For over a decade, Citgo had been using temporary scaffolding for accessing wastewater valves and pipes down a 12-foot spill containment embankment. This provisional measure had become a costly, long-term setup, with the refinery spending around $10,000 annually on scaffold rentals, and additional $8,000 when the certification expired for dismantling and rebuilding, alongside regular inspection costs.
Challenges: The continued use of temporary scaffolding was not only costly but also posed safety and operational challenges. The need for a more permanent, economical, and safe alternative was apparent, prompting the search for a better solution.
| Location | Sulphur, Louisiana |
| Project | Replacing Temporary Scaffolding |
| Client | Citgo |
| Materials/Product | Petroleum |
| Facility | Petrochemical Refinery |
JODY ASHWORTH
Regional Manager | Safety Consultant | OSHA Compliant | Advanced Technology | Fall Protection & Loading Solutions | Louisiana
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Solution: The refinery reached out to ErectaStep for a permanent stair solution. Utilizing ErectaStep’s modular design and advanced CPQ (Configure, Price, Quote) software, a suitable stair configuration was quickly devised using readily available components. This approach eliminated the need for costly and time-consuming custom fabrication.
Installation: The project commenced with the removal of the old scaffolding and was followed by a week of site preparations and concrete work. The installation of the new ErectaStep stairs was completed in just one day, thanks to the bolt-together design that required no welding, special equipment, or tools.
Results: The new ErectaStep installation led to significant cost savings by eliminating ongoing rental and maintenance expenses associated with the temporary scaffolding. The more durable and efficient stair solution not only reduced costs but also enhanced operational efficiency and safety. The refinery has since planned to replace all temporary scaffolding across the facility, with the new stairs expected to pay for themselves in under two years.
Conclusion: The transition to ErectaStep’s permanent stair solutions marks a strategic improvement in the refinery’s maintenance and safety management. This project exemplifies the economic and safety benefits of choosing durable, prefabricated solutions in demanding industrial environments. For more details on how ErectaStep can improve your facility’s safety and efficiency, contact us today.
Project Profile – RollaStep as a Scaffolding Alternative
A large tire manufacturing plant had to regularly access their heat exchangers, a piece of equipment that is used in transferring heat between a solid object and a fluid, or between two or more fluids. Workers needed a work platform to access these heat exchangers for maintenance every 4-6 weeks throughout the year. Each time scaffolding was rented and union contractors were brought in to set-up and break down the units at an expense of $2,400 each time. Additionally, you can see from the photos that the scaffolding was cumbersome, difficult to move from each heat exchanger and wasn’t OSHA compliant.
