working with suspended access systems

Selecting the Best Solution for Access Challenges in the Air, Around Curves, in Tight Corners and Underneath Structures

Executive SummarySituation Economic factors have prompted industrial and commercial construction companies to work with smaller budgets and tighter project time lines; while scaffolding and access challenges under bridges, inside boilers and separation vessels, offshore, and in/around buildings have continued to increase. Suspended access solutions can often be used to effectively address design and structural issues and offer a higher degree of efficiency, saving both time and money. However, choosing the best solution for a specific application is not always easy.

Challenge According to the Occupational Safety and Health Administration (OSHA), there are eight types of suspended access available. Sometimes a simple, cost-effective system can provide needed access, but seeking a solution based on cost alone is likely to backfire. Inexpensive suspended access solutions can be time-consuming to erect, may provide an unstable working platform, are not usually offered in combination with other access equipment, such as supported scaffolding and hoists, and ultimately could compromise safety. In addition, working with a company that provides a suspended access system, without the necessary experience, engineering, training and support to safely and optimally utilize the equipment, could be equally disastrous.

Solution Understanding what types of suspended products are available and the differences between them is key to selecting the optimum solution for a specific application. Experience has shown that multi-point access systems with rigid platforms are consistently outperforming other solutions. In addition, choosing to work with a comprehensive access solutions company, which has the background, knowledge, labor, management, equipment and skills to efficiently and safely take projects from start to finish, is also essential to the successful use of any suspended access products.

Working with Suspended Access Systems

©2013 Safway Services, LLC All rights reserved.


Many structures in the commercial and industrial markets consist of unique shapes requiring specialty access solutions. Suspended scaffolding is a great asset for difficult-to-reach locations and elevations; however several factors need to be considered before pursuing this route. There are numerous products to choose from; not all are suitable for every application. Suspended scaffold solutions can also be dangerous when not used correctly or without the proper safety equipment and training.

According to the Occupational Safety and Health Administration (OSHA), eight types of suspended access are available: Two-Point (swing stage), Single-Point Adjustable, Catenary, Multi-Point Adjustable, Interior Hung, Needle Beam, Multi-Level, and Float (ship). Each of these access solutions has its own OSHA regulations and guidelines, which must be followed. Building suspended scaffolding has the potential to be time-consuming and possibly dangerous, if not done correctly. When reviewing product information, both ease of erection and dismantling should also be taken into consideration.

Suspended Access Overview Eight Types of Suspended Scaffold

Suspended Scaffold Type Product Description and UseTwo-Point (Swing Stage) Usually used by window washers, or for high-rise construction, this is the most

common suspended scaffolding. A platform is suspend by ropes or cables connected to stirrups at each end of the platform.

Single-Point Adjustable Window washers and single-worker projects utilize this type of scaffold. This smaller platform is suspended by using only one rope or cable.

Catenary Bridges and offshore rigs are frequent users of this type of scaffold. Catenary scaffold consists of a platform supported by two horizontal and parallel ropes attached to structural members of a building or structure.

Multi-Point Adjustable Chimney hoists, bridges, construction, and other specialty projects use this type of scaffolding. A platform is supported by multiple suspension points from an overhead connection. (See diagram below showing multi-point suspended access solution with rigid platform.)

Interior Hung Used for internal work on structures, this interior-hung scaffold consists of a platform that is suspended from a roof or ceiling by fixed-length supports.

Needle Beam Steel structures and riveting gangs are two big users of this type of scaffold. Needle beam suspended scaffold consists of a platform that is suspended from needle beams and usually attached on one end to a permanent structural member.

Multi-Level Often used by window washers and construction sites, the multi-level suspended scaffolding consists of either two-point or multi-point adjustable suspended scaffolding with a series of platforms placed at various levels resting on common stirrups.

Float (Ship) A float, or ship, scaffold is a suspended scaffold used for many types of industries. This suspended scaffold consists of a braced platform resting on two parallel bearers and hung from overhead by ropes of fixed length.

To review corresponding OSHA regulations, go to www.osha.gov

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Suspended Access Overview - continuedIn addition, you will want to compare suspended access products with flexible decking versus rigid platforms. Inexpensive suspended access solutions providers often utilize low-cost flexible platforms to reduce price. These platforms are typically made of galvanized roof deck or chain link materials. Flexible platforms provide a surface that can be difficult to work on and hard to maneuver equipment across. In addition they can be time-consuming to erect, do not facilitate use in multiple applications and are not usually offered in combination with other access solutions products, such as supported scaffolding and/or hoists.

