Adding permanent access around existing industrial plant is often more complicated than designing access into a new facility.
The equipment is already in position. Pipework, ducting, cable routes and structural steelwork may restrict where stairs or platforms can be installed. Production areas may need to remain operational, and the people using the access system still need enough space to inspect, maintain and remove equipment safely.
The starting point is therefore not simply deciding where a walkway or platform will fit. The access route needs to be designed around the maintenance task, the existing plant and the physical constraints of the site.
Start With What Needs to Be Accessed
Before deciding on the structure, establish exactly why access is required.
A platform used occasionally to inspect a gauge has very different requirements from one where engineers regularly remove motors, filters or other components. The working position, frequency of access and tools or equipment being carried all affect the design.
Useful questions at this stage include:
- Which parts of the plant require routine access?
- What work will be carried out from the platform?
- How frequently will it be used?
- How many people are likely to use it?
- Are tools, components or replacement parts carried to the area?
- Does equipment need space around it for servicing or removal?
- Are there valves, control panels or inspection points that must remain accessible?
This helps establish where people actually need to stand and move rather than designing an access structure simply around the shape of the machinery.
Survey the Existing Plant and Surrounding Area
Existing industrial environments rarely provide a completely clear space for a new access structure.
Pipework may cross the proposed route. Cable trays can restrict headroom. Existing steelwork may affect the position of supports, while machinery, tanks and process equipment can limit the available footprint.
A site survey can identify these constraints before the access arrangement is developed.
Depending on the project, relevant information can include existing drawings, site dimensions, floor and equipment levels, structural details and the position of services.
The survey should also consider what cannot be moved. Rerouting a small service may be practical; relocating major process equipment simply to accommodate an access platform usually is not.
Design the Route Around the Maintenance Task
The shortest route is not necessarily the most practical one.
Someone carrying out maintenance needs to reach the correct working position with sufficient space to perform the task. A platform that reaches the equipment but leaves an engineer unable to remove a component or operate a valve has not solved the access problem.
The route may therefore need to incorporate a combination of:
- GRP walkways
- GRP access platforms
- Stair systems
- Landings
- Handrails
- Safety gates
- Supporting steelwork
Changes in level, restricted headroom and obstructions can all influence how these elements are arranged.
This is where treating the project as a complete plant access structure rather than a collection of individual products becomes important.
Work Around Pipework, Ducting and Services
Services are one of the most common constraints when access is added to an existing facility.
A walkway may need to pass above or below pipework. A platform might need to fit between existing structural members. Stair positions can be restricted by ducting or cable routes.
Designing around these obstacles requires more than making the structure fit into the available gap.
Clearances need to remain appropriate for both the people using the access system and the services themselves. Valves, inspection points and other items requiring maintenance should not inadvertently be obstructed by the new structure.
Future access to those services should also be considered. Solving one maintenance problem should not create another.
Consider How the Structure Will Be Supported
Finding space for a platform is only part of the design. It also needs an appropriate means of support.
The existing building or plant structure cannot automatically be assumed to be suitable for carrying additional loads. Existing steelwork, concrete floors, walls and other potential fixing points need to be considered as part of the engineering assessment.
Where suitable support is not available, an independent supporting structure may be required.
The loads involved will depend on the particular installation and its intended use, so support arrangements should be established for the project rather than assumed from a previous installation.
Allow Enough Working Space
Access and working space are not the same thing.
A narrow route might allow somebody to reach a piece of equipment but provide insufficient room to carry out the work once they get there.
Platform dimensions should take account of the actual maintenance activity. That can include opening access panels, removing components, handling tools and allowing personnel to work in the required position.
Equipment manufacturers may also specify maintenance or removal clearances that need to remain unobstructed.
These requirements are particularly important around pumps, motors, filters, valves and other equipment where components may need to be removed rather than simply inspected.
Think About Installation as Part of the Design
Access can be designed successfully on paper and still be difficult to install if site restrictions are ignored.
Existing industrial facilities may have limited routes for bringing fabricated sections into position. Doorways, overhead services, operating machinery and restricted lifting access can all affect how large a section can be delivered and installed.
There may also be limits on when work can take place.
Where shutdown periods are restricted, fabrication and installation need to be planned accordingly. Designing the structure in manageable sections can help where access to the installation area is limited.
These practical considerations are better addressed during design than discovered once fabrication is complete.
Why GRP Can Work Well for Retrofit Access
GRP grating is frequently considered for access structures where corrosion resistance and reduced component weight are useful.
The material can be used for grating, walkways, platforms, stairs and handrail systems, allowing several parts of an access arrangement to be designed together.
Its suitability still depends on the application. Loads, spans, support conditions, environment, fire-performance requirements and other project-specific factors all need to be considered before the material and structure are specified.
The objective is not to use GRP simply because an existing site presents a difficult access problem. It is to establish whether a GRP structure provides the right solution for that particular environment and maintenance requirement.
Plan for Future Changes
Industrial plant rarely remains unchanged throughout the life of a facility.
Equipment can be replaced, production lines altered and additional services installed. An access system designed tightly around today’s equipment without considering foreseeable changes can become restrictive later.
Where practical, the design should consider likely equipment removal routes and areas where future plant modifications could affect the access structure.
That does not mean designing for every possible future change. It means avoiding unnecessary restrictions where future maintenance or replacement requirements are already known.
Treat Retrofit Access as a Complete Design Problem
Adding safe access around existing plant is not simply a matter of positioning a platform beside a machine.
The maintenance task, access route, working area, structural support, existing services and installation constraints all affect the final arrangement.
GRP Grating Systems designs, fabricates and installs plant access structures incorporating walkways, platforms, stairs, handrails and supporting elements to suit existing industrial environments.
If access is required around existing machinery or process equipment, contact GRP Grating Systems to discuss the plant layout and access requirements.
Frequently Asked Questions
Can access structures be installed without moving existing machinery?
In many cases, an access structure can be designed around machinery already in position. This depends on the available space, required working area, structural support and installation access. A site survey can establish what is practical.
Can an access platform be designed so equipment can still be removed?
Yes, but equipment removal needs to be considered during the design. Required clearances and removal routes should be identified so the new structure does not obstruct future maintenance or replacement.
What happens if there is no suitable structure to support a new platform?
A separate supporting structure may be required. The appropriate arrangement depends on the loads, available floor space, existing structure and site conditions.
Can an access structure be installed while a plant remains operational?
Sometimes, although this is project-specific. Installation methods, working areas, site restrictions and any required shutdown periods need to be established before fabrication and installation are planned.
Can a new access structure connect to an existing walkway or platform?
Potentially, but the existing structure and connection need to be assessed rather than assuming they can carry the additional loads. The condition and suitability of the existing access system also need to be considered.