Custom Fall Protection Systems

12-Spot Railcar Unloading Fall Protection Upgrade

Johnstown, Ontario
Fuel & Petroleum
$1M+
Design & Engineering Approval Drawings Custom Fabrication Installation Retrofit / Upgrade Training Annual Inspections & Maintenance

This project upgraded an existing 12-spot railcar unloading facility to safely support simultaneous, high-volume fuel transfer operations. The solution delivers full top-access fall protection, maintains uninterrupted operations, and mitigates environmental and cross-contamination risks in a complex fuel-handling environment.

Adjustable access stairs and enclosed safety cages providing OSHA-compliant fall protection at railcar dome level.

Challenge

The facility required safe, simultaneous top-access unloading across all 12 railcars while navigating multiple ground-level fuel pipelines between tracks — without disrupting operations or compromising safety.

Key Constraints

  • Multiple active fuel pipelines between rail tracks
  • Limited space for new foundations and civil work
  • Continuous operations requiring minimal downtime
  • Strict fuel handling, safety, and environmental regulations

Risk

Prevent fall hazards and fuel exposure during simultaneous multi-railcar unloading operations.

Workflow

Enable uninterrupted access across all 12 railcars without operational delays.

Compliance

Meet OSHA standards and environmental regulations for high-volume fuel handling.

Custom Solution

Designed for safety, operational performance, and compliance.

Elevated Platforms & Pipeline Crossovers

3 key elements
  • Six independent elevated platforms fabricated for multi-spot unloading
  • Integrated crossover bridges allowing safe passage over active fuel pipelines
  • Maintained full access to railcar domes and fittings

Civil & Structural Integration

3 key elements
  • Precision asphalt cutting and excavation in constrained areas
  • New concrete footings installed without interfering with underground pipelines
  • Retrofit approach minimized site disruption and downtime

Fall Protection & Access Systems

3 key elements
  • Complete Safe Harbor system installation
  • Adjustable gangways and full-enclosure safety cages
  • Ergonomic, OSHA-compliant top-access across all unloading positions

Contamination-Safe Fuel Handling

3 key elements
  • Color-coded hose assemblies to prevent cross-contamination
  • Canadian-manufactured Novaflex composite hoses
  • Lynx dry-break couplers for spill-free, zero-loss connections

Key Deliverables

What was delivered end-to-end

Engineering & Planning

Engineered multi-platform design with integrated pipeline crossover access.

Civil & Structural Work

Precision footings installed without disrupting existing fuel pipelines.

Fall Protection Systems

OSHA-compliant platforms, gangways, and full-enclosure safety cages.

Fuel Handling Equipment

Color-coded composite hoses with dry-break couplers.

Project Highlights

Key moments and system details from the installation.

Completed 12-spot railcar unloading platforms with integrated fall protection and top-access systems for high-volume fuel transfer.
Completed 12-spot railcar unloading platforms with integrated fall protection and top-access systems for high-volume fuel transfer.
Multi-platform railcar unloading system engineered for simultaneous access across all unloading positions.
Multi-platform railcar unloading system engineered for simultaneous access across all unloading positions.
Custom-engineered elevated platforms aligned to existing rail infrastructure, enabling safe and efficient top-access unloading.
Custom-engineered elevated platforms aligned to existing rail infrastructure, enabling safe and efficient top-access unloading.
Color-coded fuel transfer piping and hose connections designed to prevent cross-contamination during multi-product unloading.
Color-coded fuel transfer piping and hose connections designed to prevent cross-contamination during multi-product unloading.
Faultless Solutions installation crew following successful commissioning of the upgraded railcar unloading facility.
Faultless Solutions installation crew following successful commissioning of the upgraded railcar unloading facility.
Adjustable access stairs and enclosed safety cages providing OSHA-compliant fall protection at railcar dome level.
Adjustable access stairs and enclosed safety cages providing OSHA-compliant fall protection at railcar dome level.
Precision civil work installing new concrete footings in constrained areas while protecting active underground pipelines.

Partners & Vendors

Trusted partners who contributed to this project.

Safe Harbor - Platforms, gangways, safety cages
Novaflex - Composite fuel hoses (Canada-manufactured)
Lynx — Dry-break couplers
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