Location: New Jersey
Industry: Pharmaceutical Manufacturing
Application: Rooftop Access & Equipment Maintenance
A New Jersey pharmaceutical manufacturing facility faced critical safety challenges following a rooftop reconfiguration. The roof was densely packed with steam lines, chilled water pipes, condenser lines, and numerous insulated ducts serving manufacturing areas, laboratories, and temperature-controlled storage below.
Maintenance crews were forced to climb over these obstacles to access essential rooftop equipment, creating serious slip-and-fall hazards. Despite “Caution Not A Step” warning labels, workers occasionally stepped on metal-jacketed insulation, causing multiple problems:
- Crushed insulation reducing energy efficiency
- Risk of damage to critical heat-tracing wires
- Increased likelihood of worker injuries
- Potential pipe failures threatening production reliability
- Compliance concerns and operational disruptions
The Solution
The plant’s design-and-build partner contacted Banks Industrial Group, an ErectaStep distributor, to develop an OSHA-compliant access solution. After conducting a detailed site analysis, Banks Industrial Group configured an ErectaStep rooftop crossover stair and platform system tailored to the facility’s specific roof layout.
The modular aluminum system provided safe, level walking surfaces across the rooftop obstacles. Support legs were adjusted to accommodate roof slope variations, ensuring stable and compliant access routes.
Installation & Results
Unlike custom-fabricated steel structures requiring lengthy engineering and extended lead times, ErectaStep’s prefabricated aluminum components bolt together quickly and efficiently. Banks Industrial Group completed the entire delivery and installation in just two and a half days—without disrupting ongoing plant operations.
The system delivered immediate benefits:
- Enhanced Safety: Non-slip decking and full OSHA compliance eliminated fall hazards
- Protected Infrastructure: Maintenance crews no longer step on insulated pipes, preserving energy efficiency
- Rapid Deployment: Installation completed in 2.5 days with zero operational disruption
- Long-Term Durability: Weather-resistant aluminum construction ensures lasting performance
- Reduced Liability: Architecture and engineering partners gained confidence in meeting stringent safety standards
According to the client: “Thanks again for your work, it all went as well as you said it would! Steve and the guys did a fantastic job. Kudos!”
Read the full case study from Banks Industrial Group: Pharma Plant Rooftop Crossover Platform
Why ErectaStep
This pharmaceutical plant project demonstrates ErectaStep’s core advantages for rooftop access applications: modular design that adapts to complex layouts, quick installation that minimizes disruption, and OSHA-compliant solutions that protect both workers and critical infrastructure. The prefabricated aluminum components provide superior corrosion resistance in demanding industrial environments while maintaining structural integrity for years of reliable service.
