Safe and Efficient Silo Access: Full-Service Solutions for Cement Facilities
Regular maintenance of diverter and switching valves is essential for ensuring cement grades remain separate and uncontaminated. However, these critical components are often located at the top of silos, where access is challenging due to narrow, aging stairways that cannot safely support workers, tools, and safety gear.
SafeRack provides a safer, more efficient alternative to renting cranes or relying on outdated stairways. Our ErectaStep modular metal stairs and industrial maintenance platforms offer a lightweight, OSHA-compliant solution that eliminates the need for welding, heavy lifting, and hot work permits. With each component weighing under 50 pounds, workers can carry and assemble the system at the top of the silo using only basic tools, improving safety and efficiency during routine maintenance.
Beyond equipment, SafeRack offers on-site safety assessments, technical guidance, and integration support to help facilities implement customized valve access solutions that fit their unique operational needs. Our modular crossovers and valve access systems minimize additional weight on silos while providing secure, ergonomic access for high-cycle maintenance environments. By combining industry expertise with innovative equipment, SafeRack helps cement facilities streamline maintenance, reduce risks, and improve long-term operational reliability.
Silo Valve Access
Safety & Compliance Expert
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Streamlined Safety and Compliance for More Productive Operations
Reliable and Compliance-Driven Silo Valve Access Solutions
Maintaining diverter and switching valves on cement silos presents unique challenges, especially when access is restricted by narrow, aging stairways. SafeRack works directly with your team to develop solutions that improve worker safety and streamline maintenance without the need for costly equipment rentals or disruptive modifications.
ErectaStep’s modular platforms and stair systems provide a lightweight, bolt-together alternative to traditional fabricated structures. With components weighing less than 50 pounds, workers can transport them to the top of the silo without requiring cranes or heavy lifting. Once in place, they assemble quickly using standard tools, eliminating the need for welding or hot work permits.
Silo tops often have strict weight limitations, making SafeRack’s aluminum crossovers and valve access systems an ideal choice. Designed for durability and stability without adding unnecessary structural load, these solutions ensure safe and efficient access to critical maintenance points.
SafeRack’s expertise ensures that projects align with OSHA, MSHA, ANSI, SPCC, and industry standards. In addition to access solutions, SafeRack provides pre-engineered safety systems for ladder and stair openings to help facilities maintain full compliance. YellowGate safety gates offer a universal fit to prevent falls, keeping workers protected while maintaining ease of movement. With components readily available and fast to install, SafeRack delivers solutions that keep cement plants operating safely, efficiently, and in full regulatory 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.
Silo Valve Access
Installations
Comprehensive Silo Loading & Unloading Solutions
SafeRack provides more than just industry-leading equipment—we partner with facilities to develop customized silo access solutions that improve safety, efficiency, and compliance. Whether loading or unloading bulk materials, our solutions are designed to integrate seamlessly into your facility’s workflow, minimizing downtime and enhancing operational reliability.
The following solutions represent just a portion of what SafeRack can provide. Our team works directly with you to assess site-specific challenges, ensure compliance with OSHA, MSHA, ANSI, and SPCC standards, and design solutions tailored to your facility’s needs.
Top Hatch Access Platforms
Accessing silo valves for maintenance and inspection requires stable, reliable platforms that can be safely used at elevated heights. SafeRack’s top hatch access platforms provide a secure working surface, allowing workers to perform necessary tasks without the risk of falls or unstable footing. Designed for cement facilities, these platforms offer an ergonomic solution that minimizes worker strain while ensuring compliance with safety regulations.
Lightweight and modular, these access systems can be easily transported and assembled without requiring cranes or extensive modifications to existing structures. Their durable construction withstands high-dust environments while maintaining structural integrity, ensuring long-term performance in demanding cement operations.
Loading Gangways with Safety Cages
Silo valve maintenance often requires safe access points that allow workers to perform inspections and repairs while maintaining three points of contact. SafeRack’s loading gangways with safety cages provide a secure and stable means of reaching critical maintenance areas. Designed to integrate with existing platforms, these gangways allow for efficient movement while minimizing fall risks.
Each gangway and safety cage is engineered to accommodate the height and positioning of silo valve access points, providing flexibility for various facility layouts. The system ensures that workers have a safe, controlled environment while working on elevated platforms, reducing the likelihood of slips and falls.
Loading Chutes
In cement facilities, space constraints can make traditional access solutions impractical. SafeRack’s loading chutes are designed to fit within tight spaces while providing a functional, streamlined method of accessing silo valves. These systems offer an efficient way to direct materials safely while also allowing for routine maintenance access.
Engineered for high-performance applications, SafeRack’s loading chutes help keep cement operations running smoothly. Their durable design minimizes material buildup and ensures continued efficiency, reducing the need for frequent cleaning and maintenance.
Early Departure Systems
Preventing accidental movements of equipment during maintenance is critical in silo valve access operations. SafeRack’s early departure systems are designed to prevent equipment from being moved before maintenance work is completed, reducing the risk of injuries and equipment damage.
By integrating with existing safety protocols, these systems create a controlled environment where workers can confidently perform their tasks. Their reliable functionality ensures that maintenance procedures can be carried out without interruption, keeping cement operations efficient and compliant.
Truck Traffic Gates
Controlling access to silo valve maintenance areas is essential for worker safety and operational efficiency. SafeRack’s truck traffic gates provide a clear physical barrier, preventing unauthorized access and ensuring that work zones remain secure. These gates help regulate movement around maintenance areas, reducing the risk of accidental interference with ongoing work.
Designed for durability, these gates withstand the harsh conditions of cement plants while remaining easy to operate. Facilities benefit from improved safety enforcement and better workflow management, ensuring that maintenance work is conducted without unnecessary disruptions.
Gangway Extended Top Handrail
For added safety, SafeRack’s gangway extended top handrail provides a visual and physical reminder for workers to ensure their equipment is properly stowed before exiting a work area. In cement facilities, where dust and debris can reduce visibility, having clear access markers helps prevent accidents and ensures compliance with safety protocols.
This extended handrail is designed to integrate seamlessly with existing gangway systems, making it a simple yet effective addition to cement silo access solutions. By improving worker awareness and reducing the likelihood of accidental slips or missteps, the system enhances overall facility safety.
Safety Gates
Properly securing maintenance areas is essential in cement facilities where workers frequently access silo valves at elevated heights. SafeRack’s industrial safety gates provide fall protection while allowing for controlled movement within maintenance zones. Their durable design ensures long-term reliability in harsh environments.
These gates can be easily adjusted to fit various opening sizes, making them an adaptable solution for different facility layouts. With a straightforward installation process and minimal maintenance requirements, they provide an efficient way to improve overall site safety.
Magnetic Swing Gates
SafeRack’s magnetic swing gates enhance access control by ensuring that workers can only enter or exit maintenance areas when conditions are safe. When integrated with gangways and platforms, these gates automatically lock when maintenance work is in progress, preventing accidental egress.
The gates unlock only when it is safe for workers to move, reducing the risk of falls or equipment interference. Designed to function as part of a comprehensive silo access safety system, magnetic swing gates help enforce safe working practices while maintaining operational efficiency.
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
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What Customers Are Saying
We are saving about 4 weeks and a ton of money by going with this option. I am using the product as a platform for servicing a pressure vessel for ease and element of change out. I like the availability and how easy the product fit to my project. We are saving about 4 weeks and a ton of money by going with this option.
By Bill S. from SPX Flow Technology
SafeRack makes the finest work platforms available. Great product, reliable, easy to use, safe, with fast delivery and friendly service. SafeRack makes the finest work platforms available.
By Jerry H. from DuPont