ANSI standards.
• Customizable Features:
  • OSHA Compliant Components, perfect for tight spaces.
  • Reduces fall distances during critical operations like railcar or truck loading.
  • Site-specific foundation designs for constrained environments.
  • On-site turn-key installation tailored to unique spatial challenges.

The successful completion of the trolley beam fall protection system at the food manufacturing facility underlines SafeRack’s commitment to providing safety solutions in even the most challenging environments. This project stands as a benchmark in the industry for addressing safety needs in tightly constrained industrial spaces, further establishing SafeRack’s position as a leader in innovative, efficient, and safe industrial solutions.

The post Custom Trolley Beam Fall Protection Solution in a Constrained Environment appeared first on SafeRack.

Pictured here are the beginnings of a structure as robust as the commitment behind this project – ErectaStep’s uniquely designed metal stair system, standing tall and ready for the next phase of development. Its mere presence on the site signals a promise of uncompromising strength and innovative engineering, mirroring the resolve of Manatee County’s public utilities.

ErectaStep’s legacy of over two decades is testament to our commitment to design and innovation in the realm of prefabricated metal stair kits. Our approach? A bolt-together system using five distinct modular components, requiring no custom tools or equipment, yet versatile enough to cater to any industry’s needs – be it petrochemical, manufacturing, or commercial.

You’ll see, nestled between our stairs, the concrete footers for what will soon become large tanks. Like the stair system itself, these concrete pads hint at what’s yet to come – a testament to our forward-thinking approach and relentless pursuit of progress.

Our pre-engineered and pre-manufactured stair kits, with their durable powder-coated handrails and laser-cut precision, serve as a testament to the quality and durability that have become synonymous with ErectaStep. It’s this unique blend of innovation and tradition that has helped us remain a valued provider across a myriad of industries, and continues to push us towards creating better, more effective solutions.

Here, we stand at the intersection of vision, innovation, and sustainability. This is ErectaStep, and we’re proud to be part of the journey towards a brighter, more sustainable future for Manatee County. Because we believe that when we build, we don’t just erect structures – we shape landscapes, we mould the future, and above all, we make a difference.

The post ErectaStep’s Pivotal Role in Manatee County’s Water Treatment Plant Expansion appeared first on SafeRack.

The post MarinaStep Ferry Gangway Installation for NYC Ferry appeared first on SafeRack.

Whether you’re complying with General Industry (OSHA 1910), Maritime (OSHA 1915), or Construction (OSHA 1926) requirements, SafeRack fall protection systems support workplace safety without compromising productivity.

• Can span up to 200 feet
• Supports up to 4 workers at a time
• Meets all OSHA requirements for horizontal cable lifeline systems

The SafeRack cable lifeline fall protection system is a lightweight, shock-absorbing horizontal fall protection system designed for use in railcar and truck tank container loading and unloading applications. The SafeRack cable system can adapt to any working environment to provide operators with OSHA-compliant fall protection that won’t interfere with getting the job done efficiently. It’s particularly advantageous in environments with limited access, low frequency of use, or with railcars of differing lengths.

The post Road Report – Lifeline installation at a Cement facility appeared first on SafeRack.

Customized OSHA-compliant loading solutions are what we are known for. Whether you’re looking for a simple crossover, replacement gangway or a complete turn-key project SafeRack has the resources to get it done on time and within budget.

SafeRack is the #1 supplier of Top Loading Arms In North America.

SafeRack is not only the largest supplier of truck loading platforms and railcar loading systems in North America but also the largest loading arm distributor for both OPW and Emco Wheaton. Loading arm projects go faster and more smoothly with SafeRack because we coordinate with pipe, electrical and civil engineers to help resolve any variables with vehicles. In addition, SafeRack offers the most extensive selection of swivel joints for the most challenging liquid handling applications. Simply put, your railcar loading systems are more productive with SafeRack.

The post Hydrochloric Acid Railcar Loading Station appeared first on SafeRack.

• Balanced design throughout their range of motion
• Can be moved into position with ease
• Designed not to hit the platform – protecting assets and the operator
• Ergonomics – one-man operation

However, not every liquid chemical can travel thru a loading arm, such as caustic or corrosive chemicals. When handling these harsh chemicals, we recommend upgrading to a by-pass arm.

By-pass arms offer the same ergonomic benefits as traditional loading arms except no fluid actually runs thru the arm; rather the arm is used to support or carry the weight of the product and/or vapor lines for ease of loading.

By-Pass Loading Arms

By-Pass Loading Arms are designed to be a low-cost alternative to rigid pipe loading arms and are constructed of Hastelloy, Alloy 20, and other specialty metals used to transfer hydrochloric acid and other corrosive chemicals.

• Cost-effective
• Easy operation
• Can be configured as a ‘hose handler’ to greatly improve hose loading operation
• Excellent alternative for ‘Food Grade’ applications where swivel joints cannot be used
• Liquid ‘by-passes’ inlet swivel joint, no metal wetted parts
• Available in 2”, 3” & 4” sizes

SafeRack is the #1 supplier of Top Loading Arms In North America.

SafeRack is not only the largest supplier of truck loading platforms and railcar loading systems in North America but also the largest loading arm distributor for both OPW and Emco Wheaton. Loading arm projects go faster and more smoothly with SafeRack because we coordinate with pipe, electrical and civil engineers to help resolve any variables with vehicles. In addition, SafeRack offers the most extensive selection of swivel joints for the most challenging liquid handling applications. Simply put, your railcar loading systems are more productive with SafeRack.

