Common Issues with Plant Platforms & How to Avoid Them

Plant platforms are rarely the headline feature of a building. Yet, when their specification is overlooked, problems tend to surface later—during installation and maintenance, or even years into the building’s life. These issues often result in rework, project delays, and compliance risks.

Here are the most common issues architects and builders run into with plant platforms, and how to avoid them:

Dissimilar metals for plant platform componentry

Some plant platform providers construct their platforms using dissimilar metals, such as an aluminium structure with steel fixings and brackets. If not properly isolated, this combination can lead to galvanic corrosion. Over time, one of the metals breaks down, causing visible damage and reducing structural integrity.

A quality plant platform provider will avoid mixed metals altogether. Alternatively, you can eliminate the risk by specifying the same metal for all structural members and fixings.

Plant platform loads exceed roof spacer capacity

Roof spacers have limited load capacity and are not designed to support the weight of plant platforms and associated equipment. Exceeding roof spacer capacity can mean that you need to add more purlins and spacers. For very heavy loads—like water tanks or equipment over 5 kPa—the roof spacers may need to be substituted (or coupled) with spacer blocks to transfer the load to the purlin.

Alternatively, you can choose a roof-mounted platform that transfers loads back to the building’s structure via purlin stubs. This is often a more efficient way to manage heavy loads.

Non-compliant plant platform fixings

Some providers use solar clamps to fix plant platforms to the roof. However, these clamps are designed for lightweight applications and perform poorly when subjected to lateral or uplift forces from live loads, wind and earthquakes.

To ensure compliance, you can specify that the platform and fixings meet AS1170 requirements. For example: Platform designs must be certified to AS1170 parts 1-4 including live, wind and seismic loads and must include adequate connection to the structure.

Plant platform loads locked in too early

Fixing platform loads too early in the design process creates risk when equipment selections change. This can lead to overdesign, increasing cost and weight, or underdesign, requiring rework.

A more flexible approach is to specify a minimum live load of 2.5 kPa, or higher as required, and allow the final design to respond to actual equipment loads. If using aluminium, your platform may be engineered for higher loads in isolated areas, reducing overall weight and material costs.

Steel swarf during plant platform installation

Swarf is a common byproduct of on-site modifications to plant platforms. However, not all swarf is created equal. Cutting and drilling steel creates hot swarf that can embed into the roof surface. This makes it difficult to remove, and any residue left behind will rust over time, leading to staining and deterioration of the roof. When this happens, responsibility is often disputed between trades, which delays rectification while the damage worsens.

Aluminium swarf, on the other hand, is much cooler than steel, so it doesn’t embed into finished surfaces. It’s easy to brush or blow away and, because aluminium is naturally corrosion resistant, it won’t damage finished surfaces.

Compromised steel finishes introduce corrosion risks

Material selection plays a key role in the long-term performance of a plant platform. Steel, for example, requires protective coatings or galvanisation to prevent rust. Any on-site modifications, such as cutting and drilling, will expose bare metal. These areas rely on touch-up coatings, which are less durable than factory-applied finishes and can lead to premature corrosion.

Aluminium is a more stable material choice for external environments. It forms a thin oxide layer when exposed to air, which protects it from corrosion. This makes it well suited to exposed and coastal applications, without the need for protective coatings.

Final thoughts

Plant platform issues are often preventable. In many cases, they result from the way the plant platform was designed, manufactured or installed. Materials, fixings and load handling all play an important role in long-term performance.

Understanding common plant platform issues can help architects and builders make more informed decisions. Decisions that reduce risk, improve durability and support the long-term performance of both the building and the plant platform.