Project Type: Rope Access Steel Erection and Ductwork Installation
Location: Walsall Energy from Waste Facility
Scope of Work: Rope access support for steel structure erection and ductwork installation
Team Deployment: 1 Rope Access Supervisor, 2 Rope Access Technicians
Access Method: IRATA-compliant rope access and rigging techniques
Overview
Think Access Ltd. were engaged to provide specialist rope access support during the construction of the Walsall Energy from Waste (EFW) facility. This major infrastructure project will play a key role in the UK’s sustainable waste management strategy, with the completed plant capable of processing up to 436,000 tonnes of non-recyclable residual waste annually and generating approximately 49 MW of electricity, enough to power around 90,000 homes.
As part of the plant’s structural and mechanical installation phase, Think Access was tasked with supporting the erection of steel structures along with installation of large-scale ductwork systems in areas where traditional access methods such as scaffolding or mobile elevated work platforms (MEWPs) were not feasible due to structural complexity and restricted positioning. By deploying an experienced rope access team, Think Access enabled safe, precise and efficient installation of critical structural and mechanical components during this complex construction project.
Scope of Works:
The project required rope access operatives to assist in positioning and securing steel framework and ductwork components being lifted into place by crane. The installation areas were located at height and within congested structural zones, making conventional access impractical or impossible.
Key challenges included:
Restricted access environments: Structural obstructions and limited floor space prevented the use of MEWPs or scaffolding in key installation zones.
Precision positioning requirements: Steel sections and ductwork components required accurate alignment with existing structural fixing points.
Working alongside crane operations: Rope access operatives were required to coordinate closely with crane operators and installation crews to safely guide suspended loads into position.
High-level installation tasks: All works were conducted at height within an active construction environment, requiring strict adherence to safety protocols and lifting procedures.
Complex structural integration: Components needed to be installed securely and to exact torque specifications to ensure structural integrity and compliance with engineering requirements. Rope access provided a flexible and highly effective solution, allowing operatives to access precise installation points safely and efficiently without introducing delays associated with conventional access systems.
Execution Summary:
Think Access deployed a three-person team consisting of one experienced Rope Access Supervisor and two IRATA-certified Rope Access Technicians to support the installation programme.
Working in coordination with crane operators, the rope access team assisted in guiding steel sections and ductwork components as they were lifted into position. Using controlled rope access positioning techniques, operatives were able to safely manoeuvre each component into its exact installation location.
Once correctly aligned, the team installed all required fixings in accordance with engineering specifications. Specialist tools, including calibrated impact and torque wrenches, were used to ensure all connections met required torque settings and structural standards.
Rigging systems remained in place until each component was fully secured and verified as structurally stable, ensuring maximum safety throughout the installation process.
The rope access approach enabled efficient progression of steel erection and ductwork installation activities without the need for time-intensive scaffold construction or repositioning of mechanical access equipment.
Supporting a Major Energy Infrastructure Project:
The Walsall Energy from Waste facility represents a significant investment in sustainable infrastructure. Once operational, the plant will not only generate electricity from residual waste but also support material recovery processes, including metal and bottom ash recycling.
The facility has also been designed with future capability to export steam or heat to district heating networks, supporting wider energy efficiency and sustainability initiatives. Think Access’s role in supporting the steel and ductwork installation contributed to the safe and efficient construction of this advanced energy facility.
Safety & Compliance:
All rope access works were carried out in full compliance with IRATA guidelines and site-specific RAMS. Key safety measures included:
- IRATA-compliant rope access systems and backup safety lines
- Close coordination with crane operators and lifting supervisors
- Controlled load guidance and positioning procedures
- Use of certified tools and calibrated torque equipment
- Continuous supervision by a qualified Rope Access Supervisor
- Full adherence to site safety and construction protocols
Rigging systems were only removed once all structural fixings were confirmed secure and installation integrity was verified.
Results and Impact:
Think Access successfully delivered specialist rope access support for steel erection and ductwork installation at the Walsall EFW facility.
Key outcomes included:
- Safe installation support for structural steel and mechanical ductwork
- Improved efficiency compared to conventional access methods
- Elimination of scaffold requirements in restricted areas
- Enhanced precision in high-level component positioning
- Full compliance with safety and engineering specifications
- Zero incidents or delays attributed to access constraints
The rope access solution ensured efficient structural assembly while maintaining the highest standards of safety and workmanship.
Require rope access support for steel erection, ductwork installation, or construction projects?
Think Access Ltd delivers safe, efficient, and highly specialised access solutions for complex industrial and infrastructure environments across the UK.
