For example:
1. A large machine is installed.
2. Pipework is added.
3. Electrical equipment is installed.
4. Maintenance access is considered afterward.
5. A narrow platform is added around the equipment.
This approach can create difficult access arrangements.
A better process is:
Equipment Layout → Maintenance Requirements → Access Route → Platform → Stairs/Ladder → Edge Protection
This allows access requirements to influence the design from the beginning.
AS 1657:2018 AND INDUSTRIAL MAINTENANCE
Maintenance personnel often work in areas that normal operators rarely visit.
This can include:
– Roof spaces
– Elevated platforms
– Machinery platforms
– Pipe racks
– Processing equipment
– Plant rooms
– Service areas
These locations may be more challenging than normal working areas.
A properly designed fixed access system can make maintenance activities more predictable and reduce unnecessary exposure to fall hazards.
COMMON ACCESS DESIGN PROBLEMS
PROBLEM 1: ACCESS ADDED TOO LATE
When access is treated as an afterthought, available space may be insufficient.
PROBLEM 2: EQUIPMENT BLOCKS THE ROUTE
Pipes, cables, ducts or machinery can reduce available clearance.
PROBLEM 3: INCONSISTENT STAIR DIMENSIONS
Variations can make movement less predictable.
PROBLEM 4: POOR TRANSITION BETWEEN LADDER AND PLATFORM
The point where a worker leaves a ladder and enters a platform requires careful design.
PROBLEM 5: MISSING OR INADEQUATE EDGE PROTECTION
Open platform edges can create fall hazards.
PROBLEM 6: POOR SURFACE CONDITION
Corrosion, contamination or deterioration can affect the usability of a walkway.
PROBLEM 7: INSUFFICIENT MAINTENANCE SPACE
Workers may be able to reach equipment but cannot safely perform the required maintenance task.
DESIGNING AN AS 1657:2018 ACCESS SYSTEM
A practical design process can follow these steps.
STEP 1 — IDENTIFY THE TASK
Determine why workers need access.
Is the purpose:
– Inspection?
– Operation?
– Cleaning?
– Maintenance?
– Repair?
– Emergency access?
STEP 2 — DETERMINE FREQUENCY
Frequent access may require a different solution from occasional access.
STEP 3 — MAP THE ROUTE
Identify the complete path from the normal working area to the destination.
STEP 4 — SELECT THE ACCESS TYPE
Consider whether the location requires:
– Stairways
– Ladders
– Platforms
– Walkways
– Landings
STEP 5 — ADD EDGE PROTECTION
Consider handrails, guardrails and other relevant protective features.
STEP 6 — CHECK CLEARANCES
Review the relationship between the access system and surrounding equipment.
STEP 7 — REVIEW THE FINISHED INSTALLATION
The final system should be assessed as a complete access arrangement rather than as individual components.
INSPECTION OF EXISTING FIXED ACCESS SYSTEMS
Existing access systems should not be ignored simply because they were installed many years ago.
Regular inspection can identify:
– Corrosion
– Cracked welds
– Loose fasteners
– Damaged grating
– Bent components
– Missing handrails
– Damaged ladders
– Deteriorated surfaces
– Structural movement
– Unauthorised modifications
The inspection should consider both the physical condition and the current use of the access system.
A system that was suitable ten years ago may no longer be appropriate after equipment or building modifications.
WHAT SHOULD BE CHECKED DURING AN ACCESS INSPECTION?
A practical inspection can consider several areas.
STRUCTURE
Check for:
– Corrosion
– Cracking
– Deformation
– Damaged connections
– Loose components
WALKING SURFACE
Check for:
– Damage
– Excessive wear
– Slippery contamination
– Missing sections
– Deterioration
STAIRWAYS
Check:
– Step condition
– Consistency
– Handrails
– Guardrails
– Landings
LADDERS
Check:
– Rungs
– Side members
– Connections
– Access points
– Surrounding clearance
PLATFORMS
Check:
– Platform condition
– Edge protection
– Access openings
– Structural support
– Working clearance
AS 1657:2018 FOR NEW CONSTRUCTION PROJECTS
For a new industrial facility, access should be considered during the engineering and architectural design stages.
A coordinated design process may involve:
Structural Design
↓
Equipment Layout
↓
Maintenance Planning
↓
Access Design
↓
Stairways and Ladders
↓
Platforms and Walkways
↓
Guardrails and Handrails
↓
Inspection and Commissioning
This approach can reduce expensive modifications later.
