Customer Challenge: Safe Railcar Access and Chemical Transloading

A major industrial facility required a custom-designed railcar loading platform to ensure safe access for workers while preventing spills during the chemical transloading process. The project needed a double-sided platform for two rail tracks, with secure access to railcar hatches for venting operations. Additionally, an effective spill containment system was necessary to prevent environmental contamination and meet compliance requirements.

SafeRack’s Solution: Engineered Safety and Spill Containment

SafeRack designed and installed a railcar loading platform with two access points per track, each featuring SAS gangways and safety cages. The safety cages were specifically built to fit the railcar’s crashbox, eliminating gaps and providing fall protection.

To prevent hazardous spills, SafeRack integrated the UltraTech Polyethylene Railcar Track Pans, ensuring any accidental overflows or leaks were safely contained. Each track was fitted with a 16-foot spill containment system, providing industry-leading environmental protection.

Key Features of the UltraTech Railcar Track Pan System

• Modular Design: 53.5-inch sections allow easy expansion for different rail configurations.


• High Chemical Resistance: All-polyethylene construction withstands harsh chemicals and extreme temperatures (-40°F to +140°F).


• Sealed System: Patented LLDPE gaskets prevent leaks between the rails and pans.


• Below-Grade Piping Integration: Built-in pipe fittings allow efficient drainage to oil/water separators or holding ponds.


• Slip-Resistant Surface: Built-in grates ensure worker safety and prevent slips on wet or oily surfaces.


• Long-Term Durability: Estimated work life of 20-30 years, with no rust or corrosion.

Installation Advantages

The UltraTech Track Pan System offers a lightweight, modular design, eliminating the need for heavy lifting equipment during installation. This reduces labor costs and allows for easy replacement of damaged sections without disrupting operations.

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Project Impact

• Safe and OSHA-compliant access to railcar hatches.


• Environmental protection by capturing chemical spills at the source.


• Increased efficiency in the chemical transloading process.


• Low maintenance costs with long-lasting spill containment.