Pneumatic Trailer & Frac Sand Truck Loading and Unloading Systems
Although no two pneumatic trailer loading solutions are identical, the type of pneumatic truck, pneumatic tanker, or hopper truck and the product being transported determine much of the design criteria. SafeRack provides solutions that improve loading productivity and throughput while ensuring the safest operations on the market.
The pneumatic dry bulk trailer industry, including frac sand trailers, cement pig trailers, and pneumatic bulk trucks, has some of the highest truck loadouts per day. Efficiently loading and unloading pneumatic trailers and bulk trailers while maintaining safety and compliance is essential for operational success.
Truck drivers have a choice when selecting facilities for pneumatic trucking operations. Whether transporting dry bulk cargo trailers, pneumatic tank trucks, or sand trailers, drivers prefer facilities equipped with SafeRack systems. Our solutions enhance efficiency and safety, attracting both experienced drivers and those looking for user-friendly, easy-to-operate equipment.
Hopper and Pneumatic Trailer
Safety & Compliance Expert
HAVE A QUESTION?
Talk to a Safety Expert Now
Streamlined Safety and Compliance for More Productive Worksites
Safe, Efficient Access for Cement Silos and Pneumatic Trailers
Maintaining cement silos and pneumatic trailers requires reliable access solutions that prioritize safety, efficiency, and compliance. SafeRack goes beyond providing high-quality access equipment—we work directly with your team to assess site challenges, ensure compliance, and implement solutions that integrate seamlessly into your operations.
Optimized Solutions for Silo and Valve Access
- Lightweight, Modular Access Systems – Routine maintenance on cement silos requires safe access to diverter and switching valves that separate cement grades. SafeRack’s ErectaStep platforms and stairs provide stable, OSHA-compliant access without the need for heavy, custom-fabricated structures.
- Easy Transport and Assembly – With modular components weighing less than 50 pounds, ErectaStep systems can be carried to the top of silos without the cost and hassle of renting cranes. All components assemble quickly using standard tools included with each system.
- Structural Efficiency – Many silo tops have strict weight limitations. SafeRack’s lightweight aluminum crossovers and valve access systems add minimal load while ensuring safe and durable access.
Compliant Fall Protection for Silo Openings
- Universal Safety Gates – Openings on silo ladders and stairways require OSHA-mandated fall protection. YellowGate provides adjustable resistance to prevent accidental openings caused by wind or misuse.
- Easy Installation and Adjustability – Designed to fit a variety of openings, YellowGate ships with all necessary hardware and installs quickly with everyday tools.
More Than Equipment—A Full-Service Safety Partner
- On-Site Safety Assessments – We evaluate your facility to identify risks and recommend solutions that improve efficiency and compliance.
- Expert Design and Integration Support – Our team collaborates with your engineers and operators to implement access systems that enhance workflow while maintaining OSHA and MSHA compliance.
- Fast Shipping, Minimal Downtime – SafeRack keeps components in stock and ready to ship, helping you maintain operations without unnecessary delays.
With SafeRack, you get more than industry-leading access solutions—you gain a safety partner committed to optimizing your facility’s efficiency and compliance.
Products
Loading Racks & Metering Skids
Truck & Railcar Transloading, Metering Skids and Loading Racks – From single-spot to multi-spot systems.
Truck & Railcar Gangways
The industry’s safest and most ergonomic gangway for truck and railcar access.
Barrier Gates
YellowGates XL barrier gate provides 6 feet of adjustability protects every pathway in your facility
Safety Swing Gates
YellowGate – The Original Universal Self Closing Safety Gate
Gate Openers and Hopper Car Shakers
The PCS-3 Hopper Car and Hopper Trailer Shakers can be modified to comply with force and design requirements set for the ACF “center-flow” hopper car, Contact us for details.
Loading Arms & Couplings
Loading Arms & Couplings
Tools and Loading Accessories
A comprehensive range of facility and loading terminal equipment, accessories and safety solutions.
