Project Type: GRP Walkway and Handrail at Roof Level
Location: Milton Keynes
Scope of Work: Supply, delivery, installation and certification of GRP open mesh walkway panels and GRP handrail system at roof level
Overview:
Think Worksafe Ltd was engaged to supply, deliver, install and certify a GRP open mesh walkway and handrail system at roof level on the Red Bull Advanced Technologies facility in Milton Keynes. The project scope covered the full installation of 38mm Gripclad GRP Open Mesh Walkway panels and a certified Gripclad GRP Handrail system in light grey, with works carried out in accordance with the agreed quotation and RAMS documentation.
Works were carried out over two months, spanning multiple site visits across the programme. The installation was carried out by a team of Think Worksafe technicians with operational and management oversight provided throughout, and all daily activity was recorded via the Get Konnected management platform.
Scope and Challenges:
The project involved the supply, delivery, installation and certification of a 38mm Gripclad GRP Open Mesh Walkway system using 2000mm x 1000mm panels and a Gripclad GRP Handrail system in light grey, at roof level on the Red Bull Advanced Technologies facility in Milton Keynes. The walkway panels were to be rested on rubber feet supplied at 6 per m2, with handrail stanchions fixed at 1.25m centres using stainless steel fixings.
A number of practical challenges were encountered during the works:
- Materials required forklifting from the delivery vehicle and lifting to roof level via a Telehandler supplied by Roofmaster. Only trained and competent MEWP-trained persons were permitted to operate lifting equipment.
- Scaffold erected around the perimeter of the roof served as temporary edge protection throughout the works. Think Worksafe operatives were not permitted to erect, alter, modify or disassemble the scaffold edge protection.
- Handrail uprights were being installed but the correct fixings to secure them down were not available on site, requiring mid rails to be installed in the interim.
- Progress was halted mid-roof as a skylight panel needed to be removed by others before work could continue across that section of the roof.
Project Solution
Following assessment of site drawings and manufacturer requirements, the Think Worksafe team designed and installed the walkway and handrail system in accordance with the quotation and RAMS documentation.
GRP Walkway Installation
The 38mm Gripclad GRP Open Mesh Walkway panels (2000mm x 1000mm) were laid out on rubber feet across the roof surface and clipped into place progressively as installation advanced. The rubber feet were supplied at 6 per m2 in accordance with the quotation specification.
GRP Handrail Installation
Once the walkway was laid, the 1.2m uprights were cut to length using a battery-operated band saw. Base plates for the GRP handrail were fitted at 1.25m stanchion centres using the supplied stainless steel fixings. Components for the mid rail, spaced at 500mm, and the top rail were slid into place and all fixings tightened progressively. The handrail system meets the requirements of BS4592: 02006+A1 2012 Industrial flooring, stairs and handrails for general duty (0.36kN/m), independently tested by the Engineering Department at Lancaster University.
Access and Materials Handling
Access to the roof was via a hacky staircase. All tools and materials were transported to roof level using the Telehandler provided by Roofmaster. Materials were manually lifted onto the Telehandler, raised up and over the temporary edge protection, and removed manually at roof level. Proper manual handling techniques were applied throughout in line with SSOW00-03.
Execution Summary:
On-site works were carried out by our IRATA rope access operatives, with the Operations Manager providing operational input during the Red Bull Advanced Technologies phase. Manager sign-off was provided by site management via the Get Konnected platform.
Key activities carried out across the programme included:
- Walkway panel layout and initial setup across the full roof area, with all components positioned and ready for assembly
- Progressive handrail installation across all roof sections, including uprights, mid-rails, double handrails, ramps and back wall
- Flooring installation completed across key roof areas, with works phased around third-party activities on site
- Snagging, final adjustments and completion ensuring all railings were tightened and all sections brought to a finished standarded.
All site activity was recorded daily via the Get Konnected management system, with photographic evidence and manager sign-off logged for each day.
Results and Impact
The Red Bull Advanced Technologies project delivered a certified GRP walkway and handrail system at roof level on the facility in Milton Keynes. Key outcomes included:
- All workmanship warranted for twelve months from the date of completion in line with Think Access Group terms and conditions.
- Supply and installation of 38mm Gripclad GRP Open Mesh Walkway panels across the roof, rested on rubber feet at 6 per m2.
- Installation of a certified Gripclad GRP Handrail system in light grey, meeting the requirements of BS4592: 02006+A1 2012 for general duty loading (0.36kN/m), with stanchions at 1.25m centres.
- All works carried out in compliance with the RAMS (TWS-RAMS-20140) and relevant safe systems of work, including general PPE, manual handling, portable power tools, edge protection tube and fit, and client site access and egress procedures.
- Detailed daily site records maintained throughout via the Get Konnected platform, providing full transparency to the client.
Conclusion
This project demonstrates Think Worksafe Ltd’s capability to supply, deliver, install and certify GRP walkway and handrail systems at roof level on complex commercial and specialist facilities. Think Worksafe operatives navigated access constraints, coordination with other trades and programme adjustments whilst maintaining progress and quality standards throughout the works.
