Summary
Essex-based specialty minerals provider Imerys Aluminates sought to improve the safety of their tanker loading site. Previously relying on mounted handrails and fall arrest solutions such as ropes and harnesses, their safety measures posed significant risks to workers and were less efficient for operations. Imerys needed a solution that prioritised fall prevention over fall arrest and allowed safe access to tanker tops for opening manway covers. IFC Inflow delivered a bespoke fall prevention system, addressing their unique challenges and improving safety, efficiency, and compliance.
Challenges
- Access to Multiple Manway Covers: The tankers used at the site had up to six manway covers, which the client required to be accessible from a single location.
- Uneven Tanker Surfaces: The tankers had a slope, being taller at the front than at the back. This made creating a fully secure, level fall prevention system more complex and increased the risk of falls.
- Site-Specific Requirements: The system needed to be adaptable to varying tanker sizes and integrate seamlessly with the existing site layout.
Solution
To address these challenges, IFC Inflow proposed and implemented a VertiLev fall prevention system, consisting of:
- 10m Long Safety Cage: Designed to match the longest tanker on-site. An internal moving gate allowed adjustment for smaller tankers, ensuring compatibility across all vehicles.
- Tilting Mechanism: The cage included a tilting mechanism to align with the tanker’s slope, minimising the gap between the cage and the tanker and eliminating fall risks.
- Pneumatically Powered Features: The cage, gates, and tilting mechanism were all pneumatically powered, enhancing ease of use, efficiency, and safety.
- Bespoke Gantry: A purpose-built gantry provided safe and straightforward access to the safety cage, designed to fit the available space and meet site-specific requirements.
- Drive-Off Protection System: Prevented unauthorised access and accidental damage caused by driving off before disengaging the system.
Outcome
The installation, commissioning, and handover process was completed smoothly in just five days, allowing the site to be fully operational the following week. Imerys Aluminates was thrilled with the system, which provided a highly effective solution to their tanker loading safety challenges. The project not only improved worker safety and operational efficiency but also garnered industry recognition, winning an award in 2021 for the Safer Handling of Inbound & Outbound Materials. This achievement solidified Imerys’ commitment to making their site as safe as possible for their team.
Check out the video below to find out more about the solution we provided for Imerys Aluminates.