Early Departure
Our safety interlock system prevents accidental drive-offs and can be designed into your pump, fall protection or any other preferred loading apparatus.
Hopper and Pneumatic Trailer
Installations
Pneumatic Trailer & Frac Sand Loading and Unloading Solutions
SafeRack provides loading and unloading solutions designed to improve efficiency and safety in pneumatic trucking and bulk trailer operations. The following solutions highlight just a few ways we support pneumatic dry bulk trailer loading, pneumatic tanker unloading, and hopper truck handling. Our team works closely with you to assess site-specific challenges, ensure compliance, and design a system that integrates seamlessly into your operations.
Safer Pneumatic Trailer Loading
SafeRack’s innovative offset safety cage features flared and tapered rungs designed for pneumatic trailer loading, giving the lid or manhole a full range of motion to open and close the hatches. The design also ensures that the gangway and cage will not interfere with hatch access and movement when the equipment is lowered on top of the truck.
Top Hatch Access Platforms
Designing an effective top hatch access platform requires a comprehensive approach that considers site constraints, traffic flow, vehicle types, and operational goals. SafeRack works directly with your team to develop solutions that optimize safety, efficiency, and throughput in pneumatic trailer and bulk trailer operations.
- Custom and Retrofit Solutions – Many cement industry loading racks have varying designs, requiring tailored solutions for safe access. Our experienced team specializes in retrofitting existing systems, ensuring seamless integration with minimal downtime while improving safety for pneumatic tankers, hopper trucks, and other bulk transport vehicles.
- Fast, On-Site Design Capabilities – Using advanced 3D configurator software, our experts assess your site, design a solution, and provide approval drawings and budgetary pricing—all before leaving your facility. This streamlined approach is particularly beneficial for pneumatic dry bulk trailer loading and unloading applications.
- Versatile Vehicle Compatibility – Our platforms are designed to accommodate single, multi-hatch, and pup-style pneumatic trailers, as well as mixed-use facilities handling sand trailers, frac sand trailers, and pneumatic bulk trucks for various dry bulk applications.
With SafeRack, you get more than a product—you gain a trusted partner who streamlines the design, approval, and implementation process to keep your pneumatic trucking operations running safely and efficiently.
Loading Gangways with Safety Cages
SafeRack designs loading gangways with safety cages to provide secure, OSHA-compliant access for bulk loading operations. Our team works closely with customers to develop solutions that enhance safety, efficiency, and operational flow while supporting various pneumatic trailer, bulk trailer, and pneumatic tanker configurations.
- Seamless Integration for New and Existing Facilities – Whether installing a new system or retrofitting aging loading racks, SafeRack designs gangways that fit within your facility’s constraints while improving safety and workflow efficiency for pneumatic trucks, hopper trucks, and other bulk transport vehicles.
- Real-Time Configurations & Approval – Our advanced 3D configurator allows us to design gangway systems specific to your application, generating approval drawings and pricing during on-site consultations. This is particularly valuable for operations involving pneumatic dry bulk trailers, frac sand trailers, and pneumatic bulk trucks.
- Flexible Solutions for Various Loading Needs – Our gangways and safety cages accommodate different pneumatic trailer configurations, including single, multi-hatch, and pup-style designs. They also support mixed-use operations handling cement pig trailers, sand trailers, and pneumatic tank trucks, ensuring safe and efficient loading across a range of industries.
Loading Chutes: Space-Saving, Efficient Solutions
When space constraints or budget limitations impact loading operations, SafeRack designs customized systems that integrate seamlessly with silo loading chutes. These applications often require innovative layouts to maximize efficiency while maintaining compliance and operator safety, particularly for pneumatic trailers, bulk trailers, and pneumatic tankers.
- Optimized Designs for Limited Space – Many silo loading chutes have restricted clearance, requiring adjustments to gangway storage positions and safety cage configurations. SafeRack’s design team specializes in solutions that fit within tight spatial constraints without compromising safety, ensuring smooth loading for pneumatic bulk trucks, hopper trucks, and sand trailers.