The cost to build ground-supported scaffold gets more expensive as working elevations increase because supported scaffolding is three-dimensional (length, height and width) while suspended scaffolding is two-dimensional (length and width). This means that ground supported scaffolds require more material to reach greater elevations, while suspended scaffolds utilize the same amount of equipment, regardless of elevation. When projects require work to be done at a specified location, high off the ground, suspended scaffold provides an efficient, cost-saving solution.

Multi-point suspended access scaffold with rigid platforms provides a stable work surface and has been used to address multiple access challenges with a high degree of efficiency. These modular platforms are designed for easy installation to save on labor, can be “built in the air” to save time and “leapfrogged” to reduce equipment costs. Leapfrogging is the process of removing material from one end to be used at the other. Leapfrogging uses less material and can increase project profitability. In addition, by using a cantilevered system with rigid platforms, erectors can assemble a product more safely.

When engineered, multi-point suspended access systems can be designed to withstand high loads at a 4:1 ratio, span over large areas, fit unique shapes and be combined with other access solutions, such as supported scaffolding. Rigid platforms provide safe barriers between the area where work is performed and anything below. Properly trained, laborers can safely function at high elevations, allowing multiple trades to operate side-by-side with a high degree of efficiency, uninhibited by any restriction of what may be below the platform. This valuable access solution can be configured to meet the needs of many applications in both the commercial and industrial industries.

Multi-Point Suspended Access Systems with Rigid Platforms

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Commercial ApplicationsBridges

Many bridges within the United States are nearing retirement age with almost one-third of the 600,000 bridges already exceeding their expected lifespan of 50 years. Maintenance is in high demand, while funding is low. Bridge maintenance usually requires work to be done underneath the bridge – which is over water, roads, railroads or other non-ground accessible areas. Occasionally, though, work needs to be performed above traffic (on archway bridges) without disrupting traffic flow. Due to the nature of the locations where the work is to be performed, the potential for high costs and large project time lines is significant.

Suspended access solutions are the preferred system used to perform maintenance and repair on these difficult-to-reach areas on bridges. One frequently used suspended access solution on bridge projects has been catenary systems. Catenary suspended scaffolds are commonly built by attaching cables horizontally to bridge anchors, and vertically from under the deck of the bridge. Once the cables have been placed, platforms that are built out of galvanized roof deck or chain link materials are laid across the working surface area. The platforms of these catenary systems are flexible, creating a work surface that constantly bows when stepped upon. Without rigid surfaces to walk on, work is slowed because labor and materials cannot easily move across the surface of the system.

Multi-point suspended access systems with rigid platforms have been consistently out-performing catenary systems on bridge projects. Advantages include easier and safer installation and dismantle, as well as a reliable, level work surface. In addition, these systems can be engineered to closely fit the curves of virtually any bridge design.

I-430 Bridge Project Two side-by-side bridges connect Little Rock with North Little Rock across the Arkansas River. Sections of concrete piping each 40 feet long and weighing almost 7,000 pounds, needed to be installed under the bridge to serve as water lines. In the past, to complete such an enormous task, contractors would use cranes and barges. This meant that the pipe was hoisted by crane from a barge, installed by work crews, and then finally inspected, one section at a time.

When presented with this challenge, Safway Services, the access company for the project, engineered a multi-point suspended access solution with a rigid platform to provide a flat “factory floor” surface that enabled workers to hoist and install the pipeline, while inspectors followed closely behind. The pipeline no longer needed to be added section by section with a crane and barge. Using a suspended access solution with a rigid platform sped up productivity by more than 35 percent creating significant savings.

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Specialty Commercial Structures: Atriums, Domes, Aquatic Centers, Airports and More

Specialty commercial structures often require a customized approach. Usually heavily trafficked, these facilities can prove to be costly to maintain and repair – especially when the structure’s main use is interrupted in the process. If the maintenance work or repair requires supported scaffolding to be erected to reach high elevations within a structure, erection and disassembly of the scaffold can prove to be disruptive to regular activities at the location. Multi-point suspended scaffolding with rigid platforms can offer a safe and effective means of providing work surfaces for repairs well above any regular activities, without the interruption of a structure’s use.

Catenary suspended scaffolds cannot be easily adjusted or configured to fit commercial structures other than bridges due in large part to the installation techniques. Installing catenary scaffolding on commercial projects would be next to impossible without tying into the structure horizontally. In addition, the flexible platforms, such as chain-link material, would not be an effective barrier to keep pedestrians and others below the work surface safe. They also do not lend themselves to material movement or support the use of traditional scaffold on top of the deck.

