Fall protection systems are required by OSHA for any work platforms in a facility that are elevated over four feet. Dual-gate safety solutions are often the best method of creating a permanent safe environment. To select the right mezzanine safety gate solution for your area, you need to review the available space in your area, the size of the pallets being moved and the procedure for loading and accessing the material. But, there is another decision that has to be made before selecting the proper safety device - what the safety gate will be made of and how it will be finished or painted.
To select the right construction material for the safety gate, review the environment in which the gate will installed to determine if the area has any specific requirements.
In a basic warehousing or material handling environment where palletized material is lifted to an upper level and picked or moved with pallet jack, painted mild steel is often the right choice. This is an economical and durable solution. Most manufactures use a powder-coating process over wet paint for a more durable finish that will not flack or crack.
We recommend using a two-color scheme in opposing colors so the moving components stand out from the stationary parts. This helps increase safety awareness for the employees working around the ledge. For example, we powder-coat our Roly Model frames silver, with safety yellow for the gates, and our Pivot Model frames in blue with yellow gates.
Sometimes it is preferable for the safety device to blend in to the facility environment, so it’s possible to select a custom color to match existing guardrails or rack structures. In other instances, it’s advantageous to select a custom color that clashes with the surrounding area, again for safety. For example, one of our customers paints everything blue and yellow in their facilities, but requests the pallet drop gates be painted red in order for the areas to stand out as potential hazards.
The key to selecting color for your safety systems is to take a look at your surroundings to determine what should blend in and what should stand out. Then, talk to your safety gate supplier to work on color schemes that fit your needs. Most companies have several colors to choose from or can match colors with RAL numbers.
Some facilities may have sanitation requirements that do not allow any type of paint, whether powder coat or wet. Some of these areas may be able to use mild steel equipment with specialty finishes such as Steel-It Paint, which includes FDA approved stainless steel pigments. For food or processing plants it is imperative to review the specific sanitation requirements for each area and to communicate those requirements to the safety gate supplier.
Many processing plants feature applications in which ingredients are moving through the pallet drop area. In these instances, stainless steel is often the best choice as it allows material to be washed down and cleaned without concern of flaking or chipping paint contaminating the ingredients.
When it comes to stainless solutions, some designs work better than others. It’s ideal to have as few moving parts as possible, and necessary to be able to clean all of its components without allowing water to enter the structure where it cannot fully drain.
For our units constructed in stainless steel, the entire design is fabricated out of 305 stainless steel with all stainless hardware. All open ends are capped to prevent water and debris from entering the system. When required, we can use continuous welds, and eliminate any bolts holes in the tubing. And before shipping the unit to the facility, we electro-polish the entire unit to remove any burn marks from the welding process in order to ensure installing the cleanest system available.
If your application uses caustic material, galvanized steel or aluminum gates may be required. We can also construct the safety gates from these materials to match the other equipment in the facility.
The key to making sure your safety system is constructed out of the right material is to review the specific requirements with operations, maintenance and safety teams to determine the specific requirements are in the facility so those features are designed into the gate system. We've had some pretty extravagant requests when it comes to paint colors and construction over the years. If you have a special request, we can accommodate it.
Our story of turning custom safety gates into standard models in our product line continues with the history of our Open Top safety gate model. This model, like the others, was driven by a customer need that we saw in other facilities across many industries. We’re seeing a pattern - are you?
We were contacted by a major chemical company that had pallet drop areas on their production platforms that were unsafe because they were just using latch chains across the edge for fall protection. These chains were often left open, leaving workers exposed to falls from the ledge, and even created another safety hazard - the potential to trip over the chain when it was closed. The company’s safety team wanted to replace this unsafe situation with one of our dual-barrier systems that would ensure a fall protection barrier was in place at all times.
Our traditional dual-gate safety systems were quickly ruled out as an equipment choice because the operation used an overhead hoist. Up until that time, all of our standard safety gate models had overhead mechanics, which would have interfered with the customer’s operations. At this facility, hoists were used to lift super sacks from the ledge of the production platform and move them back into a hopper. It’s fairly common in chemical and food manufacturing plants to find the use of overhead devices, like vacuums or hoists, in these plant processing applications where bags of ingredients are blended. We knew that instead of asking the customer to change their operations, we had to design a system that would integrate with their application.
The safety gate that our team had to create for the customer’s facility needed to use two interconnected gates that would close one side while opening the other, without any overhead components that would integrate with the overhead hoist. This required a new dual-gate design that connected the gates off to the side After testing many prototypes, the Open Top Model was created.
The Open Top safety gate features ergonomically counterbalanced gates that make for easy operation. When the ledge gate opens to the side, the rear gate closes, preventing employees from falls off the platform. The gates are connected with solid torque shaft and hardened gears, which are housed in a metal enclosure to protect the components and to keep people’s hands away from the moving parts. Overhead vacuums or chain hoists can then access the pallet drop area and can pass through overhead. When the ledge gate is closed, it creates a fall protection barrier at the ledge, and the rear gate opens to the side, allowing employees to safely access the material. In addition to accommodating overhead obstructions, the Open Top is also a good solution if tall pallets are being loaded into the pallet drop area.
Our customer installed the Open Top model at their facility and were happy that the safety gates not only provided fall protection, but did not impede on production. Since the creation of the Open Top model, we've installed them in locations throughout the U.S. They are available in powder-coated mild steel or in all stainless steel construction. Open Top models can be fabricated in custom widths and depths and and are even available in ninety-degree configurations.