Design-build: a worthwhile solution for safety and cost

Design-build shouldn't mean reinventing the wheel. An industry leader in access and fall protection systems explains why custom and customized-standard systems are often a far superior choice to start-from-scratch designs that involve multiple contractors.   

by Ed Sullivan

Many materials handlers, manufacturers and service providers can attest – some from harrowing experience – that it's a bad idea to force-fit off the shelf solutions to meet their custom safe access or bulk loading requirements. 

It is a worse idea to procrastinate on needed access systems due to uncertainties about design and construction, to expose your plant to lower efficiencies and your people to needless hazards because you have concerns about effectively managing subcontractors. Yet it happens.

More than likely, the company that finds itself in either of these predicaments is simply lacking information. They need to know that design-build or customization of standard systems is the only practical and safe solution to many non-standard access situations.

"Some process managers and service providers are reluctant to consider design-built solutions because they assume that they will be expensive, time-consuming and involve a several different suppliers," said Gene Nelson, design engineer for Carbis Inc., a supplier of bulk loading and safe access systems. "They are unaware that design-build suppliers can provide turnkey solutions that are more than cost-effective in terms of added efficiency. Of course, safety concerns go way beyond economics."

Carbis is well qualified to address such issues. Company founder Samuel Carbis designed the first aluminum fire ladder in 1930. Since then the company has achieved legendary status in the fall-protection and bulk-loading industries. The Carbis product line includes modular bulk loading products such as gangways, rail gates and loading arms, plus a wide array of fall protection, safe access, spill containment and structural equipment.

"Just as with other industries, the real need today is for integrated solutions that often require the design-build-systems approach for customized 'one-of-a-kind' equipment that is tailored to specialized applications or unusual environments," Nelson said.

Design-build has become integral to Carbis operations. While offering a broad selection of standard bulk loading and access equipment, its vast experience allows it to specialize in providing turnkey, custom solutions to applications with special requirements ranging from fold-down railings to complex terminal facilities.

For example, a company came to Carbis with a problem where there wasn't sufficient room for a loading platform to be placed between two rail spurs where loading and offloading was to be conducted. However, since the spurs still needed to be utilized, the company requested that Carbis design and build a system for them to access hopper cars on each of the two rails. The solution included a portable unit that was placed between the two rail spurs and was equipped with a power system that enables the unit to move forward and backward on a special track. This design-build solution not only allowed the company to make huge gains in operating efficiencies, but also saved an expensive investment and delays in reconfiguring the loading terminal.

"The hopper loading system allowed our customer to perform a critical operation where there simply wasn't room for a standard solution," Nelson explained. 

He added that Carbis also designed similar portable units that were not self-powered, but towed by a forklift or truck into the desired position. One such installation required a fully self-contained unit complete with safety shower, unloading pumps, air compressors and access equipment to load and unload rail cars and tank trucks from the top. 

"With our experience in bulk loading terminals, even complex design-build projects are often a matter of proving the right combinations of technologies and equipment," Nelson said.

Nelson pointed out that fall protection and access equipment also often requires customization that can benefit customers through added convenience, efficiencies and safety. For instance, a major food and material handling conglomerate recently needed a way to better control the loading and equipment passed up and down an elevator shaft in one of its facilities.

"The equipment was carried in a basket that was raised and lowered on a cable attached to a crane," said Nelson. "The basket was pulled by hand from the shaft into the needed position and then lowered to the floor, a cumbersome and hazardous operation." 

To solve the problem, Carbis designed and fabricated a self-contained cart with wheels and gangway, which eliminated the need for workers to haul the suspended basket into needed position. When not in use, the gangway pivots up out of the way to become a protective railing.

"More often than truly customized equipment, Carbis loading and protection solutions require modification of standard equipment," said Nelson. "Although normally less expensive, such equipment may be even more cost-effective and important to safety."

Carbis furnished such a modified-standard solution when a major aerospace corporation requested custom equipment for maintenance access to its Space Shuttle simulators. 

The needed equipment required an aluminum platform, which was designed for easy assembly and disassembly, plus railed ladders and folding cross-brace members. The unit can be transported to various locations by engaging retractable swivel castors mounted to each ladder base. Adjusting the height of the platform is as simple as removing pins, repositioning the ladders and reinstalling the pins.

Nelson said that both fully-customized and modified-standard loading, access and fall protection systems can be designed, fabricated and installed much more quickly than many customers expect. Design time can require as little as one or two weeks, and turnkey fabrication and installation time typically involves eight to 12 weeks.

"Of course, improved productivity and profits gained by added efficiencies and throughput are usually the main issues," said Nelson. "But then safety is always important. Anything less than a perfect safety record can dramatically affect the bottom line. If an accident occurs, not only will a skilled employee be injured, but the loading or access system design may be questioned, possibly even involving OSHA."

Clients today want projects designed and built on fast-track schedules. The pressures for reduced project cycles sometimes results in construction beginning while the project is still in the design process. This can be a big mistake. Many business owners are seeing that their businesses are changing so quickly – including outsourced functions such as building bulk loading facilities – that early decisions now carry a greater financial risk.

Delivering the system needed on time usually entails more problems when there are multiple contractors in play. However, when companies engage the services of qualified design-build firms, the design-build cycle can be greatly reduced and executed almost simultaneously.

In addition to all the conceptual, engineering and construction work, qualified design-build suppliers can offer important value-added advantages to clients. For example, Carbis will train operators for a bulk loading facility, evaluate emerging safety issues and work proactively with OSHA on the state and federal levels on training and compliance issues. 

Carbis is a premier manufacturer of customized bulk loading/safe access equipment and structural steel components. For more information about Carbis bulk loading solutions, contact Carbis, Inc. at or visit the Web site at www.carbis.net. 

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