Case Study: Custom Industrial Catwalk Installation for Outdoor Tank Access

Industrial Catwalk Provides Safer, Long-Lasting Solution in Harsh Outdoor Conditions

A leading industrial manufacturer’s facility faced a critical safety issue: the existing ladder access to its outdoor storage tanks had become dangerously corroded and unstable. These tanks, which store food-grade additives, require routine cleaning and maintenance, but the current access setup posed a significant risk to crews.

The facility team turned to Warehouse Optimizers, Inc. (WOI) for a custom-engineered industrial catwalk solution that would provide safe, long-term access to each tank in the cluster while withstanding the harsh outdoor conditions.

Solution: A Galvanized, Octagonal Catwalk with Built-In Safety

WOI delivered a custom, galvanized catwalk and stair access system, purpose-built to solve the unique challenges of the job site:

Material Selection for Durability

The entire structure was hot-dip galvanized to resist corrosion caused by weather exposure and chemical vapors. This ensures lasting structural integrity and minimizes maintenance over time.

Custom Layout

Instead of a straight or circular path, WOI’s team engineered a unique shape that allows safe, direct access to each tank from a central platform. This configuration keeps workers closer to the tanks for more efficient cleaning and inspection.

Precision Installation Over Uneven Terrain

One of the biggest challenges was the uneven cement platform beneath the tanks. To achieve a perfectly level walking surface, the team custom-shimmed each support column, taking multiple site measurements and completing several iterations to ensure the highest level of accuracy.

Integrated Safety Features

Multiple tie-off locations were built into the catwalk structure so that maintenance crews could secure themselves before working near or inside the tanks. This feature directly supports the facility’s commitment to OSHA-compliant work environments.

Seamless Navigation Around Obstacles

WOI’s layout had to consider and work around existing site structures, which required precise planning and on-the-fly adjustments during installation.

Outcome: A Safe, Durable Access Platform Built to Last

Thanks to the WOI team’s meticulous planning, experienced field crew, and commitment to safety, our customer now has a fully operational and safe access system for their outdoor tanks. The industrial catwalk not only enhances worker safety but also streamlines routine maintenance and cleaning operations, adding long-term value to the facility’s operations.

Why WOI? Your Trusted Partner in Installation Excellence

At Warehouse Optimizers, Inc (WOI), safety is our top priority. A poorly installed system can endanger employees, inventory, equipment, and infrastructure. That’s why WOI provides professional installation services to ensure the integrity and security of your warehouse and industrial systems.

With over 300 installations completed annually, our experienced team handles everything from permitting to final signoffs, ensuring seamless project execution.

WOI Professional Installation Includes:

• OSHA-Trained Project Managers
• Drug-Free Workplace Certification
• Daily Job Safety Analysis and Jobsite Inspection
• Authorized and Trained Forklift, Scissor Lift, and Aerial Lift Operators
• TN & AL Licensed General Contractor #00046536 ($1M License)
• Insurance Experience Mod. Rate 1.0
• Full Insurance with a $5M Umbrella

The WOI Total Satisfaction Experience™

When you partner with WOI, you gain more than just design and installation expertise—you receive a dedicated team committed to your success. The WOI Total Satisfaction Experience™ is built on five key principles:

1. Listening to Your Needs – We take the time to understand your unique challenges and requirements.
2. Executing with Precision – Our expert team ensures your system is tailored to exact specifications.
3. Adhering to Timelines – We respect project deadlines to minimize disruptions and maximize efficiency.
4. Ensuring Safety – Every aspect of our work prioritizes safety for your employees and operations.
5. Attention to Detail – We meticulously oversee every phase of the project to deliver a flawless result.

Improve safety and operational efficiency with WOI’s custom design and installation services. How can we solve your challenges? Let’s schedule a consultation and get started on your next project.

WOI Service Areas

Nashville TN, Knoxville TN, Clarksville TN, Memphis TN, Chattanooga TN, Johnson City TN, Huntsville AL, Birmingham AL, Bowling Green KY, Asheville NC, Charlotte NC, Kalamazoo MI, South Bend IN