Secondary Containment Access Stair Installation

SafeRack installed three ErectaStep® crossover stair systems to provide safer access to chemical storage tanks within a secondary spill containment facility. The installation allows personnel to cross concrete containment walls and reach critical tank access points without relying on conventional ladder access. Designed for an industrial chemical storage environment, the Secondary Containment Access Stair solution combines stable platforms, OSHA-compliant handrails, slip-resistant treads, and corrosion-resistant aluminum construction. The modular configuration also provides flexibility for changing facility requirements.

What Is a Secondary Containment Access Stair?

A Secondary Containment Access Stair provides a safe way for personnel to move across containment barriers and reach equipment positioned within or around secondary containment areas. In this project, ErectaStep crossover stairs were configured to span concrete containment walls and provide access to chemical storage tanks. The three stair units feature elevated 3 x 3-foot platforms that create stable working areas above the containment walls. This configuration supports routine activities such as tank inspection, sampling, liquid-level monitoring, and maintenance.

Why Safe Access Matters in Secondary Containment Areas

Chemical storage facilities require reliable access to tanks, valves, gauges, and other operating equipment while maintaining appropriate separation from spill containment structures. Conventional access methods can make routine inspection and maintenance more difficult, particularly where containment walls create elevation changes. The Secondary Containment Access Stair installation provides a dedicated access route that helps personnel reach these areas more efficiently. OSHA-compliant handrails and aggressive tread patterns provide additional protection when workers are operating around elevated platforms and industrial conditions. The containment system itself provides an important environmental safeguard by capturing potential leaks or spills and helping prevent contamination of surrounding soil and groundwater.

How the ErectaStep Crossover Stairs Work

ErectaStep crossover stairs use a modular bolt-together design based on five core components. The system can be assembled without welding or specialized tools, allowing the stairs and platforms to be configured around existing facility structures. For this installation, the crossover units were positioned at strategic locations around the containment area. Personnel can use the stairs to move over the concrete walls and access tank tops, gauging points, fill ports, valve assemblies, and other maintenance locations. The modular approach also makes future configuration changes easier if equipment layouts or access requirements change.

Key Features of the Installation

• Aluminum Construction: The three crossover stair systems use lightweight aluminum construction suited to the chemical storage environment. Other available finishes include galvanized steel, 304 stainless steel, and steel, depending on project requirements.
• Elevated Work Platforms: Each unit incorporates a 3 x 3-foot platform that provides a stable surface for personnel working around tank access points.
• OSHA-Compliant Handrails: Handrails provide fall protection around the elevated platforms and stair access areas, supporting safer movement during inspection and maintenance activities.
• Slip-Resistant Treads: Aggressive tread patterns provide traction in demanding industrial environments where maintaining secure footing is important.
• Modular Bolt-Together Design: The Secondary Containment Access Stair system uses standardized components that can be installed without welding or specialized tools. This design supports faster installation and future modifications.

Applications in Chemical Storage Facilities

This type of access system can support a range of activities around chemical storage and process equipment, including:

• Tank inspection and routine sampling
• Access to liquid-level gauging points
• Fill-port and valve access
• Equipment maintenance
• Chemical storage operations
• Access across secondary containment walls
• Routine servicing of elevated equipment

In this project, the tanks stored process chemicals used in industrial water treatment and cooling tower operations. Overhead piping distributed these chemicals throughout the facility to support manufacturing processes.

Project Benefits

The installation provided three dedicated crossover access points while minimizing disruption to facility operations. Because ErectaStep uses a modular bolt-together system, the installation could be completed without the welding and fabrication requirements associated with many custom-built access structures. The aluminum construction also provides durability in demanding environments with relatively low maintenance requirements. Combined with modular expansion capabilities, the system gives the facility a practical access solution that can adapt as operational needs evolve.

SafeRack Project Support

SafeRack’s Regional Area Managers provided on-site safety assessments to help identify access challenges and determine appropriate crossover configurations for the facility.

The project also incorporated several elements of SafeRack’s broader support approach, including:

• Design consultation for access points and clearances
• Compliance verification
• Coordination with existing facility infrastructure
• Technical integration support
• Preventive maintenance planning

This project demonstrates how site-specific assessment and modular access equipment can be combined to address challenging industrial access requirements.

What was installed at the chemical storage facility?

SafeRack installed three ErectaStep crossover stair systems to provide access over concrete containment walls and to chemical storage tanks.

What equipment can workers access with the system?

The installation provides access to tank tops, gauging ports, fill ports, valve assemblies, and other points used for inspection, sampling, loading, and maintenance.

Why was aluminum used for the crossover stairs?

Aluminum provides lightweight construction and corrosion resistance, making it suitable for demanding industrial environments such as chemical storage areas.

Can the crossover stair configuration be modified later?

Yes. ErectaStep’s modular design allows components to be reconfigured or expanded as facility layouts and access requirements change.

How does this installation support safer operations?

The Secondary Containment Access Stair system provides dedicated stair access, elevated work platforms, handrails, and slip-resistant treads, helping personnel reach equipment more safely than relying on ladder access.