Apopka, Florida // Engineering & Manufacturing // Est. 2004

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Fuel farm access system modernization

Orlando International Airport (MCO) Fuel Farm Access System Modernization

MCO’s fuel operations team needed to solve an access challenge across its fuel farm — not by replacing existing infrastructure, but by connecting isolated platforms into one seamless, OSHA-compliant network. JE engineered a galvanized steel system that maximized the value of existing investments.
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See the route
Project record
In service
Connected, not replaced
existing platforms kept and extended
Facility MCO fuel farm
Material Hot-dip galvanized steel
Scope Connective walkways only
  • Orlando International Airport · fuel farm
  • Hot-dip galvanized steel
  • Interfaces with existing platforms
  • Commercial airport facility
01
The challenge

Four Platforms, and No Way Between Them

The fuel farm’s pumps and equipment were served by fall protection platforms installed over time as disconnected sections rather than a unified network. Maintenance personnel repeatedly climbed up and down between areas and crossed over horizontal piping — inefficient, non-continuous, and not fully aligned with current OSHA requirements.
TRAVEL ROUTE ACROSS THE FARM // ELEVATION
3 BREAKS VS 0
BEFORE Four sections, three breaks in the route
4 ISOLATED SECTIONS GROUND RETURN AT EACH GAP

Every gap meant climbing down, stepping over the pipe, and climbing back up.

AFTER The same four sections, bridged at deck height
ONE CONTINUOUS NETWORK BRIDGED ABOVE THE PIPING

One continuous route from end to end — no descent, no pipe crossing.

Ground level
Horizontal piping run
Existing platform section
New connective walkway
Route walked before: down, over the pipe, back up

The four existing sections are unchanged in both views. What JE added is the three walkways that bridge the gaps at deck height — so the route runs end to end without touching the ground.

Constraint 01

Disconnected Legacy Platforms

Existing sections functioned independently rather than as one network.

Constraint 02

Inefficient Travel Routes

Personnel repeatedly climbed down and back up, crossing piping between pumps.

Constraint 03

Partial OSHA Alignment

Existing infrastructure didn’t fully meet current compliance requirements.
02
The solution

Engineered to Interface, Not to Replace

JE designed and installed a custom galvanized steel access system that connected the previously isolated platform sections into one continuous, OSHA-compliant elevated network — engineered to interface directly with the existing infrastructure rather than replace it, preserving the customer’s prior capital investment.
Each constraint answered by a design decision

Constraint 01

Existing sections functioned independently rather than as one network.

Design decision

Integrated Platform Connectivity

Custom walkways connected previously isolated platform sections, engineered to interface directly with the existing structures rather than replace them.

Constraint 02

Personnel repeatedly climbed down and back up, crossing piping between pumps.

Design decision

Continuous Elevated Route

Bridging each gap at deck height removed the ground return entirely — technicians cross above the piping instead of stepping over it.

Constraint 03

Existing infrastructure didn’t fully meet current compliance requirements.

Design decision

OSHA-Compliant Fall Protection

The entire access route was upgraded to meet current requirements — not only the new connective sections.
Why hot-dip galvanized steel

An outdoor fuel farm is a corrosion environment that never lets up.

Galvanized steel was selected for long-term corrosion resistance in an outdoor industrial environment — the same reasoning that puts marine alloys on JE’s harbour work, applied to a fuel facility in Florida.
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03
Operational impact

A Continuous OSHA-Compliant Network, Built Without Replacing Existing Infrastructure

Technicians can now travel across the entire fuel farm without repeatedly returning to ground level, no longer stepping over piping systems, with every pump and maintenance point connected through one continuous access network.

No trip to ground

Improved Efficiency

Continuous access significantly reduces travel time between work locations.

Feet stay on deck

Enhanced Safety

Eliminates the need to cross piping or navigate inefficient access paths.

Nothing torn out

Extended Infrastructure Life

Enhanced existing assets rather than replacing them, preserving prior capital investment.
JE connected every previously isolated platform section at the MCO fuel farm into one continuous access network — upgrading the entire route to current OSHA compliance while preserving and extending the life of existing infrastructure.
05
Technical & operational FAQ

Frequently Asked Questions

Q01

Did this project require replacing the existing platforms?

No — JE engineered new connective structures designed to interface with and extend the existing infrastructure rather than replace it.
Q02

What material was used for the new structures?

Hot-dip galvanized steel, selected for long-term corrosion resistance in an outdoor industrial fuel farm environment.

Let's Turn Your Requirements Into a Solution

Platforms that don’t connect to each other? The fix is usually the gaps, not the platforms.
Process facilityAccess threaded through what is already there.
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