Engineered Retrofit Strategy
- The platform was reinforced with additional structural steel to restore integrity and extend service life, avoiding the cost and disruption of a complete rebuild.
Custom Fall Protection Systems
Asphalt Truck Loading Platform Retrofit & Safety Upgrade
Custom Fabrication
Design & Engineering
Installation
Retrofit / Upgrade
Safety System Integration
Structural Reinforcement
Surface Preparation & Industrial Coating
This project involved a cost-effective retrofit of an aging asphalt truck loading platform at IKO’s Hamilton facility. Rather than pursuing a full platform replacement, the existing structure was preserved and strategically upgraded to extend asset life while significantly reducing capital costs. The result is a modernized, fully compliant loading platform that enhances operator safety, improves durability, and supports long-term operational efficiency.
Challenge
The existing asphalt truck loading platform required critical safety and access upgrades while remaining fully operational. A complete replacement was not feasible due to cost, downtime, and site limitations, requiring a retrofit solution that improved compliance and operator safety without disrupting daily operations.
Key Constraints
- Active loading operations during construction
- Existing structural footprint had to be preserved
- Exposure to extreme weather and winter conditions
- Integration of new loading arms and fall protection on an aging platform
- Strict safety and regulatory compliance requirements
Risk
The existing loading platform showed signs of corrosion and structural fatigue, increasing the risk of long-term failure and safety incidents if left unaddressed.
Workflow
A complete replacement would have required extended downtime and major disruption to daily asphalt loading operations. The solution needed to minimize operational interruption.
Compliance
Upgrades were required to meet current safety and access codes while maintaining compatibility with existing infrastructure and loading equipment.
Custom Solution
Designed for safety, operational performance, and compliance.
Surface Rehabilitation
- Abrasive blasting was performed to properly prepare all steel surfaces, followed by the application of a high-performance industrial coating system designed for long-term corrosion resistance.
Safety & Drainage Improvements
- New industrial floor grating was installed to improve drainage, reduce slip hazards, and enhance overall platform safety.
Operator Protection & Access
- Fully enclosed operator control sheds were constructed to shield personnel from wind, cold, and severe weather conditions, improving safety and productivity year-round.
Advanced Loading Systems
- State-of-the-art Safe Harbor loading gangways with integrated safety cages were installed, paired with premium OPW loading arms to provide secure, ergonomic, and code-compliant access during truck loading operations.
Key Deliverables
Engineering & Planning
The platform was reinforced with additional structural steel to restore integrity and extend asset life without removing the existing structure.
Installation
On-site build with minimal operational disruption.
Safety & Compliance
Guarding, access control, and fall protection.
Commissioning
Final verification, handoff, and operator readiness.
Project Highlights
Key moments and system details from the installation.
Talk to an expert Have a similar site challenge? We can engineer a safer, easier system end-to-end.
Request a Consultation