Retrofitting Eyewash Stations into an Older Plant: A Practical Sequence

Short answer: Retrofit in this order: hazard map, route and 10-second walk, supply pressure measured flowing, drainage path, then equipment. Doing it in the reverse order - choosing the unit first - is what turns a two-week job into a two-month one.

Step 1: Hazard map before any product discussion

Mark every point where a worker can be exposed, then draw the 10-second walking route from each to the proposed unit position. Retrofits fail here most often: the only free wall is 25 seconds away, or the direct route is blocked by a permanent rack.

If the route fails, the answer is a different position or a second unit - not a faster pump.

Step 2: Measure pressure flowing, not static

Older plants often have adequate static pressure and inadequate flowing pressure at the far end of a branch. Fit a gauge on the outlet, open the valve, and read it while water runs. If the figure is below the 30 psi requirement, the options are:

• Re-pipe the branch in a larger diameter

• Take the supply from a closer, larger main

• Add a local booster with a fail-safe bypass

• Substitute a gravity-fed portable unit where plumbing cannot be changed

Step 3: Find the drainage path

A 15-minute flush is a lot of water. In an older building the nearest floor drain may be in another room, or the floor may fall the wrong way. Options in order of preference: existing floor drain, new trench drain to the nearest gully, a containment tray with a pump, or a location change.

Discharging onto a walkway is not an option - it converts a chemical hazard into a slip hazard at the exact moment someone is running to the unit.

Step 4: Match the unit to the constraints

Step 5: Commission and hand over

Record four numbers: flowing pressure at the outlet, flow rate, outlet temperature, and spray pattern height above the standing surface. Then assign the weekly activation to a named role and open the log. A retrofit without an owner reverts to non-compliance within a quarter.

Frequently asked questions

Can I use the existing domestic water line?

For eyewash-only duty on a short branch, often yes - after measuring flowing pressure. Not for a combination shower.

Do I need to break the floor for drainage?

Not always. A containment tray with a small transfer pump avoids excavation, at the cost of a maintenance item that must be on the inspection sheet.

What if the building cannot take a wall load?

Use a pedestal unit. A loaded wall-mounted unit plus a person leaning on it is a real load case, not a theoretical one.

How long does a typical retrofit take?

The equipment installs in a day. The supply and drainage work sets the schedule, which is why they are measured first.

Planning a retrofit

Send us photographs of the location, the nearest supply point and a rough sketch with dimensions. We can shortlist two or three configurations before you commit to pipework - start with the eyewash range or the portable units for interim cover.

Sources: ANSI/ISEA Z358.1-2014 installation and performance requirements; CCOHS emergency shower installation guidance.