Custom Fall Protection Systems

Tanker Truck Loading Area Fall Protection Upgrade

Mississauga, Ontario
Lubricants & Chemical Manufacturing
$250k–$1M
Approval Drawings Custom Fabrication Design & Engineering Installation Retrofit / Upgrade Safety System Integration

Valvoline Canada engaged our team to design and implement a comprehensive fall protection solution at their Mississauga facility, addressing safety risks associated with employee access to tanker truck top hatches during liquid loading operations. The solution was engineered to integrate seamlessly with an existing canopy structure while delivering continuous, regulation-compliant fall arrest protection.

Challenge

Valvoline required a fall protection solution that would provide continuous, safe top-access to tanker trucks while working within an existing loading bay canopy and active facility operations.

Key Constraints

  • Existing canopy structure could not be removed or fully modified
  • Limited space for new foundations within an active loading area
  • Requirement for uninterrupted access along tanker length
  • Requirement for uninterrupted access along tanker length

Risk

Fall exposure during elevated tanker access under an active loading canopy.

Workflow

Maintain continuous, efficient top-access without disrupting existing operations.

Compliance

Meet fall protection standards within strict structural and site constraints.

Custom Solution

Designed for safety, operational performance, and compliance.

Canopy Integration

3 key elements
  • Engineered a continuous fall arrest system integrated through the existing canopy
  • Strategically notched canopy structure to avoid full demolition or replacement
  • Enabled safe operator movement along the tanker length while remaining tied off

Structural & Foundation Work

3 key elements
  • Excavated and installed 18-foot-deep concrete footings to support fall arrest infrastructure
  • Utilized precision diamond core drilling for accurate installation through existing concrete
  • Minimized operational disruption while maintaining structural integrity

Key Deliverables

What was delivered end-to-end

Engineering & Planning

Custom-engineered fall protection designed around existing canopy and site conditions.

Installation

On-site excavation, core drilling, and system installation with minimal operational impact.

Safety & Compliance

Continuous fall arrest protection meeting industry and regulatory standards.

Commissioning

Final inspection and system verification for immediate operational use.

Project Highlights

Key moments and system details from the installation.

Tanker Truck Loading Area Fall Protection Upgrade highlight image
Deep foundation excavation and reinforcement cage installation to support new fall protection infrastructure.
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Auger drilling operations for 18-foot concrete footings required for fall arrest system foundations.
Tanker Truck Loading Area Fall Protection Upgrade highlight image
Auger drilling operations for 18-foot concrete footings required for fall arrest system foundations.
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Overhead fall protection beam integrated beneath existing loading canopy without full structural removal.
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Completed fall arrest system spanning the tanker loading lane, enabling protected access along vehicle length.
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Final installation view showing continuous fall protection coverage within the active loading bay.
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