An energy company in West Central Florida needed a safer way for technicians to access pH metering sensors located over a water channel, where operators had been leaning over existing handrails to perform readings and maintenance. Over time, this created fall-risk exposure and ergonomic strain, so the safety team pursued an engineered, OSHA-compliant access platform to protect workers while maintaining reliable pH monitoring for effluent discharge compliance.
Challenge: Safe pH Monitoring Over Water
Like many commercial and industrial operations that discharge treated effluent, the facility must continuously monitor pH to ensure neutralization is effective and meets federal and state regulatory requirements before releasing water to the environment. pH sensors installed near the outfall record discharge pH for inspection and documentation, but the original setup forced technicians to reach over a guardrail and water, making routine readings, cleaning, and electrode changes increasingly unsafe.
pH neutralization systems often use one sensor to control dosing and a second sensor downstream to confirm final discharge pH and provide a permanent record. These instruments require periodic cleaning and calibration, especially where oily films, solids, or abrasive particles can coat or damage the electrodes, which means workers must access them frequently in all conditions.
Custom Cantilevered ErectaStep Work Platform Solution
To eliminate workers leaning over the handrail, the site partnered with ErectaStep to design a cantilevered work platform that extends out over the water, bringing the technician directly to the pH metering sensor in a stable, guarded work zone. The platform uses robust knee bracing and a rigid support structure so the deck can project past the existing railing while maintaining the load capacity and stiffness required for safe maintenance over a hazardous area.
The installation leverages ErectaStep’s modular work platforms and access platforms, built from corrosion-resistant aluminum with non-slip surfaces and OSHA-compliant handrails to handle continuous exposure to water and chemicals. Because the system is pre-engineered and bolts together using standardized components, the platform was installed quickly with minimal disruption and without custom fabrication or hot work.
OSHA Compliance and Safe Means of Access
OSHA requires that when a work platform is more than 24 inches above or below its access point, an approved means of access—such as fixed stairs, portable ladders, or other compliant systems—must be provided instead of makeshift solutions. Stacked blocks, loose materials, or leaning over railings are considered “unstable objects” and are specifically prohibited as safe working platforms, particularly where fall hazards exist over water or lower levels.
The new cantilevered platform integrates with ErectaStep’s modular metal stairs, delivering a dedicated stairway and guarded walking surface that meets or exceeds OSHA requirements for tread depth, riser height, rail height, and mid-rail/knee bracing. This design creates a defined point of access to the pH sensor, eliminating the need for technicians to balance on railings, reach over water, or improvise temporary supports to reach critical instrumentation.
Supporting Reliable pH Neutralization and Sensor Maintenance
Reliable pH neutralization depends on accurate sensor readings before and after treatment, which requires sensors to remain clean, accessible, and properly maintained. Common issues such as oily or solid coatings, abrasive particles, and fouled reference junctions can shorten sensor life or skew readings, driving many facilities to specify flat-surface sensors, double-junction designs, and quick-change cartridges in demanding service.
By positioning a stable work platform directly over the pH sensor location, the West Central Florida energy facility can perform regular cleaning, calibration, and electrode replacement without rushing, overreaching, or working from awkward positions. This improved access supports accurate recording of discharge pH for inspections and audits while reducing the risk of slips, trips, and falls during sampling and maintenance tasks.
Why ErectaStep for Water and Wastewater Access
ErectaStep’s modular system is widely used for maintenance platforms, work platforms, and water management access applications where equipment is installed over basins, channels, or containment. The aluminum construction resists rust and corrosion, providing long service life in wet, chemical, or wastewater environments while maintaining a rigid, OSHA-compliant walking surface.
Because components are fully modular, the operations team can reconfigure or expand this installation as treatment equipment changes or replicate the design at other pH monitoring points across the plant. Additional guardrails, safety gates, or crossover sections can be integrated using ErectaStep’s broader portfolio of industrial stairs, work platforms, and safety systems to standardize access across the company’s water and wastewater operations.
Key Benefits of the West Central Florida Installation
- Improved worker safety by replacing leaning over handrails with a fully guarded cantilevered platform and OSHA-compliant stair access over water.
- Corrosion-resistant aluminum construction and knee-braced cantilever design engineered to support live loads while projecting over a water channel.
- Enhanced pH sensor accessibility for regular cleaning, calibration, and replacement, supporting accurate pH neutralization and discharge compliance records.
- Fast installation using pre-engineered, bolt-together components, eliminating custom fabrication, welding, and extended downtime.
- Scalable, modular platform system that can be adapted or replicated for additional effluent monitoring points, valves, and instrumentation access throughout the facility.