AS 1657:2018 FOR EXISTING FACILITIES
Existing facilities can present a different challenge.
Older access systems may have been installed under previous requirements or modified multiple times.
A practical assessment can begin with:
– What access systems exist?
– What equipment do they serve?
– How frequently are they used?
– Have they been modified?
– Are there visible defects?
– Are access routes obstructed?
– Have surrounding conditions changed?
– Is the current arrangement still suitable?
This can help identify areas that require detailed engineering review.
WHY COMPLIANCE SHOULD NOT BE TREATED AS A CHECKBOX
A common approach to standards is:
Compliant / Non-Compliant
However, access safety requires more context.
A technically compliant component can still be affected by:
– Poor maintenance
– Environmental contamination
– Equipment changes
– Obstructions
– Corrosion
– Unauthorised modifications
Therefore, effective access management should combine:
Design + Installation + Inspection + Maintenance + Change Management
AS 1657:2018 QUICK REVIEW CHECKLIST
ACCESS ROUTE
– Is there a clear route to the work area?
– Is the route suitable for its intended frequency of use?
– Are there unnecessary obstacles?
PLATFORMS
– Is the platform suitable for the intended task?
– Is the walking surface maintained?
– Is appropriate edge protection provided?
WALKWAYS
– Is the route clear?
– Is the surface suitable for the environment?
– Are changes in level properly addressed?
STAIRWAYS
– Are steps consistent?
– Are handrails and guardrails in good condition?
– Are landings appropriate?
LADDERS
– Are ladders structurally sound?
– Are rungs and connections secure?
– Is the transition to the destination safe?
MAINTENANCE
– Is corrosion controlled?
– Are damaged components repaired?
– Are modifications recorded?
– Are inspections documented?
FREQUENTLY ASKED QUESTIONS
What is AS 1657:2018?
AS 1657:2018 is an Australian Standard covering fixed platforms, walkways, stairways and ladders that provide access to and within workplaces.
Why is AS 1657 important?
It provides a recognised framework for designing and constructing fixed access systems intended to support safer movement and work in industrial environments.
Does AS 1657 apply to ladders?
Yes. Fixed ladders are one of the access systems covered by the standard.
Does AS 1657 cover platforms?
Yes. Fixed platforms used for workplace access and related activities are included within its scope.
Does AS 1657 cover handrails and guardrails?
Handrails and guardrails form important parts of the access systems addressed by the standard.
Can AS 1657 be used for existing access systems?
The standard is commonly considered when assessing fixed workplace access systems, but the applicable requirements for an existing installation can depend on the project, jurisdiction, legislation and circumstances.
Is AS 1657 only for factories?
No. Fixed workplace access systems can be found across many industries, including manufacturing, mining, energy, utilities, processing plants and other industrial environments.
FINAL THOUGHTS
AS 1657:2018 is fundamentally about providing practical and safe fixed access to workplaces.
The most effective access system is not necessarily the one with the largest platform or the most complicated design.
It is the system that allows workers to reach their destination, perform the required task and return safely.
Good access design should therefore consider the entire journey:
Where does the worker start?
How do they get there?
What obstacles exist along the route?
What work needs to be performed?
How do they safely leave the area?
For industrial facilities, incorporating these questions into the design, inspection and maintenance process can help create more reliable fixed access systems.
AS 1657:2018 should be considered as part of a broader workplace safety and engineering process, together with applicable legislation, building requirements, structural considerations and site-specific risk assessments.
Safe access begins with good design — and continues with regular inspection and maintenance.
ARTICLE MT-21
INSERVICE PULSED EDDY CURRENT TECHNIQUE FOR
CORROSION SCREENING
MT-2110 SCOPE
This Article specifies requirements for inservice pulsed
eddy current (PEC) examination of components constructed
from ferromagnetic materials for detection of
corrosion or erosion or both.
When specified by the invoking documents, the PEC examination
described in this Article shall be used together
with Article MT-1. Terms used in this Article are defined
in Article MT-1, Mandatory Appendix I, MT-I-121.13.
MT-2120 GENERAL
(a) PEC examination, as described in this Article, is an
examination of a low alloy carbon steel or cast iron component.
PEC examination is usually performed through a
cover. PEC examination is used to find areas with inservice
anomalies (typically corrosion or erosion) either
internally or externally.