- Proven Expertise – With years of experience in the industry, we have developed advanced design techniques that overcome the challenges of silo limitations. Our solutions support the efficient loading of pneumatic dry bulk trailers, cement pig trailers, and other bulk transport vehicles while maintaining worker safety.
- Collaborative, On-Site Assessments – Our experts work directly with your team to evaluate site-specific challenges, provide layout recommendations, and ensure that loading chute systems align with operational goals and regulatory requirements. Whether handling frac sand trailers, pneumatic tank trucks, or bulk hopper trucks, SafeRack provides space-saving solutions designed for efficiency and safety.
Early Departure Systems: Enhancing Safety & Preventing Equipment Damage
Prevent premature departures and protect your loading infrastructure with SafeRack’s early departure systems. Designed to enhance safety and minimize costly damage, these solutions ensure that loading procedures are properly followed before a pneumatic trailer, bulk trailer, or pneumatic tanker leaves the loading spot.
- Custom Implementation Support – SafeRack’s team provides on-site assessments to help facilities integrate early departure systems effectively, ensuring seamless compatibility with existing operations and safety measures. These solutions are designed to accommodate a variety of transport vehicles, including pneumatic bulk trucks, hopper trucks, and sand trailers.
- Integrated Safety Controls – The system securely interlocks with a truck’s braking mechanism, preventing movement until the loading process is completed according to your facility’s safety protocols. This added layer of security is crucial for operations handling pneumatic dry bulk trailers and cement pig trailers, where premature departures can cause significant disruptions.
- Reduced Risk of Equipment Damage – By ensuring compliance with proper procedures, early departure systems help prevent costly damage to gangways, loading arms, and other critical infrastructure. These safeguards are particularly important for high-volume facilities handling frac sand trailers, pneumatic tank trucks, and bulk hopper trucks, where equipment reliability is essential for smooth operations.
Truck Traffic Gates: Preventing Premature Departures with Integrated Safety
SafeRack’s truck traffic gates enhance safety by preventing premature departures and ensuring gangway and cage systems are properly raised before a pneumatic trailer, bulk trailer, or pneumatic tanker leaves the loading area. Designed for seamless integration, these gates create both a visual and physical barrier for added protection in pneumatic trucking operations.
- Automated Safety Synchronization – Traffic gates lower in coordination with gangway and safety cage operations, reminding drivers of pneumatic bulk trucks, hopper trucks, and sand trailers to follow proper departure procedures.
- Enhanced Visibility for Added Protection – Optional high-visibility red and green LED illumination improves awareness, providing clear stop-and-go signaling to operators of pneumatic dry bulk trailers, cement pig trailers, and other bulk transport vehicles.
- Custom Integration & Expert Support – SafeRack’s team offers on-site assessments and design consultations to ensure traffic gates are properly implemented for maximum safety and efficiency at facilities handling frac sand trailers, pneumatic tank trucks, and bulk hopper trucks.
Gangway Extended Top Handrail: Added Safety for Drive-Off Prevention
SafeRack’s extended top handrail provides an extra layer of safety by preventing premature truck departures while the gangway is in a lowered position. Designed for high visibility and ease of use, this solution enhances safety in pneumatic trucking, bulk trailer, and pneumatic tanker operations by ensuring proper loading procedures are followed.
- Increased Driver Awareness – The extended safety orange handrail reaches into the platform area, serving as a clear visual cue for drivers of pneumatic bulk trucks, hopper trucks, and sand trailers to properly stow equipment before exiting.
- Prevention of Costly Mistakes – By reducing the risk of drive-offs with equipment still deployed, this handrail helps protect gangways, safety cages, and loading infrastructure from damage. This is particularly critical for operations handling pneumatic dry bulk trailers, cement pig trailers, and frac sand trailers, where equipment reliability is essential.
- Seamless Integration – Designed to work with SafeRack’s gangways and platforms, the handrail extension is an easy addition that enhances overall safety and operational efficiency for pneumatic tank trucks, bulk hopper trucks, and other bulk transport vehicles.
