Jeff Mirisola
Getting maintenance workers and equipment safely into furnaces and other vessels is rarely straightforward. These spaces are often tight, complex and elevated in a way that makes access anything but simple. Crews frequently have to bridge gaps or navigate awkward spaces just to reach the work area. At the same time, strict safety requirements leave very little margin for error, which makes a reliable, well-designed access solution essential.
Custom-engineered access ramps offer a safe, efficient approach to shutdowns. Specialized manufacturers play a key role by combining site-specific engineering, high-quality materials and long-term design experience into a solution that helps waste-to-energy (WTE) operators improve safety, reduce downtime and create a long-lasting access plan.
Custom-Made Design Features
One of the biggest benefits of working with an original equipment manufacturer is quality and experience. Ramp manufacturers engineer options for unique obstacles. Each access ramp is specially designed to ensure proper fit for optimum efficiency, portability and safety. Original equipment manufacturers have worked with hundreds of customers to solve specific challenges and, in partnering with them, managers can tap into that knowledge and success to find the custom-made designs, building materials and specialized solutions for their facility.
This individualized approach is the first and perhaps most important factor managers should consider when partnering with a specialized manufacturer. Engineers review the blueprints of the facility and the access requirements for each vessel before creating a custom design that ensures safety and efficiency. From approach angle to threshold height, custom-made access ramps are engineered to fit the specific parameters of the project with precision and forethought.
In fact, many custom-engineered ramps incorporate standard safety features, such as curbs, rails and fall guards, to protect workers as equipment moves across the ramp. Some also include safety cages that integrate seamlessly with the ramp design to protect workers on the bridge from falling debris. Other ramps can be designed with modular features, capable of being used for more than one vessel within a facility. Manufacturers have created ramps with turns integrated into the design to go around building features like pillars or air ducts and piping. They鈥檝e also created ramps that can be assembled onsite by hand when getting equipment to the area is impossible. Specialized ramp manufacturers have engineers in-house to develop new solutions to meet the unique needs of each facility.
Material Selection Considerations
Manufacturing materials are an important factor of custom designs to increase efficiency, portability and safety. Specialized manufacturers have access to high-quality materials that make their ramps lighter and safer than steel. Although steel ramps are strong, they鈥檙e also very heavy, requiring additional time and equipment to assemble. Industry-leading manufacturers incorporate high-strength 6061-T6 aluminum, which makes the ramp as strong as steel at a third of the weight. Ramps constructed from this material support as much as 20,000 pounds (9,071 kilograms) live load and offer a 3:1 safety factor.
Sales and Service
Perhaps the biggest benefit of partnering with a specialized manufacturer, however, is the customized care you get from a dedicated sales and service department over the life of the ramp.
Experience means a lot when it comes to design features and material selection, but it is also an important factor of customer service. From planning to installation, a professional manufacturer is able to think of all the little things that could inhibit efficiency. Experts are available to answer questions and are better prepared to handle hiccups that might slow down maintenance. And when things don鈥檛 go to plan, extensive experience allows them to quickly offer solutions to keep the project on schedule.
Partnering with a specialized manufacturer also provides access to after-sales service. Many manufactures make themselves available for ramp inspections for several years. Custom manufactured ramps are also continuously tested to maintain industry safety ratings. If an issue is discovered, manufacturers will work with customers to fix defects. Choosing a specialized manufacturer also means customers will have access to spare parts, should a component be misplaced or damaged during storage. Even though each design is custom made, a specialized manufacturer will keep designs on hand and can easily remake the necessary component.
Optimize ROI
Investing in a custom access ramp with a specialized equipment manufacturer solves any access challenges WTE plants face. The flexibility of design and ease of assembly are vital to limit downtime and increase maintenance productivity. Year after year, a custom-engineered ramp system allows crews to get the job done safely and efficiently, ramping up productivity and optimizing ROI.