Project Profile: ErectaStep Rail Crossover System at Fertilizer Production Facility
A global producer of phosphate and potash crop nutrients required a compliant access solution for workers servicing railcars during bulk fertilizer offloading operations inside an enclosed rail-spur building. With trains positioned inside the structure during loading, personnel needed safe passage to either side of the track—without walking between coupled railcars, an OSHA violation that exposes workers to crushing hazards, slip/trip injuries, and struck-by incidents.
SafeRack’s ErectaStep delivered a 15-foot-high modular crossover stairway that spans the building opening, allowing workers to cross over the train while it’s being unloaded. The design eliminates at-grade track crossings and the need to navigate between railcars, keeping the loading operation moving while protecting personnel from line-of-fire and fall hazards.
The Safety Challenge
Dangerous at-grade crossings: When unloading, railcars are coupled and it’s impractical to walk around entire train and walking between railcars during the unloading creates serious risks:
- Workers exposed to moving equipment, including railcar shifts during spotting or coupling
- Slip, trip, and fall hazards on uneven ballast and track infrastructure
- Struck-by incidents from mobile equipment or process piping around the facility
- OSHA 1910.30 requires fall protection and compliant access for elevated work; crossing between railcars violates safe passage standards
Limited access to both sides of the building: With a long train with coupled railcars inside the structure, workers needed safely access both sides of the track without disrupting rail traffic or entering the track envelope.
Height clearance requirement: The crossover needed to clear a loaded railcar by several feet—requiring a 15-foot elevation—making portable stairs or temporary solutions impractical and non-compliant.
ErectaStep Solution
Modular 15-foot crossover stairway system installed at the building entrance, featuring:
- Dual stair towers with OSHA-compliant 42-inch guardrails, mid-rails, and toe boards on both approaches
- Straight platform span crossing the full width of the rail opening, providing clear passage over the track with adequate headroom for loaded railcars
- Prefabricated bolt-together construction using galvanized steel for corrosion resistance in a fertilizer production environment where phosphate dust, moisture, and outdoor exposure are constant
- Adjustable base supports anchored to existing concrete pads, eliminating the need for welding or specialized foundations and allowing fast installation with minimal rail downtime
- Slip-resistant tread plates and uniform riser heights to reduce trip hazards during high-traffic shifts
- Future expansion capability: Modular design allows additional platforms or landings to be added if the facility expands or changes loading procedures
Operational Benefits
Compliance and risk reduction:
- Eliminates at-grade track crossings and walking between railcars during bulk unloading operations
- Meets OSHA 1910.23–.30 requirements for stairways, platforms, and elevated work access
Zero downtime during loading:
- Workers can safely cross to either side of the track while the train is spotted inside, keeping the loading schedule on track
- No need to wait for railcars to decouple or move out of the structure before personnel can access equipment or perform inspections
Rapid deployment:
- Prefabricated ErectaStep components shipped ready to install, with no custom fabrication or field welding required
- Bolted assembly completed in days rather than weeks, minimizing impact on facility operations
- Adjustable design accommodates minor variations in concrete elevation and can be relocated if track or building layout changes
Durability in harsh conditions:
- Galvanized finish resists corrosion from phosphate dust, potash residue, and outdoor weather exposure common in fertilizer production and rail-loading environments
- Heavy-duty construction supports high-frequency use during shift changes and loading cycles
Use Cases for Phosphate and Potash Facilities
Railcar loading terminals:
- Safe crossover access during bulk fertilizer loading when trains occupy enclosed or partially enclosed buildings
- Elevated platforms for hatch inspections, sample collection, and valve operation on both sides of the train without entering the track zone
Processing and storage areas:
- Access over conveyor belts, rail tracks, or process piping where at-grade crossings create struck-by or entanglement hazards
- Elevated walkways connecting buildings or equipment platforms separated by active rail lines
Maintenance and inspection:
- Safe access to roofline equipment, ventilation systems, dust collectors, and structural inspection points around rail-served production buildings
- Crossover stairs for accessing both sides of loading racks, pump islands, or bulk storage facilities bisected by rail spurs
Multi-modal logistics hubs:
- Crossovers at truck-rail transload facilities where both modes operate simultaneously, keeping ground-level traffic separated from elevated personnel routes
- Connections between process areas and rail loading zones in fertilizer blending and bagging operations
Why ErectaStep for Rail Applications
- Prefabricated and fast: Modular components ship ready to assemble, cutting project timelines and avoiding custom fabrication delays
- OSHA-compliant out of the box: Uniform risers, slip-resistant treads, 42-inch guardrails, and proper load ratings built into every configuration
- Adaptable and expandable: Bolt-together design allows easy reconfiguration or extension if rail layout, building access, or operational needs change
- Corrosion-resistant finishes: Galvanized steel, aluminum, and stainless options withstand fertilizer dust, outdoor exposure, and wash-down environments
- No welding or hot work: Critical in facilities handling flammable or hazardous materials, ErectaStep installs with hand tools and mechanical fasteners only
Project Outcome
The ErectaStep 15-foot crossover eliminated a major compliance gap and safety risk at this fertilizer production facility. Workers now cross safely over the train during unloading operations, reducing exposure to crushing hazards and struck-by incidents while keeping the rail schedule moving. The prefabricated system installed quickly with no disruption to production, and the modular design provides flexibility for future expansion or reconfiguration as the facility grows.
For fertilizer producers, chemical plants, bulk terminals, and any rail-served operation where workers need safe passage over active tracks, ErectaStep crossover stairs deliver compliant, durable access that keeps people safe and operations efficient.
