Engineered SafeRack Platform,
Gangway, Safety Cage
& Integrated Systems
SafeRack partnered with a liquid isocyanates and polyol petrochemicals facility to design an engineered-to-order railcar terminal for chemical bulk loading. The solution combined SafeRack-manufactured equipment with integrated components to improve safety, uptime, and compliance at the rail spur.
Installed SafeRack Equipment
- SafeRack loading platform – Custom-designed, fixed railcar loading platform providing elevated access for multiple spots, engineered for fall protection and efficient hose and arm positioning. The platform layout supports safe egress, clear traffic paths, and future expansion at the rack.
- SafeRack railcar access gangway – G4/GX-style railcar gangway, the #1 selling gangway in North America, giving operators a stable, self-leveling walking surface to the railcar manway. Extra width supports bulky PPE required for handling isocyanates and polyols.
- SafeRack safety cage – Railcar safety cage sized to enclose the work area at the top of the car, minimizing gaps and reducing fall exposure during hatch opening, sampling, and connections. The cage is designed to work in conjunction with the gangway and platform for OSHA-compliant access.
CHEMICAL BULK LOADING
Railcar Terminal
SafeRack engineered and supplied a full railcar off-loading system for isocyanates and polyols, focused on safe access, spill control, and safety.
Integrated System Components
- Prefabricated pipe rack (ErectaRack / integrated pipe support) – Bolt-together, prefabricated pipe rack used to route product, utility, and return lines from the loading rack to the process area with minimal field fabrication. This reduces installation time, hot work, and long-term maintenance on pipe supports.
- Top and bottom loading arms – Integrated loading arms for both top and bottom railcar connections, improving ergonomics versus hose-only systems and helping operators maintain proper reach and alignment. Properly configured arms support repeatable, low-spill connections for hazardous liquids like isocyanates.
- Grounding system – Railcar grounding and monitoring equipment to verify a proper ground before product transfer begins, reducing the risk of static discharge in a flammable or reactive environment. Interlocks can be tied into loading controls for added protection and operational discipline.
- Lighting – Task and area lighting around the rack to maintain visibility at valves, gauges, and walking surfaces during night or low-light operations. Good visibility supports safer inspections, connections, and emergency response.
- Spill containment pans – Railcar spill containment track pans to capture drips and incidental releases under the loading area. This helps control housekeeping, supports SPCC planning, and reduces the risk of product migrating into the yard or stormwater.
Your Full-Service Partner for
Bulk Loading Terminal Design & Compliance
– More Than Superior Products –
- On-Site Safety Assessments
Complimentary evaluations to identify risks, ensure compliance, and improve workflow efficiency. - Proprietary Configurator
Save time and costs with same-day 3D renderings, loading platform layout drawings, and budgetary quotes—all with built in compliance and efficiency.
- Compliance and Productivity Optimization
Expert design support to meet safety regulations while streamlining operations and reducing downtime. - Large Project Consultation
Collaboration with your team to design loading platform solutions that meet regulations and facility needs.
How the System Supports Safety Peace of Mind for your Facility
- The platform, gangway, and safety cage reduce fall risk so operators can work confidently at height around hazardous petrochemicals.
- Integrated loading arms, grounding, lighting, and containment pans work together to reduce spill risk, static hazards, and unplanned downtime at the rack.
- By delivering a complete, engineered system instead of piecemeal components, SafeRack helps operations, safety, and maintenance teams sleep better knowing the terminal is compliant, efficient, and built for long-term reliability.
