How Rope Access Cut Costs for Refractory Lining Inspection in Half

MISTRAS’ Benicia, California rope access team recently delivered faster, safer, and more visible mechanical inspection by utilizing rope access and real-time camera technology in lieu of traditional scaffolding. 

The Challenge 

When a client required a visual inspection of their reactor/regen refractory lining, the obvious approach would have involved building extensive scaffolding throughout the vessel.

This method would have required:

• A large crew

• Multiple shifts

• High costs

• Additional safety considerations

Scaffolding can also create visual obstructions during inspections, and because it is mechanical in nature, it even carries the potential to cause additional damage inside the asset.

Rope Access: A Safer, Modern, Cost-Effective Approach 

However, the Benicia team approached the challenge differently. Initially tasked with eliminating fall hazards before scaffolding construction, the team recognized an opportunity to perform the inspection entirely through rope access, leveraging prior experience completing similar inspections.

The Results

Through rope access, the team completed the client’s reactor/regen visual inspection in a single 16-hour shift,  a process that would have traditionally required six to seven shifts using scaffolding. 

By eliminating the need for extensive staging and reducing the manpower requirement from roughly 10–15 personnel to a small team of 6 highly-skilled rope access technicians, the client benefited from:

• Significantly lower labor and setup costs

• Faster turnaround times

• Improved safety

• Reduced visual obstructions caused by scaffolding

Real-Time Visibility with Camera Technology

Additionally, the team utilized 360° body-mounted cameras (Fig. 1) to provide the client with real-time, high-quality photos and video throughout the inspection process. This allowed the client: 

• Full visibility into the condition of the vessel as the work was being performed, 

• More time to evaluate findings

• Better insight to plan any necessary repairs
  
  
  

Figure 1

MISTRAS’ Benicia, CA Rope Access Mechanical Services include:

• All methods of NDT (MT, PT, UTT,  PAUT, RT, CR, ET)

• Visual API-510 , 570 ,653 & 936

• Welding

• Cleaning

• Part Replacements, Light Bulbs, Speakers, Sprinkler Heads 

• Coatings, Painting, and Removal 

• Cooling Towers Inspection 

• Video live feed camera inspections 

• Blasting 

• Bridge Inspections 

• Marine Vessel Inspections

Unlock the possibilities of rope access for mechanical services with MISTRAS’ Benicia Team.