(b) The PEC examination system consists of a probe
that contains a device for generating a (primary) magnetic
field and a device for detecting the secondary field
emanating from the component, resulting from eddy currents
generated by the primary field. The device used for
detection may be the same as the device used for generation
of the primary magnetic field.
(c) In common PEC examinations, the primary field is a
direct current (DC) magnetic field that is switched to generate
eddy currents. The time between switching, i.e., the
time for which the DC magnetic field is on, is called the excitation
pulse. Due to switching of the magnetic field, eddy
currents are generated. After switching the magnetic
field, the eddy currents will decay. The secondary magnetic
field is recorded and displayed on a graph. In a successful
examination, the characteristics of the shape of the
decay curve are extracted. These characteristics correspond
to the wall thickness of the component.
(d) PEC examination is usually performed as a relative
measurement, where the system is calibrated on a reference
spot on the component.
(e) PEC examination provides an estimation of volume
of material under a footprint area. Basic measurement
will yield a result roughly proportional to the average
wall thickness in the area in which eddy currents are generated.
The basics of PEC system operation are described
in Nonmandatory Appendix A to this Article.
MT-2121 WRITTEN PROCEDURE REQUIREMENTS
MT-2121.1 Requirements. PEC examination shall be
performed in accordance with a written procedure that
shall, at a minimum, contain the requirements listed in
Table MT-2121.1-1. The written procedure shall establish
a single value, or range of values, for each requirement.
MT-2121.2 Technical Feasibility Evaluation. Due to
the properties of PEC examination, a technical feasibility
evaluation shall be performed. This technical feasibility
evaluation shall comprise the following, as a minimum:
(a) an evaluation of the ability of PEC examination to
penetrate the cover. This shall be performed with theoretical
or practical methods.
(b) an evaluation of the ability of PEC examination to
detect anomalies sufficiently for the intended purpose
of the examination. This may be performed theoretically
or practically. The evaluation shall include a call level, a
level over which indications are recommended for followup
examination. The minimal detectable defect, as determined
in the technical feasibility evaluation, shall be
indicated.
(c) a trial measurement on the component. The test
measurements at the reference location (see MT-2151)
may be the same as the trial measurement, provided the
measurement results correspond to the results of (a)
and (b). Correspondence shall be reported.
MT-2121.3 Changes to Requirements. A change of a
requirement in Table MT-2121.1-1 identified as an essential
variable from the specified value, or range of values,
shall require revision of the technical feasibility evaluation.
A change of a requirement identified as a nonessential
variable from the specified value, or range of values,
does not require revision of the technical feasibility evaluation.
All changes of essential or nonessential variables
from the value, or range of values, specified by the written
procedure shall require revision of, or an addendum to,
the written procedure or scan plan, as applicable.
MT-2122 SCAN PLAN
A scan plan shall be developed. The scan plan shall address,
as a minimum, the items listed under scan plan in
Table MT-2121.1-1. Extent, location, and coverage of testing
shall be graphically shown, e.g., on isometric drawings
of piping or engineering drawings of the component, noting
testing locations
3.1.3 Method 2 – Passivation in Citric Acid
3.1.3.1 Bath Composition
Passivation shall be accomplished by immersion in an aqueous solution of 4 to 10 weight percent anhydrous citric acid (see 8.10). Additives such as wetting agents, inhibitors, and algicide or fungicide may be used as applicable. Other additives, such as ammonium hydroxide, may be used in order to stabilize or fix the pH of the bath as applicable.
3.1.3.2 Operating Conditions
Bath temperature shall be 70 to 160 °F (21 to 71 °C), with an immersion time of not less than 4 minutes for baths operating over 140 °F (60 °C), not less than 10 minutes for baths operating in the range of 120 to 140 °F (49 to 60 °C), not less than 20 minutes for baths operating in the range of 100 to 119 °F (38 to 48 °C), or not less than 30 minutes for baths operating below 100 °F (38 °C).
3.1.4 Rinsing
Immediately after removal from the passivating solution, the parts shall be thoroughly rinsed.
3.1.4.1 The final rinse shall be carried out in clean water (see 8.12), followed by drying.
SAE INTERNATIONAL AMS2700™G Page 6 of 13
3.1.5 Post-Treatment
When post-treatment is specified, directly after rinsing, parts made from ferritic, martensitic, or precipitation-hardening steels shall be immersed in a solution containing 4 to 6% by weight of sodium dichromate dihydrate (Na2Cr2O7·2H2O) at 140 to 160 °F (60 to 71 °C) for 1 hour, followed by rinsing and drying.