Madison Square Garden RenovationMadison Square Garden, which takes up most of two city blocks in the heart of Manhattan in New York City, is host to numerous top-name events. Due for extensive renovations and upgrades, this unique structure required a customized approach to access. While some areas were able to tolerate a supported scaffold structure, often crews needed to work at elevated levels within the structure, while not disturbing the flow of business on lower levels. In addition, the floor of the arena had to be protected. The access company for the job engineered a combination of supported and suspended scaffolds together with several unique custom solutions to enable all work to be performed with a high degree of efficiency. A key challenge on the project was creating access on top of Penn Station, which is situated underneath Madison Square Garden and serves as a major New York City transportation hub. Workers needed to access areas of the arena above, while not disrupting the busy Amtrak station below. A suspended access system provided the perfect solution. A 15,000-square-foot platform was put in place and in use for over a year. Due to this innovative use of a suspended access system, the Amtrak station was able to operate safely without any interruptions, while construction and renovation work was performed above.

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Zinc Roaster Dome Access ChallengeWhen Nyrstar, a leading global multi-metals company, needed access to a 43-foot-wide by 71-foot-tall zinc smelting roaster dome, in Clarksville, Tenn., their primary concern was worker safety. To make the necessary renovations on the roaster dome, which was expected to add another 30 years to the lifespan of the roaster, the refractory brick that lines the dome had to be replaced. After 33 years of enduring temperatures as high as 1,700 degrees Fahrenheit, Nyrstar safety officials didn’t want workers directly under the 65-pound bricks during renovation, for fear they could collapse. Knowing this at the start of the project, the access company for the project used a modular platform access system. This allowed all work to be performed from above instead of below the dome. The access solution involved cutting a hole into the top of the structure, and then lowering a small, circular starter platform. From this platform, the bricks around the leading edge were removed. As the bricks were cleared away, making the space larger, the platform was expanded to provide additional access. In total, the platform grew to 40 feet in diameter.

University of Virginia Aquatic CenterBuilt over 15 years ago, the University of Virginia Aquatic Center is home to an Olympic-sized pool – approximately 50 meters by 25 yards. Access to the entire ceiling was required when the air handling system needed repairs. Safway Services, the access company hired by the contractor, installed a work platform utilizing 22,000 square feet of QuikDeck®, a suspended access system, and 8,000 square feet of Systems™ Scaffold. This allowed multiple tradespeople to operate side-by-side and access the ceiling, without needing to drain the pool, which would have been necessary if a traditional scaffold structure was used for access.

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Industrial ApplicationsPower Generation Facilities Power generation facilities – coal dust combustion boilers, nuclear power plants, hydroelectric dams and thermal stations – include an array of unique structures that demand regular maintenance, repair and updating. These projects, which can range from a concentrated job in a targeted area to a full shutdown and turnaround, are usually performed under strict deadlines, with tight budgets and require a workforce that has industry-specific knowledge and experience. In addition, the Department of Energy (DOE), the Environmental Protection Agency (EPA), OSHA, and the Federal Trade Commission (FTC), all oversee policy and regulation for power generation facilities and have guidelines that must be followed.

Coal dust combustion boilers are prime examples. These boilers contain numerous large tubes that carry thousands of pounds of water, that when heated turns into steam. Over time the tubes erode and need repair, and the shape of these boiler structures and spaces often require unique access solutions. Many times supported scaffolding is built up inside the boiler. Increasingly, however, suspended access solutions have been safely used to reduce downtime and cost. This is especially true when work only needs to be performed at the upper levels of the boiler.

Boiler Access Solution Cuts Budget by HalfBy utilizing a suspended access solution inside the boiler of a 650-megawatt unit in the Ohio Valley, significant time and money were saved. By creating a platform inside the boiler 180 feet in the air, which was suspended from chains and supported by existing steel beams, instead of using a supported scaffold solution, the total budget for the job was cut in half and the overall timetable was reduced.

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Off Shore Rigs and Ships Stringent safety guidelines in the maritime industry make the need for regular maintenance a given. OSHA, the US Coast Guard, the Bureau of Ocean Energy Management (BOEM), the EPA, and International Safety Management (ISM), are just some of the governing bodies that designate codes and regulations that offshore rigs and ships need to take into consideration. Often maintenance on these rigs and ships require that workers perform repairs beneath the level of the deck on the outside of these structures under tight deadlines. In these instances, suspended access systems have proven to be an ideal solution.

