Manufacturing can encompass everything from a simple plastic plug to a sophisticated mainframe computer. It can be as time-honored as metal-casted pump housing or as modern as a foldable smartphone.

Manufacturing a car includes assembling every part and parcel that goes into it: rubber hoses, catalytic converters, windshield wiper arms, transmission gears, batteries, airbags, and on and on and on before you get to the unnecessary license plate frame from the dealership.

Manufacturing is diverse and dynamic, but a common denominator is to prioritize worker safety, especially for work-at-height tasks. These are also varied and can include:

• Maintenance areas for large machinery.
• Elevated assembly lines.
• Loading and unloading stations.
• Storage areas.
• Large tank and vessel access.
• Restricted control instruments.
• Inspection and quality control areas.
• Production equipment access.
• Rooftop building services systems.

Something in common for all manufacturing plants to consider is using modular or fabricated work access platforms to significantly reduce safety risks, increase productivity, and ensure compliance with safety standards.

The modular platform approach.

A pipe-fitted, modular work platform is an ideal combination of simplicity and versatility. Its essential components include:

1. Aluminum or glass-reinforced nylon treads that are anti-slip, non-bounce, and self-draining.
2. Aluminum or galvanized steel support frames and guardrails.
3. Aluminum or galvanized steel pipe fittings available in a wide range of stock connection designs to assemble the frames, stairs, platform decks, and guardrails to accommodate assorted sizes, configurations, and work access needs.
4. Secure, stable bases that can be flanges, plates, or recycled PVC deadweights.

Benefits of modular platforms.

• All components are strong, durable, and corrosion-resistant for harsh environments or outdoor exposure.
• Meets OSHA standards for walking/working surfaces and guardrails
• Easy to install using simple tools – no welding or drilling required and minimal disruption to operations.
• Can be reconfigured or expanded if there are changes to the facility or work requirements.
• Available with optional features for added utility and efficiency.
• Provides workers with optimum freedom of movement to perform tasks and confidence that they are protected.

Types of Modular Platforms:

A. Fixed Access Platforms

Fixed (or static) platforms offer a permanent solution for areas where workers frequently need access, such as around large production equipment, loading and unloading stations, or on the rooftop. They are especially beneficial when machinery requires regular monitoring, adjustment, maintenance, or repairs.

B. Mobile Work Platforms

Mobile work platforms are ideal for manufacturing plants that need flexibility. They feature heavy-duty locking casters and can be easily moved from one location to another (e.g., storage areas, inspections, outdoor applications). Mobile platforms are safer and more efficient than ladders.

C. Custom Platforms

Manufacturing plants often have unique requirements that can be addressed by customizing modular platform designs. Examples include:

• Toe boards to keep tools and equipment from falling off or people accidentally stepping off the platform’s edge.

• Racks and shelves to store frequently used tools and equipment.

• Shop services, such as air, water, and electricity.
• Smooth handrails to help traverse platform stairs.
• Self-closing safety gates to cover the platform deck opening at the stairs and provide an added measure of fall protection. Gates can be aluminum or galvanized steel and feature a spring-loaded mechanism that automatically closes behind the worker.

The fabricated platform approach.

A fabricated work access platform can still feature several modular aspects (e.g., anti-slip treads); however, it is typically welded using lightweight, high-strength structural grade 6061 aluminum per AWS D1.1 & D1.2 and inspected by a certified welding inspector.

Adjustable height capability is a strong reason for choosing a fabricated platform. It can also accommodate optional features of a custom modular platform and be equipped with casters for mobility.

A fabricated platform will excel in strength and durability, making it ideal for permanent and heavy-duty use. Although modular components are attractive for an “industrial” look, welded designs can have a more streamlined aesthetic appearance that may be preferred in some plants.

How can we help you?

In a manufacturing facility where employees must work at heights, safe access platforms—modular or fabricated—are an essential fall protection measure to perform many of these tasks safely and productively.

If you are responsible for safety at your facility, FlexDecks can help. Our comprehensive services include hazard assessments, design and consultation, engineering, manufacturing, installation, and follow-up inspections and maintenance. Contact us for an evaluation of your facility’s safety needs.