3.1.5.1 When post-treatment is not specified, see 8.2 for guidance.
3.2 Properties
3.2.1 Corrosion Resistance
Parts shall meet one of the following conditions or, when specified, a test in AMS-STD-753. When a test is not specified, any of these tests may be used. Parts containing 0.85% carbon or more (such as SAE 440C) shall be exempt from these tests.
3.2.1.1 Humidity Test
Parts shall be free from visible red rust after exposure to 95% minimum relative humidity at 100 to 115 °F (38 to 46 °C) for not less than 24 hours.
3.2.1.2 Water Immersion Test
Parts shall be free from visible red rust after alternately immersing in deionized or distilled water having an initial conductivity of 5 μS/cm or less for at least 1 hour and allowing to dry in room temperature air for at least 1 hour, until 12 cycles of immersion and drying have elapsed (see 8.13).
3.2.1.3 Copper Sulfate Test
A test solution containing 8 g of copper sulfate (CuSO4·5H2O) and 2 to 3 mL of sulfuric acid (H2SO4, sp. gr. 1.84) in 500 mL of high-purity water having a conductivity of 5 μS/cm or less (see 8.14) shall be applied to the part, or the part shall be immersed in the test solution. The part’s surface shall be kept wet for 6 to 6.5 minutes. Rinse and dry the surface without disturbing any deposits. Parts shall be free of any copper-colored deposits, which indicate the presence of unacceptable free iron. The effectiveness of copper sulfate solutions shall be validated by one of the following methods:
8.11 Guidelines for alternative passivation solutions that may be useful to the cognizant engineering organization are as follows:
8.11.1 Bath Composition
Passivation has been accomplished by immersion in a bath of an aqueous solution of 20 to 55% by volume of 42 degree Baumé (sp. gr. 1.4) nitric acid (HNO3) (see 8.10).
8.11.1.1 It is recommended that the concentration of the nitric acid be above 40% for free machining steels.
SAE INTERNATIONAL AMS2700™G Page 11 of 13
8.11.1.2 Where the acid concentration is less than 35% by volume and for ferritic and martensitic steels, it is recommended that additional oxidizers be added to the bath in the form of 2 to 6% by weight of sodium dichromate dihydrate (Na2Cr2O7·2H2O).
8.11.1.3 For the purpose of removing lead alloys from surfaces, molybdic acid (HMoO3) may be added to the bath at a concentration of up to 0.35 weight percent.
8.11.2 Operating Conditions
Bath temperature should be in the range of 70 to 155 °F (21 to 68 °C) with an immersion time of not less than 30 minutes for baths operating at temperatures below 100 °F (38 °C), not less than 20 minutes for baths operating at temperatures below 125 °F (52 °C), or not less than 10 minutes for baths operating at temperatures above 125 °F (52 °C).
8.11.3 For certain high-carbon corrosion-resistant steels, such as SAE 440C, it may be desirable to passivate with the parts anodic for 2 to 3 minutes at 2 to 3 V to prevent etching.
8.11.4 For local areas or where immersion is impractical, passivation has been accomplished by the use of thickened passivation solutions, such as pastes or gels, to maintain contact with stainless steel surfaces for the required time.
8.12 It has been found that water containing up to 200 ppm total dissolved solids may be considered to be clean, but this limit is not a requirement. Rinsing may be accomplished with stagnant, countercurrent, and/or spray rinses.
8.13 Distilled water may give more consistent results in the water immersion test compared to deionized water. Water used in the water immersion test will not maintain its initial conductivity during the test.
8.14 High-purity water may be prepared by distillation, ion exchange, continuous electrodeionization, reverse osmosis, electrodialysis, or a combination thereof.
8.15 It has been found that iron concentration in the passivating solution exceeding 2 weight percent may reduce the ability to remove iron contamination from parts.
Conditioner Additive STANDARD by General Motors Worldwide , 02/01/2024 What it covers
The standard defines requirements for a multifunctional diesel-fuel additive package intended for GM aftermarket use. It is designed to provide:
* Fuel-system lubricity improvement
* Corrosion protection
* Injector and engine cleanliness
* Fuel stability enhancement
* Cetane-number boosting
* Compatibility with low-sulfur and ultra-low-sulfur diesel
* Use with biodiesel blends up to B20 (20% biodiesel)
Defines the technical requirements and performance specifications for a multifunctional middle distillate fuel additive intended for General Motors aftermarket use.