Rigid Rail Fall Protection For Railcars & Trucks

Our durable rigid fall protection system features an enclosed track with optional bypass capability. No other rigid rail fall protection system provides bypass capability combined with the enclosed track benefits of FlexRail and no other company in North America has designed more fall protection systems than Flexible Lifeline Systems.

Eliminate Ice And Snow Build-Up

The FlexRail enclosed track completely eliminates snow or ice build up providing unprecedented ease of movement when you need it most. The retractable lifeline remains overhead at all times providing additional support on slippery surfaces. We recommend that the user “lock” the retractable lifeline and use it as additional support while walking.

Eliminate Dust And Debris Buildup

The FlexRail provides an unprecedented 1:100 movement-to-weight ratio. The retractable lifeline remains overhead at all times completely eliminating any potential for an in-line swing-fall. The enclosed track completely eliminates dust and debris build-up, providing a maintenance-free fall protection system. Old style I-beam trolley systems are prone to dust and debris build-up on the exposed flanges, which is knocked off the beam when the trolley passes by and potentially into the railcar or truck resulting in contaminated product. This is no longer a concern with the FlexRail.

FlexRail for Trucks

Easy To Use Fall Protection

The system is completely hands-free, allowing the employee to concentrate on the task at hand. Due to the 1:100 movement-to-weight ratio, the retractable lifeline remains directly overhead at all times, eliminating the possibility for an in-line swing fall.

Easy Future Expansion

The modular style of the FlexRail makes it easy to add sections when you expand your capacities. We’ll even design your system with your expansion plans in mind to further reduce costs when you are ready to increase capacity.


Combine a competitive initial cost with minimal ongoing maintenance, increased productivity, and peace of mind, and a FlexRail system may well be the choice for you.


The FlexRail enclosed track is by far the most reliable rigid rail system in use today. With its 1:100 movement to weight ratio, the elimination of dust, debris, and ice and snow build up, it is the safest system in use today. With systems installed all over the world, FLS provides you with the peace of mind you deserve, knowing that you’re providing employees with the best fall protection system available.

Optional Bypass Capability

With each user on their own enclosed track, multiple users gain the added benefit of bypass resulting in increased safety and productivity.


All structural components are hot-dip galvanized for added durability and corrosion control. The teflon wheels of the sealed bearing trolleys do not damage the coating resulting in years of maintenance free use. A life expectancy of 25 years, maintenance free, is not uncommon in most industries.

Single Pedestal FlexRail

The single pedestal FlexRail system shown above combines the FlexRail system with a single column and pier. It is ideal for congested areas where multiple pedestals would interfere with traffic flow.

Access Stairs And Platforms

FlexRail systems are available with a stair and access gangway to provide safe and easy access. A variety of heights are available and can be customized to suit your specific applications and requirements.

FlexRail Attached to Structure

Attaches To Any Structure

FlexRail systems can be custom-manufactured to attach to any structure as needed. While this is ideal for low overhead applications, the low weight-to-movement ratio means high overhead systems are feasible even with the longest retractable lifelines. Our safety industry experts’ comprehensive understanding of the multiple connection and span options available makes attaching FlexRail to any structure possible.

Flexrail – Railcar/truck Fall Protection Case Studies

Greif St. Gabriel Case Study

Overhead fall protection was needed to safely access the tanker trucks in the inside truck bays as well as the railcars along a 300’ section of track.

Tri-point Case Study

FLS engineered a solution to accommodated the facility’s overhead gantry cranes so they could travel unimpeded by the overhead self-retracting safety lanyards.

Greif-Delta Case Study

FLS designed and installed three FlexRail Fall Protection Systems, one approximately 350 feet in total length over the rail line and two FlexRail approximately 292 feet in total length over the loading area and rail line.

Teknor Apex Case Study

Overhead fall protection was needed on the old and new plastics silos for workers to connect the feeder tubes to tanker trucks while on top of the trucks. FLS designed, fabricated and installed 8 FlexRail Systems.

CRRC Chicago Enterprise Center Case Study

As part of the new development, FCL Builders contracted Flexible Lifeline Systems for the design, fabrication, supply, inspection, load testing and certification of the FLS’ rigid rail fall arrest solution, FlexRail.

Nelson Brothers Case Study

FLS provided foundation design and anchor bolts for gallow mounting, as well as all fabricated parts, hardware, and system components.

Rigid Rail Fall Protection for Railcars & Trucks Animation

Railcar/Truck Fall Safety Solutions