Project Type: Fall Restraint Lifeline and Non-Slip Rooftop Walkway Installation
Location: Teeside Industrial Estate, Thornaby
Scope of Work: Supply, installation, testing and certification of a horizontal lifeline system and non-slip rooftop walkway on trapezoidal profiled metal roof sheets
Overview:
Think Worksafe Ltd was engaged to supply, install, test and certify a horizontal fall restraint lifeline system and a non-slip rooftop walkway at an industrial unit on Teeside Industrial Estate. The systems were mounted onto existing trapezoidal profiled metal roof sheets, in the area surrounding roof-mounted solar panels, in accordance with the agreed quotation and supporting RAMS documentation.
A MEWP was included within the contract to provide safe access and to assist with the loading of materials to the roof. The finished systems provide safe ongoing access for maintenance personnel, in full compliance with current UK working-at-height regulations.
Scope and Challenges:
The scope of works covered the following:
Lifeline System (Fall Restraint):
- Approximately 56 linear metres of Axxessline fall restraint system installed across the main roof
- Anchor point positions marked and installed using manufacturer-approved fixings for trapezoidal sheets
- All roof penetrations sealed to maintain weatherproofing
- Horizontal stainless-steel lifeline cable installed with tensioners and intermediate supports
- Cable tension applied in accordance with manufacturer instructions
- Travellers supplied for system use
- Fall restraint harness and 2-metre lanyard supplied for system use
- System certified safe to use on completion
Walkway System:
- Approximately 59 linear metres of 600mm wide Axxesswalk UPVC walkway installed
- Walkway path laid to design route, from access point to plant and maintenance zones
- Walk Angel I-beams fixed to roof profile crowns using self-drilling, self-sealing Tek screws without compromising roof performance
- uPVC Walk Angel boards mounted between beams to suit the 6-degree roof pitch
- Adjoining panels connected with jointing plates
- System certified safe to use on completion
The project required careful management around the solar panel array. Exclusion zones were maintained around the panels throughout, no loading or material storage was permitted on the panels, and the team remained aware of the DC electrical hazard present even during isolation.
The roof was confirmed as non-fragile and suitable for imposed loads prior to access, with operatives restricted to the designated walkway route at all times.
All works were carried out by trained technicians, with all PPE supplied by Think Worksafe. The client received login access to the GetKonnected cloud management platform, giving visibility of all site operatives, equipment logs and daily site activities.
Project Solution
The lifeline and walkway systems were installed in sequence: the lifeline was put in place first, with the walkway then installed in accordance with the design layout to suit the roof pitch.
Cable swaging was carried out on site using a minimum of four swages per end as per manufacturer’s specifications to a calculated end load of 15kN. The final installation comprised three 15-metre sections and one 12-metre section of lifeline, totalling approximately 57 metres of lifeline and accompanying walkway system.
Testing was documented on completion, with all swage ends verified to 15kN. Waste was disposed of in the site skip on completion of works.
Installation was carried out in accordance with the following standards: BS EN 795:2012, BS 7883:2019, BS EN 516:2000 and manufacturer installation instructions.
Execution Summary:
On-site works were completed across two consecutive days, running from 08:00 to 17:00 each day. Two operatives attended site throughout. Key activities included:
- Day one: materials loaded to the roof using a MEWP; walkway installation commenced
- Day two: walkway installation completed; lifeline system installed and all swage ends tested to 15kN
- Testing witnessed by the client representative on completion
- All waste removed to site skip
- Full client and manager sign-off completed via the GetKonnected platform
No extra works were undertaken outside the agreed scope.
Results and Impact
The project delivered a certified fall restraint lifeline and rooftop walkway at the Teeside Industrial Estate site. Key outcomes included:
- Approximately 63 metres of Axxesswalk UPVC non-slip walkway installed and certified
- Axxessline fall restraint system installed across approximately 56 linear metres, with all swage ends tested to 15kN
- All roof penetrations sealed to maintain weatherproofing
- Installation certified in accordance with BS EN 795:2012, BS 7883:2019 and BS EN 516:2000
- Travellers and fall restraint harness supplied for system use
- All photographic evidence and activity logs recorded through the GetKonnected platform
- Full client and manager sign-off completed on site
Conclusion
This project shows Think Worksafe’s capability to deliver combined fall restraint and rooftop access solutions on live construction sites, working safely in the proximity of electrical plant. Both systems were installed, tested and certified within two days, with no extra works required and full compliance documentation completed via GetKonnected.
