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Cement silos require routine maintenance, especially the diverter valves or switching valves, which are crucial to keeping cement grades separate. Often, these components can be found at the top of a silo. The access to the top is usually a narrow, winding, and aging stairway and cannot accommodate the additional weight of a worker, safety gear, and tools.
Instead of renting expensive cranes to lift large, heavy, fabricated units, SafeRack’s line of ErectaStep’s metal stairs and industrial maintenance work platforms feature modular, lightweight components that weigh less than 50 pounds each. They can be easily carried to the tops of silos and then assembled quickly and with little more than a wrench. Because ErectaStep’s components bolt together with no welding required, it eliminates the need for a “hot work” permit that is commonly needed in most facilities. Lightweight crossovers and valve access systems do not add much weight to the tops of the silos and keep workers safe while performing routine maintenance.View Full Text
Truck drivers have a choice as to what facility they go to for cement to load their pneumatic trailers. Not just the aging population, but also the less physically strong and those wanting easy to use equipment tend to gravitate toward facilities that cater to their needs, and that is why drivers want to go into plants and terminals with SafeRack systems.
Quote or discuss your installation.
Start by selecting loading application
Below are some of the elements of a chemical handing installation for illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs.
Typically, as a starting point, we will need to know answers to these questions for your project
- Do you require a new platform system or retrofitting to the existing platform?
- How many trucks per day cycle through your facility?
- What types of vehicles are being accessed?
- Is a manual system or powered system required?
- What are your expectations on lead times?
- Would you like a turn-key solution?
- Are you interested in reducing or eliminating lower back strains at your loading racks?
In addition, we undertake a detailed site survey to check and clarify all dimensions and other salient issues.
Top Hatch Access Platforms
Platform design is dictated by application or form of function. Many factors are considered when creating a solution. Available real estate at a facility, types of vehicles, traffic patterns, and desired throughput are all taken into consideration during the design phase.
Retrofit applications are a routine exercise for our staff. There is an existing population of thousands of loading racks in the cement industry with many varying designs. We can readily implement our years of experience to provide an industry best turn around on drawings and equipment delivery. In fact, most applications can be laid out on-site by our sales staff using proprietary, state of the art 3D software that can produce approval drawings and equipment pricing before leaving your facility.
Pneumatic trailer configurations can be single, multi-hatch or pup style. Additionally, some facilities will service multiple types of vehicles, like loading proppant boxes along with pneumatic trucks.
Loading Gangways with Safety Cages
Standard widths on cement gangways is 24″. Wider style gangways are available when circumstances warrant. Powered gangway solutions are also an option, with both hydraulic and pneumatic solutions being commonly used.
Each gangway will be fitted and factory balanced with a cement industry-specific extended profile cage. These were designed in collaboration with leading industry cement companies to address cement specific needs. Accommodating multiple hatch opening orientations while decreasing gaps between the access system and vehicle to prevent operators from falling off is the primary focus.
GX SELF-ADJUSTING STAIR (SAS) GANGWAY
SafeRack’s NEW GX SAS gangways uses Retractalok power-assist technology allowing operators to raise or lower effortlessly, light as a feather to lift, solid as a rock. Tested in the most critical applications, this revolutionary new gangway outperforms all others. Available in multiple lengths and widths. Learn More
In some instances when budgets or lack of real estate drive this requirement we can design and layout systems that work in conjunction with loading chutes in silos. Typically these applications are very limited spatially and require modifications to gangway storage positions and cage design and layout. Over the years SafeRack has developed design techniques that mitigate silo limitations.
Another system option that was developed jointly with cement producers. It prevents truck drivers from raising the gangway and cage systems which would create an unsafe condition where the operator could fall under the cage while negligently trying to lift it to open or close an improperly spotted truck hatch.
Early Departure Systems
The device increases safety at your loading spot and helps prevent damage to your loading racks. A driver or operator attaches the interlock fitting to the braking system of the truck, guaranteeing the process you put in place will be followed before the tanker can be loaded.
Truck Traffic Gates
Traffic Gates on specially designed elevated pedestals are synchronized with gangway and cage operations. The traffic gate will lower when the gangway system is lowered creating a visual and physical barrier that reminds truckers to raise the system before driving off. An option for high visibility red and green LED illumination can be integrated into gates for an even higher level of drive-off protection.
Gangway Extended Top Handrail
The SafeRack handrail extension helps prevent truck drive-offs while the gangway is in a lowered position. The elongated safety orange top handrail extends into the platform to remind drivers to properly store equipment before leaving the platform and returning to their trucks.
Safety Orange Cages
Standard aluminum cages factory finish blend in with pneumatic truck colors. Our bright safety orange powder coat finish improves visibility and prevents early drive offs that damage the loading platform and equipment, creating downtime.
Magnetic Swing Gates
A magnetic safety gate can be linked to any gangway and cage operation. When the gangway and cage are in the down position a proximity switch engages the swing gate lock to prevent egress from the loading rack platform. Operators can freely leave the platform once the system is in proper stored position.
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
- 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
TURN KEY OFFERING
We can provide installation services on our equipment. Using our certified installation group ensures a quick, professional installation done by qualified personnel who can guarantee the equipment is in proper working order when the job is complete. Operator training is a standard part of this service. * For illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs
Routine maintenance is required on cement silos. These diverter valves or switching valves on the silos are crucial to keeping cement grades separate.We can supply ErectaStep that can be easily transported up to the tops of these silos. Many times access up to the top is by narrow winding and aging stairways. our ErectaStep line of equipment is the perfect solution for valve access that requires stands to access.
Components are less than 50 pounds and can be walked up to the tops of the silos instead of having to rent expensive cranes to lift big heavy fabricated units. Once all parts are accounted for they can be assembled with everyday tools that are included in the package.
Many times the tops of the silos cannot accommodate much more weight than is already there. Our lightweight aluminum construction crossovers and valve access systems do not add much weight to the tops of the silos once they are fully assembled.
Some fabricators or maintenance shop personnel do not engineer and build systems that meet code. Our patented, pre-engineered components and designs meet or exceed OSHA/MSHA guidelines.
These silos have ladder and stair openings that also require mandated fall protection. Our universal fitting YellowGate is recommended to protect employees from falling out of these openings. This security is heightened with the patented Malbec tensioner that keeps the gate closed at all times at a tension level that resists accidental opening due to wind. Infinite tension levels adjustment allows workers to set the gate to whatever force is preferred for a particular application. Like the ErectAStep line it comes with all necessary hardware and tools to install the unit. It is a purchasing managers dream in that it is the only universal gate that
Components are in stock and ready to ship so no waiting.
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Located in South Carolina
Located in South Carolina
Located in South Carolina
Located in South Carolina
Located in South Carolina