Offshore Rig Access Saves Critical TimeA contractor based out of Canada needed an access solution that would allow workers to perform maintenance and repair on an offshore oil rig. Using multiple products, including a suspended access system, along with more traditional scaffold and high-capacity personnel hoists, a solution was engineered that reduced the installation time by half. A barge was used to float a starter platform out to the offshore rig. Once the starter platform was in place, rig winches were used to lift the platform into the air. Once there, workers were able to build the rest of the suspended platform in the air.

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Saving Time and Money on Primary Separation Vessel MaintenancePrimary separation vessels are large funnel-shaped vessels about 100 feet in diameter that extract oil from sand. A primary separation vessel produces approximately 90,000 barrels of oil per day, so when scheduled maintenance makes a shutdown necessary, oil company managers need highly efficient solutions.

During a recent shutdown at a refinery in Alberta, Canada, a suspended access system proved to be an ideal solution. The product’s unique ability to be engineered to fit any shape allowed the suspended scaffold to efficiently fit inside the round vessel. The customer’s turnaround time for the maintenance project was lowered from 16 days to five, saving the customer no less than $96 million.

Petroleum Facilities The oil refining industry continues to face tough challenges. Many refineries are forced to run at high volumes with as little downtime as possible. Maintenance is sometimes delayed to meet increased demand. Due to these circumstances, it is critical that any maintenance or repair work – especially if a shutdown or turnaround is required – be executed in a safe and highly efficient manner. With the use of suspended access solutions, some petroleum refinery companies have saved time and rental or purchasing fees, ultimately reducing costly shut-down time.

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Finding the Right Access PartnerAccess and scaffold providers that not only supply a complete line of complimentary products but also have broad experience, as well as the knowledge and skills unique to an industry, are essential to maximizing the efficient use of any suspended access system. Every project within the industrial and commercial markets is unique. Using an access provider that can offer custom solutions, take a project from the planning stages through execution, management and wrap-up, and at the same time provide comprehensive safety and training, is often the key difference in increasing productivity and profit margins. When considering a suspended access solution, you also will want to look at the provider to see what kinds of support service they offer and how they perform in the following areas:

Safety Safety is one of the most important considerations when doing work that requires rigging and suspension. According to OSHA, fall protection has received the highest amount of citations in the industrial and commercial markets (OSHA 1926.501). In fact, as you can see in the chart below, fall protection citations were listed as one of the top three cited violations over a three-year period. In 2011, 6,274 inspections were performed by OSHA, and 7,275 citations were given. Often a single job site

was issued more than one citation.In light of numbers like this, it is important to think about how new construction and maintenance can be performed with multi-point suspended scaffolds as safely as possible. With tight budgets already in place, no company can afford to pay the fines for having unsafe practices or work environments. To reduce the chances of being fined, safety must be emphasized and training must be sought. It is imperative that key decision-makers in the construction industry look at their access company’s track record in safety, as well as the guidelines they have in place to support safe practices and job sites.

Training Training is invaluable to increase efficiency and ensure safety. Providing product training allows equipment users to perform their jobs quickly, safely and with the best possible results. Be sure to ask any potential access company about the various training options available to accommodate your specific project needs.

Engineering and PlanningIn many instances, when working with suspended access products, engineering and design are critical to saving time and money, while increasing safety and overall efficiency. Before you partner with an access company on any project, consider the size and depth of their engineering support.

Seek an access solutions partner that has a solid staff of licensed civil, structural and mechanical engineers, as well as state-of-the-art Computer-Aided Design (CAD) and structural analysis

software for optimum performance. Then be sure to allow sufficient time to plan ahead.

Rental, Sales and InventoryNeeds vary from company to company and project to project. Some require only occasional access, while others may need it on a regular basis. Turnkey solution providers that seek to accommodate individual organizational needs provide a multitude of products for rent and/or purchase. In addition, consider product availability through branch locations and regional distribution centers with the capability to efficiently schedule delivery of equipment with minimal transportation costs and time.

Project Tracking Systems and AccountabilityBy providing comprehensive data about your project from start to finish, an access solution provider can offer real-time information about equipment, inspections, labor and productivity for increased cost transparency. Good project tracking systems allow managers to monitor and capture data about every aspect of any job. This includes:

• On-site scaffold and equipment productivity• Types of equipment utilized• How the equipment is being used• Inspections• Cubic foot rate• Dismantling status• Total labor hours/employees’ daily time• Historical data for future reference

Having access to this data increases efficiency, eliminates non-productive time, decreases the need for modifications and inventory, and helps minimize your project costs.

