Pipe Rack System Installation

ErectaRack’s pre-engineered pipe racks reduce the lengthy engineering and fabrication process. Our modular components can be manufactured quickly without the need for custom engineering. We’ve taken the long and tedious task of designing and installing a pipe rack system and simplified it. ErectaRack’s pipe racks can save you time and money.

What Is a Pipe Rack?

Pipe racks are elevated steel support structures that safely route and organize process piping, cable trays, and utilities through an industrial facility. They can improve access, simplify maintenance, and protect uptime.

A well-designed pipe rack reduces structural steel, keeps operators out of danger zones, and makes future expansion easier. Unlike ground-level pipe tracks on sleepers, pipe racks are raised structures that free up ground space and improve protection from vehicle traffic and flooding.

Why Pipe Racks Matter

Slips, trips, and falls account for 15% of all accidental deaths and make up 20% of all job-related injuries. The annual medical cost for incidents is $70 billion in workers’ compensation and medical expenses.

Pipe racks improve safety and prevent accidents by separating hot, high-pressure, or hazardous lines from walkways and work areas. On the material end, pipe racks cut capital and life-cycle costs by optimizing pipe routing and steel tonnage, reducing clashes and rework during projects.

ErectaRack’s pipe racks support uptime by standardizing routes, simplifying inspection and maintenance, and giving clear access to valves and equipment.

Benefits of ErectaRack’s Modular and Prefabricated Pipe Racks

ErectaRack’s modular, pre-engineered pipe rack systems eliminate the lengthy design and fabrication process traditional pipe racks require, allowing facilities to move from planning to installation in days. A few key benefits that SafeRack’s approach brings include:

• Faster installation. Traditional pipe racks demand months of engineering and field fabrication; ErectaRack systems are pre-engineered and ready to assemble, cutting project timelines from months to days and minimizing operational disruption.
• Lower labor costs. Bolt-together modular components eliminate the need for field welding, specialized fabricators, and complex construction crews—standard mechanical assembly reduces labor hours and costs while allowing less specialized crews to install with confidence.
• Built-in compliance. Every ErectaRack system is precision-designed for structural integrity and worker safety. It utilizes integrated platforms, guardrails, and access features engineered to meet or exceed OSHA standards, avoiding late-stage compliance issues.
• Easier expansion. Modular designs allow facilities to start with one or two tiers and easily add, reconfigure, or extend systems as operations grow. Custom sizing and configurations are available without the need for re-engineering, making future upgrades simple and cost-effective.

How SafeRack Supports Pipe Rack Projects

SafeRack’s full-service approach begins with design support from Regional Area Managers and engineering specialists who work directly with your team to lay out pipe racks, plan related access infrastructure, and integrate fall protection systems—all while keeping compliance requirements and operational throughput at the forefront of every decision.

To accelerate delivery and reduce construction risk, SafeRack leverages modular, prefabricated components, including ErectaStep’s stairs, platforms, and prefabricated pipe racks. These systems integrate seamlessly with your existing structural steel, dramatically speeding installation timelines and eliminating the need for extensive onsite welding and hot work that can disrupt operations and introduce safety hazards.

Beyond products, SafeRack offers complimentary on-site safety and efficiency assessments conducted by experienced Regional Area Managers. During these site walks, the team reviews your existing pipe racks, identifies congestion points and safety risks, and recommends targeted upgrades designed to minimize downtime during planned turnarounds.

If you share your facility type (refinery, chemical, power, terminal) and project timing, a SafeRack Regional Area Manager can recommend a pipe rack and access approach that balances safety, cost, and installation time. Learn more about the different ways we can make a difference for your job site.