Secondary Containment Access Stair Installation

SafeRack ErectaStep® Crossover Stairs Improves Safety and Compliance at Secondary Containment Area

This installation features three ErectaStep crossover stair systems providing access to chemical storage tanks within a secondary spill containment facility, improving worker safety and compliance in this hazardous environment.

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Project Overview

The installation consists of three ErectaStep aluminum crossover stair units strategically positioned to provide safe access over concrete containment walls to chemical storage tanks storing process chemicals including acids and treatment chemicals. The elevated platforms enable personnel to safely cross containment barriers while maintaining OSHA compliance and environmental protection standards.

Installation Specifications

The ErectaStep crossover stairs feature SafeRack’s patented bolt-together modular design utilizing five core components that enable rapid deployment without welding or special tools. Each unit incorporates:

• Lightweight aluminum construction with optional galvanized, 304 stainless steel, or steel finishes for chemical resistance
• 3 x 3 foot platforms providing stable work surfaces above containment walls
• OSHA-compliant handrails ensuring worker safety at elevation
• Aggressive tread patterns offering slip resistance in industrial environments
• Modular expansion capability allowing future configuration changes as facility needs evolve

Facility Requirements

Chemical Storage Operations

The tanks, marked for acid storage, house critical process chemicals used in industrial water treatment and cooling tower operations. The overhead piping system distributes these chemicals throughout the facility to support manufacturing processes. Secondary containment basins meet EPA requirements by providing 110% containment capacity of the largest tank volume.

Access Needs Addressed

The multi-level platform system provides essential access to:

• Tank tops for routine inspection and sampling operations
• Gauging ports for liquid level monitoring
• Fill ports and valve assemblies for loading operations
• Maintenance access points for equipment servicing

Safety and Compliance Features

The ErectaStep installation delivers comprehensive fall protection while maintaining operational efficiency. The system’s design eliminates ladder access, reducing fall risks during routine operations. All components meet or exceed OSHA standards for industrial access equipment.

Environmental Protection

The concrete secondary containment system, accessed via the ErectaStep stairs, serves critical environmental protection functions:

• Captures potential leaks or spills from storage tanks
• Prevents soil and groundwater contamination
• Ensures compliance with EPA spill prevention regulations
• Provides emergency response access for spill mitigation

Installation Benefits

Operational Advantages

The bolt-together design enabled rapid installation with minimal facility disruption. Standard components shipped from inventory within 3-5 days, significantly reducing project timeline compared to custom fabricated solutions. The modular system allows for future reconfiguration without extensive modifications.

Long-term Value

The aluminum construction provides exceptional durability in chemical environments, resisting corrosion while requiring minimal maintenance. The system’s modularity ensures adaptability as facility needs change, protecting the customer’s investment.

SafeRack Services Integration

This installation exemplifies SafeRack’s comprehensive approach to industrial safety solutions. Our Regional Area Managers (RAMs) provided on-site safety assessments to identify specific access challenges and optimize the crossover configuration. The project leveraged SafeRack’s full-service capabilities including:

• Custom design consultation to ensure proper clearances and access points
• Compliance verification confirming adherence to OSHA and environmental regulations
• Technical integration support coordinating with existing facility infrastructure
• Preventative maintenance planning to maximize equipment longevity

Project Outcome

The three ErectaStep crossover stairs now provide safe, efficient access to critical chemical storage infrastructure while maintaining full environmental compliance. Workers can perform inspection, sampling, and maintenance tasks with confidence, protected by OSHA-compliant fall protection systems. The installation demonstrates how SafeRack’s proven ErectaStep technology delivers immediate safety improvements while supporting long-term operational excellence in hazardous industrial environments.

This successful deployment reinforces SafeRack’s position as the trusted partner for fall protection and access solutions in chemical processing facilities, where safety, compliance, and operational efficiency are paramount.