The post Prevent soft tissue injuries by upgrading your loading terminal with a By-Pass Loading Arm appeared first on SafeRack.

– Alan Ward, Saint Paul Mountain Vineyard

Testimonial

We are Saint Paul Mountain Vineyard, Appalachian Ridge Artisan Hard Ciders. We’re located in Western North Carolina within the Crest of the Blue Ridge AVA, and we’ve grown into the position where we needed to have our wine-making capabilities here.

So, when we decided to build a winery, we visited many facilities to see what the owners would have done differently. And the catwalks were one of the most important aspects for the winemaker getting access to the tanks and being able to service the tanks which is a crucial portion of making the wine.

https://www.saferack.com/go/vineyard-stair-installation/
Most of them are custom in that once they’re made you can’t move them unless you come in with a welder and a saw and you have a big mess. What we like about ErectaStep is that it is flexible, but it still has the highest quality. The aluminum was very lightweight. The powder coating was just top-notch. They’re all OSHA-approved. It was a very pleasant and economically viable process for us.

The bottom line was that their product was very, very competitive. More so than the folks that we had quoted. It was very affordable for us but in our opinion a higher quality and a more versatile product in that if we change the location of our tanks or add some extra catwalk, it’s very flexible.

They do a lot of commercial work for large companies, and we were very fortunate to work with them. It surprised me how flexible they were working with a small winery like ours. We’re very fortunate to have ErectaStep in our process.

I couldn’t believe how quickly we got it erected today. You know, in a 10 000 square foot winery, we were able to complete it in one day which is just unimaginable. It’s top-of-the-line, in my opinion. It’s just really a high-quality product.

I can’t tell you enough about how you need to talk with these folks, not just because of your time constraints but just because of the quality of the product and the uniqueness of the flexibility of being able to make it fit what your needs are instead of making your needs fit to what it is.

I’m old enough to have seen a lot of things in the wine industry, and this is just one that’s a pleasant surprise. And if you’re a mid-sized winery, a small winery, or a large winery, I would recommend you talk to these folks if you’re adding or changing your catwalks because it’s a unique and high-quality product that you can get going quickly. And time is money and money is time, and ErectaStep helped us with both.

The post ErectaStep Catwalk installation at Saint Paul Mountain Vineyards Testimonial appeared first on SafeRack.

Location

Project

Service

Client

Materials/Product

Materials/Product

SafeRack was approached by Senior Mechanical Engineer, Richard Davenport, to provide a Turn-key offering for a single spot rail loading solution. Adamant about having one point of contact for the full completion of the project. SafeRack performed a site visit and quickly found their custom fall protection and loading procedure to be cumbersome and unsafe. Due to the extreme caution that comes with loading Oleum an upgrade was a must. As a result, SafeRack designed and installed a railcar loading platform canopy with a MaxRack elevating safety cage solution.  Our MaxRack safety cage takes safety to another level so the operators can provide full attention to loading such a potent product.  We were able to repurpose existing equipment to reduce the cost of equipment needed and demolition performed.

Although no two Oleum 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 Oleum?

• Many standard cage configurations available
• Units available for both truck and railcar applications
• The counterweighted design allows for smaller, less expensive drive components
• Pneumatic or electric motor drive options
• Off the shelf replacement parts available quickly & easily
• Robust galvanized steel columns and carriage
• Patent-pending manual override or raise/ lower in case of power or air pressure loss

The new MaxRack powered elevating handrail system is the only elevating safety cage on the market that can be raised and lowed manually if your facility loses power or plant air. The unique counterbalanced cage design coupled with our exclusive dual input gearbox enables smooth operation as well as the ability for the operator to manually raise and lower the cage with ease in the event of a power loss.

The post Project Profile – Lanxess Oleum Loading Facility appeared first on SafeRack.

In the high seas of remote Alaska, loading and unloading people and supplies can be treacherous. SafeRack’s MarinaStep custom marine gangway proved to be the perfect solution for a local fish processor’s safety improvements. In the case of this particular project, the berthing area was not square with the face of the dock causing the work barge to be vulnerable to hazards when aggressive storms blew in. Keeping vessel operators safe regardless of the weather and efficient loading and unloading of products and supplies was the key to keeping this busy fish processing plant running smoothly.

The MarinaStep custom gangway was designed with legs of differing heights to even out the loading dock. These legs support a 4′ by 30′ long truss gangway using a flat ramp walk surface stamped with durable traction surface and cleats to allow for operation at angles up to 30 degrees. The gangway also pivots left and right with an attachment that allows operators to quickly disengage and remove it from the platform. The gangway can also be collapsed and stored easily during the off-season.

The challenging design requirements for this project were no problem for our talented team. Our installation specialists made a visit to the remote location to ensure total success. Our ability to meet the client’s tight deadline was imperative as any delay would have impacted their production for the entire season. The delivery of this product was the fun part. The MarinaStep gangway was shipped from South Carolina to Seattle by truck and then loaded onto a barge for the trip north. The trek took a total of nearly 2 months and the project was a huge success.

The post Custom Alaska MarinaStep Installation appeared first on SafeRack.