Safety Gates: Adjustable, Secure Access Control
SafeRack’s industrial safety gates provide flexible, OSHA-compliant fall protection and access control for a wide range of applications. Designed for durability and ease of use, these gates enhance worker safety while integrating seamlessly into existing loading and platform systems for pneumatic trailers, bulk trailers, and pneumatic tankers.
- Adjustable for Various Openings – SafeRack’s safety gates accommodate openings from 16” to 36” and can be easily adjusted in the field using only a wrench, allowing for quick installation and modifications. These gates provide effective access control in facilities handling pneumatic bulk trucks, hopper trucks, and sand trailers.
- Seamless Integration with Loading Operations – Safety gates can be linked to gangways and safety cages, ensuring secure access during loading and unloading for pneumatic dry bulk trailers, frac sand trailers, and pneumatic tank trucks.
Magnetic Swing Gates: Enhanced Safety Through Automation
- Operator-Friendly Design – Once the gangway and safety system are properly stowed, the gate automatically releases, allowing workers to exit safely without additional steps. This automation supports high-volume operations for pneumatic dry bulk trailer loading and unloading.
- Automatic Safety Locking – When the gangway and cage are in the lowered position, a proximity switch engages the swing gate lock, preventing unintended egress from the loading rack platform. This added safety feature is particularly beneficial for operations involving cement pig trailers, bulk hopper trucks, and pneumatic tanker systems.
Loading 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.
FAQ
SafeRack’s equipment meets or exceeds OSHA and MSHA standards for fall protection and worker safety. Our gangways, loading racks, early departure systems, and safety gates are designed to comply with the latest regulations, ensuring a safe work environment for cement, fly ash, and frac sand operations.
SafeRack’s ergonomic gangways and loading platforms streamline the loading and unloading process, reducing wait times and helping prevent demurrage fees. Our solutions are designed to maximize throughput while maintaining the highest levels of worker safety.
Yes! SafeRack offers customized loading solutions tailored to the specific needs of cement, fly ash, and frac sand operations. Our experts can conduct an onsite evaluation to design a system that optimizes safety, efficiency, and compliance.
SafeRack’s gangways and platforms are constructed from heavy-duty aluminum, offering durability and corrosion resistance even in demanding cement and frac sand environments. Our equipment is built to withstand high-cycle use while maintaining safety and performance.
SafeRack’s grounding and bonding systems are designed to eliminate the risk of static discharge during the loading and unloading of cement, fly ash, and frac sand. Our systems verify a true ground connection before product flow begins, preventing static buildup that could lead to sparks or explosions in dusty environments. With SafeRack’s grounding solutions, you ensure worker safety, reduce fire hazards, and stay compliant with OSHA regulations.
SafeRack provides OSHA-compliant gangways, loading platforms, and fall protection systems that offer safe and efficient access to silos used in cement, fly ash, and frac sand operations. Our equipment allows workers to safely load and unload materials while reducing the risk of falls and improving throughput. With options like self-leveling gangways, safety cages, and custom platforms, SafeRack helps you optimize silo access while keeping workers protected and your operations running smoothly.
Projects
-
Secondary Spill Containment Calculator
Secondary Containment: How to Calculate Capacity for SPCC Compliance and Environmental Protection Secondary spill containment is essential in protecting the…
-
The Alternative to Scaffolding
Benefits of Using ErectaStep and RollaStep Solutions Over Scaffolding Benefits of Using ErectaStep’s Solutions Over Scaffolding Traditional scaffolding presents many…
What Customers Are Saying
Better than the competitor's product. We like the product and have had very few problems with regards to maintenance. The platforms and gangways look better than the competitor's product. The coating is very thick and we have not seen any rusting even on our older installation. Charles MacEachern has a great way of dealing with customers – his communication skills are very good and he is there for the customer when needed.
By Daryl B. from Bayer Crop Science
We love our ErectaStep product! Very knowledgeable and willing to assist in any manner to complete my order. Would recommend SafeRack to anyone.
By Brian R. from NULL