Project Type: Roof Walkway Supply & Installation, Ladder Access, Fall Restraint Lifeline
Location: Shotton Mill, Deeside, CH5 2LW
Scope of Work: Walkways and Ladder Access across TM1 Building, Bale Building and Reel Storage Building
Overview:
Think Worksafe Ltd was engaged to supply and install a comprehensive roof access and safe walkway system across multiple buildings at the Shotton Mill facility in Deeside, North Wales. The project covered the TM1 Building, the Bale Building and the Reel Storage Building, each presenting its own configuration requirements and access challenges.
The scope was developed following a detailed site survey and quotation process, with works to be undertaken by Think Worksafe fall protection engineers operating in compliance with all relevant British Standards including BS EN 795:2012, BS 8610:2017, BS 7883:2019, BS EN 1422-4 and BS 4211.
Scope and Challenges:
The Shotton Mill project presented a number of practical challenges that required careful coordination and adaptability from the Think Worksafe site team:
Works were carried out under CDM regulations all operatives were inducted prior to commencement and worked within client-issued work at height permits.
- Materials including Dukmat rolls, walkway panels and ship ladders needed to be craned or manually carried to roof level. Crane lifts were subject to weather conditions and the team had to coordinate closely with the client to schedule lifts appropriately
- Scaffolding pallets left on the roof by other trades on multiple occasions blocked walkway installation routes and had to be moved before work could progress
- On the lower level roof area, access issues initially prevented the Dukmat from being laid, requiring the team to source and arrange an additional access ladder before works could continue
- During the initial build of the ship ladder on the lower level TM1 roof, incorrect measurements were identified. This was flagged promptly and corrected in subsequent visits
- Walkway snagging identified areas where only four levelling bars had been fitted rather than the specified five, and some boards had been damaged and scuffed by other trades working on the roof. These were rectified during dedicated snagging visits
Project Solution
Following assessment of site drawings, building configurations and manufacturer requirements, Think Worksafe’s fall protection engineers designed and installed the access and walkway systems to meet the specific needs of each building.
Axxesswalk Walkway Installation
The Axxesswalk system was installed in two orientations depending on roof profile requirements. Where boards ran 90 degrees to the crown direction, long support I-beams were placed running the length of the walkway section with uPVC boards mounted in the short orientation between them. Where boards ran in line with the crowns, short support beams were placed perpendicular to the profile with boards mounted in the long orientation. Beams were fixed to the crown profile using self-drilling tek screws, with joining plates used to connect adjoining panels.
Dukmat Loose Laid Walkway
The Dukmat PVC walkway was supplied in 600mm x 10 metre rolls, rolled out and positioned across the Kingspan TopDeck roof surface. Rolls were cut to length using tin snips where required.
Ship Ladder and Aluminium Ladder Installations
Each ladder installation followed a structured six-step process: marking and drilling fixing points using a plumb line for alignment; installing bottom wall brackets and mounting the base section; adding intermediate ladder sections using connectors whilst maintaining standard rung pitch; installing any intermediate rest platforms; fitting safety hoops at the required height and spacing; and finally installing the top section with handrails and toe boards. Base plates were fixed using rivets or heavy-duty anchor bolts to suit the specific substrate at each location.
Fall Restraint Lifeline
The Axxessline fall restraint lifeline on the Reel Storage Building was installed rivet-fixed to the KS1000RW roofing sheets. The system was supplied in a single straight run and tested by swaging cable terminations to a minimum of four swages per end, with each swage load-tested to a minimum of 5kN using a Hydrajaws testing tool in line with manufacturer guidance.
Execution Summary:
The on-site works were carried out by a two-person team, with operational oversight provided by the Operations Manager Site visits were recorded daily via the #thinkworksafe Get Konnected management system, with photographic evidence, client notes and manager sign-off logged for each day.
Key activities carried out across the programme included:
- Ongoing coordination with the client regarding crane lifts and material deliveries to the roof.
- Initial snagging of walkway installations across TM1 lower and higher bale roof areas, correcting missing joining plates, replacing damaged boards and adding missing levelling bars
- Completion of the first spur on the TM1 main roof with levelling and joining plates attached
- Progression through additional spurs on the main roof as scaffolding obstructions were cleared and materials made available
- Laying of approximately 90-100 linear metres of Dukmat on the lower level TM1 roof
Results and Impact
The Shotton Mill project delivered a comprehensive roof access and fall protection solution across three buildings at a complex active construction site. Key outcomes included:
- Installation of over 960 linear metres of compliant roof walkway systems across TM1, Bale and Reel Storage buildings
- Four certified access ladders ranging from 2 metres to 10.5 metres providing safe level-change access at key points across the site
- A 106 linear metre certified fall restraint lifeline on the Reel Storage Building, ensuring users remain in restraint whilst working at height on the roof
- All installations carried out in compliance with relevant British Standards and manufacturer specifications
- Detailed daily site records maintained throughout via the Get Konnected platform, providing full transparency to the client
Throughout the project the Think Worksafe team demonstrated practical problem-solving capability, adapting to access restrictions, material delivery delays and third-party trade impacts whilst maintaining progress and quality standards.
Conclusion
This project demonstrates Think Worksafe Ltd’s capability to deliver multi-disciplinary fall protection and roof access solutions across complex, multi-building sites. Working under CDM regulations alongside the principal contractor and client team, our engineers provided walkway systems, certified ladder access and fall restraint infrastructure designed to keep operatives and maintenance personnel safe for the lifetime of the installation.
