Published on: November 18, 2025
Precision Fall Protection for High-Risk Tanker Maintenance
Hazard: Workers accessing the tops of 12 foot high tanker trucks for cleaning and maintenance. Surfaces are uneven, narrow, and frequently slippery, creating a high severity fall risk.
Solution: A custom engineered 156 foot Kee Line Overhead Cable Lifeline system designed to bypass overhead pipe and duct obstructions.
Benefits: Achieved 100% fall arrest coverage while meeting strict budget requirements through a value engineered design that reduced material costs and installation time.
The Challenge: Navigating Complexity in a High-Risk Zone
Sika Corporation operates a high volume manufacturing facility in Conyers, Georgia. A critical part of their daily operations involves maintenance teams climbing atop tanker trucks for cleaning and inspection.
At a walking surface height of 12 feet, the risk of a fall is classified as high. In a chemical manufacturing environment, these surfaces are often uneven and can become slippery. This makes fall protection a vital Your Money / Your Life (YMYL) priority. The facility presented a significant engineering challenge because the maintenance bay was crowded with overhead ductwork and piping. Initial assessments suggested that moving this infrastructure would be necessary, but that would have been cost prohibitive for the plant.
The Solution: Adaptive Engineering and Value-Driven Design
Flexible Lifeline Systems (FLS) was engaged to protect workers without expensive utility relocation. This project highlights our Expertise and Authoritativeness through a 14 month consultative process that prioritized the client’s budget and site specific needs.
The project evolved through three design phases. While a Rigid Rail system was initially considered, FLS engineers recognized it would exceed the budget due to required structural modifications. Instead, our team developed a value engineered Kee Line Overhead Cable solution.
When the decision was made to keep the existing overhead pipes in place, FLS issued a change order to install the system at a lower elevation. By performing a rigorous structural and load analysis, our engineers replaced traditional compression bracing with high tension tieback cables. This pivot reduced material costs and installation time. It successfully brought the final system within the $80,000 budget while maintaining full OSHA and ANSI compliance.
A Turn-Key System for Total Peace of Mind
The final installation at the Sika plant provides a seamless safety experience for the maintenance crew. The 156 foot overhead system allows for 100% coverage throughout the length of the bay. A worker can move from end to end without ever needing to disconnect.
To ensure the system was ready for immediate use, FLS provided a complete turn key package:
- Two sets of user equipment: Self Retractable Lifelines (SRLs), Universal Full Body Harnesses, and Taglines.
- Professional Certification: A fully engineered and tested system that meets the highest safety margins.
This project demonstrates the FLS commitment to being a single source partner. By leveraging our internal engineering expertise to solve for physical obstacles and budget constraints, we provided Sika with a world class safety solution that protects their personnel and their bottom line.
Ready to enhance safety and efficiency at your facility? Contact Flexible Lifeline Systems for a comprehensive safety audit and let our team of experts help you find the perfect solution for your work at height.