Fall Protection

Years 2009 (Oct-Sep)

2010 2011 2009 to 2011 Comparison

# Inspections 7,358 7,584 6,724 8%# Violations 7,139 8,010 7,725 2%

Penalty Amount $9,816,313 $16,156,231 $23,612,158 140%

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Choosing the Best Suspended Access System for Your Project

Performing on tight budgets has forced many companies to search for access and scaffold providers that produce safe, effective, creative and low-cost solutions. Through the innovative use of suspended access systems, numerous companies have been saving significant time and money on projects, while also enhancing safety. Key factors to be considered in using suspended scaffolds are product compatibility, training, ease of installation and dismantling, safety and pricing. In addition, to get the most out of any suspended access system, you will want to work with a scaffolding company that is able to provide innovative, turnkey solutions to resolve project challenges along with a full line of complementary products, a strong record in safety, excellent training, engineering support, project-tracking and accountability. Multi-point suspended scaffolding access solutions with rigid platforms provided by turnkey access solutions providers safeguard personnel and the public, as well as a company’s profit margin.

Jerry Dolly is the manager of the Bridge Division at Safway Services, which provides QuikDeck®, a suspended access solution, for use in commercial and industrial applications. Founded in 1936, Safway Services is headquartered in Waukesha, Wis. Through its network of approximately 85 branch locations in the U.S. and Canada and a system of distributors across South America, Safway provides scaffolding and access solutions for commercial construction, industrial and infrastructure applications. As an industry leader, Safway provides sales, rental, labor services, training, engineering, design, safety and project management. With an extensive inventory and a full line of access products, Safway experts design and implement safe, economical access solutions for projects of any size and scope. For additional information, visit www.safway.com.

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• QuikDeck® is multi-point suspended scaffold with a solid working platform, enabling employees to work effectively without being hindered by a flexible platform.

• QuikDeck’s® unique design allows it to be assembled from a few basic components and configured to fit almost any shape or size.

• When purchased, the QuikDeck® suspended access system provides better long-term ROI. QuikDeck® is composed of galvanized metal making its components' lifespan five times longer than its competitors.

• Engineering design and assistance is readily available at low cost. • QuikDeck® can also be combined with other scaffolding access

solutions. This provides the opportunity to approach difficult access situations with dynamic and creative solutions.

• QuikDeck® is designed to meet OSHA required weight bearing ratios of 4:1 and can be configured to up to 150 pounds per cubic foot for uniform live load ratings.

• Safway’s QuikDeck® suspended access division also has a diversified workforce with in-depth knowledge of the product line, all safety regulations that apply to suspended scaffolding, and extensive knowledge of different market segments and their access needs.

• Safway also provides international access through 90 plus locations. This allows Safway to provide quality labor, products and services at any time and from anywhere.

• Safway’s QuikDeck® suspended access system saves valuable dollars through an innovative, patented, cantilevered erection technique, allowing the suspended access system to be "built in the air."

• QuikDeck® can also be “leapfrogged” to allow crews to complete jobs in sections and reduce equipment costs.

• With 5,000 square feet of QuikDeck® platform per flatbed truck, shipping costs are greatly reduced.

QuikDeck® Suspended Access System

Safway Services, LLC Scotia - Glenville Industrial Park, Bld. 406 Toll free: (800) 582-9391 Telephone: (518) 381-6000

QuickDeck® System CapacitiesPlatform Self Weight

"Dead-Load" 7lb/ft2 (35Kg/m2)

Multi-Point Suspended Scaffold Applications (Man-Riding)

Maximum Rated Capacities

Protective Shield Applications (Non-Man-Riding)

Maximum Capacities

Suspender Grid Nominal

Configurations

16 ft (4.88m) X

16 ft (4.88m)

8 ft (2.44m) X

16 ft (4.88m)

8 ft (2.44m) X

8 ft (2.44m)

8 ft (2.44m)X

16 ft (4.88m)*

8 ft (2.44m)X

16 ft (4.88m)

8 ft (2.44m) X

8 ft (2.44m)*

Uniform Live Load Rating

25 lb/ft2

(122 Kg/m2)50 lb/ft2

(244 Kg/m2)75 lb/ft2

(366 Kg/m2)100 lb/ft2

(488 Kg/m2)125 lb/ft2

(610 Kg/m2)150 lb/ft2

(732 Kg/m2)

*Chain is two-parted in this configuration

ORN 1880 2/13

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working with suspended access systems

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