Published on: July 21, 2026
Securing Tanker Loading Operations Under Accelerated Timelines
Hazard: Facility personnel regularly climb onto the cylindrical, slick surfaces of chemical tanker trailers 10 to 12 feet above a concrete foundation to perform material offloading and line washing, facing severe fall exposures in high-traffic work zones.
Solution: A 52-foot overhead Kee Track rigid rail system custom-mounted directly to existing roof purlins using engineered hanger link brackets and high-strength fasteners.
Benefits: Eliminated fall clearance risks with zero-deflection rigid track arresting, bypassed floor-mounted obstructions to preserve ground vehicle flow, and resolved fall hazards with zero operational downtime via a fast-track five-day delivery schedule.
The Challenge: Low Clearance and High-Throughput Demands
The RoyOMartin Corrigan OSB facility stands as the largest single-site producer of Oriented Strand Board in North America. Inside the Edge Sealer Unload Area, technicians routinely access the tops of delivery tankers to handle resins and industrial chemicals. The cylindrical tops of these trailers present uneven, slick surfaces with zero integrated anchorages. Because workers operate only 10 to 12 feet above the concrete slab, standard cable lifelines could allow excessive sag and ground deflection during an arrest event. The solution required an ultra-low fall clearance profile that attached cleanly to the building envelope without obstructing chemical transfer hoses or logistics traffic below.
The Process: Rapid Structural Validation and Field Execution
FLS engineers initiated the engagement with an on-site structural audit to measure existing steel profiles and evaluate operational workflows alongside facility operators. The engineering team completed a comprehensive structural analysis, calculating and resolving all dynamic fall arrest loads from the rail attachment brackets through the structural purlins and into the facility foundation.
When the plant faced urgent scheduling needs in early September 2025, FLS pivoted to a rapid-deployment strategy. Leveraging modular, pre-engineered Kee Track components instead of lengthy custom shop fabrications, FLS transitioned the project from verified engineering submittals to complete installation in just five calendar days. A two-person field crew mounted the overhead infrastructure across two days without disrupting active plant logistics.
The Solution: Overhead Rigid Rail Infrastructure
FLS installed a targeted, single-user fall arrest setup configured directly for tanker operations:
- 52-Foot Kee Track Rigid Rail: Continuous overhead track providing smooth travel along the entire working length of the chemical tanker, minimizing swing fall hazards and arresting falls almost instantaneously.
- Engineered Hanger Link Assemblies: Heavy-duty V-frame hanger arms and purlin brackets secured via grade 5 hardware and bulb-tite rivets, distributing dynamic loading across multiple roof structural members.
- Specialized PPE Integration: Outfitted with an overhead SkyLoc II self-retracting lifeline (SRL) and high-efficiency trolley assembly, allowing operators hands-free, fluid movement along the vehicle.
- Zero-Footprint Structural Design: Suspended entirely overhead to keep the ground-level transfer bay 100% free of posts or vehicle obstacles.
Summary: Long-Term Industrial Compliance Partnership
The completed installation at Corrigan OSB highlights how precision engineering and modular hardware can solve urgent fall hazards without operational trade-offs. FLS delivered full OSHA and ANSI compliance in record time, transforming a high-risk material offload station into a secure, protected loading bay.
To maintain peak performance and structural integrity, the overhead rigid rail system is integrated into the FLS safety lifecycle program for recurring annual certified safety audits.
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.
