Background: A refinery storage tank farm engaged in raising containment walls throughout the facility faced significant challenges in maintaining safe access over the elevated walls. The existing stair/crossover system became obsolete due to the increased wall height, and the initial plan was to rent scaffolding for the duration of the project. This approach, however, proved costly and inefficient. The refinery sought a more sustainable, cost-effective, and safe access solution.
Challenges:
- Elevation Changes: The raised containment walls rendered existing access solutions inadequate.
- Costly Scaffolding: Renting scaffolding was estimated at $3,500 for erection and an annual rental fee of $8,500 per scaffold. The costs quickly escalated given the facility’s scale with hundreds of tanks.
- Safety and Compliance: Maintaining OSHA compliance with rented scaffolding involved frequent inspections and posed stability risks.
Solution: The refinery opted for ErectaStep’s modular access platforms as a permanent replacement for the scaffolding. ErectaStep provided a custom solution configured to meet the new height requirements and ensure continuous safe access over the containment walls.
Installation Details:
- Site Assessment: A 10-minute job walk was conducted, and a quote was provided the same day, complete with detailed drawings.
- Quick Deployment: ErectaStep components were shipped within 2 business days.
- Efficient Installation: A three-man crew installed the system before lunch, starting at 7:30 a.m. on the installation day.
Financial Impact:
- Initial Costs: The total cost for the ErectaStep system was $14,000.
- Cost Savings: Compared to the annual rental of scaffolding, the ErectaStep solution provided savings starting from the second year. Given the large number of tanks, the cumulative savings were substantial.
Benefits:
- Cost Efficiency: The refinery saved on recurring rental and maintenance fees associated with scaffolding.
- Enhanced Safety: ErectaStep’s platforms are designed to be OSHA-compliant, reducing the risk of accidents and ensuring a stable working environment.
- Durability: Made from industrial-grade aluminum, ErectaStep’s platforms are resistant to rust, warping, and rot, ensuring long-term use with minimal maintenance.
- Modular Flexibility: The modular design allowed for easy reconfiguration and adaptability to different access needs within the facility.
- Fast Installation: The pre-engineered components required no special tools or welding, enabling quick and efficient assembly.
Conclusion: The switch from rented scaffolding to ErectaStep’s modular platforms provided the refinery with a robust, compliant, and cost-effective access solution. This decision not only enhanced operational safety and efficiency but also resulted in significant cost savings over time. The refinery’s adoption of ErectaStep exemplifies the practical benefits of modular, prefabricated access solutions in industrial settings.
