Location: West Bromwich
Scope of Work: Inspection and remedial trimming of internal A-frame cladding panels; installation of approx. 60 corrugated cladding sheets to the ACC overhang structure via IRATA rope access.
Team Deployment: 3 IRATA-qualified rope access technicians.
Access Method: IIRATA-compliant rope access — ropes rigged and tension lines set specific to each working area across the structure.

Overview:

A specialist cladding contractor required rope access support to carry out remedial trimming of internal A-frame panels and the installation of corrugated cladding sheets to the ACC overhang at an operational energy-from-waste facility. With live site operations ongoing and a complex multi-trade environment managed under CDM regulations, rope access provided the safest and most efficient solution, eliminating the need for scaffolding or MEWPs across the full scope of works.

The Challenge:

A structural cladding contractor required specialist rope access technicians to carry out two distinct scopes within the Air-Cooled Condenser (ACC) structure at the Enfinium Kelvin energy-from-waste facility in West Bromwich. The scope covered remedial trimming of all internal A-frame cladding panels, required to maintain a uniform clearance of 20–40 mm from adjacent bundles and the installation of approximately 60 corrugated cladding sheets to the ACC overhang.

The environment presented significant access and coordination challenges. No drawings were available indicating steel clashes, pipe locations or dimensions in the overhang area, meaning all cutting and fitting had to be assessed and executed directly on site. The facility was operating under CDM regulations with a principal contractor overseeing a complex multi-trade environment, and works could not deviate from the agreed scope without written instruction.

The Solution:

Think Access deployed a three-person IRATA-qualified rope access team, supervised by an IRATA Level 3 technician, to carry out the full scope of works in two phases.

For the A-frame remedial works, ropes were rigged and tension lines set up inside the ACC structure. Each wall was worked through systematically, with panels assessed individually and trimmed using aviation snips and nibblers to achieve the required 20–40 mm clearance. Where a sheet was subsequently identified as too tight on inspection, fixings were removed, the sheet repositioned to the correct height, re-drilled and fully re-fixed with new rivets before ropes were moved to the next area.

For the ACC overhang cladding installation, corrugated sheets were fixed using cordless hand tools, with complex notching and cutting carried out around steel beams, pipes, ducts, cable trays and cross bracings all assessed on site without clash drawings. All sheets were raised to the workface by rope hauling or mechanical means; no manual carrying up structural steel was permitted. Sharp edges were protected prior to lifting, and stitcher positions were marked at 500 mm spacings for riveting.

All tools used at height were tethered in accordance with the project SSOW. Client sign-off was obtained throughout, with daily activity logged digitally via the Get Konnected platform, providing real-time visibility of operatives, equipment and progress at every stage.

Results:

The project was delivered in full, with all steelwork and cladding handed over to the client in a clean, compliant and fully rectified condition. Key outcomes included:

• Full A-frame remedial scope completed across all walls inside the ACC structure, with every panel trimmed to the required 20–40 mm clearance standard.
• Approximately 60 corrugated cladding sheets installed to the ACC overhang, with all complex notching and fitting carried out on site without available clash drawings.
• Zero safety incidents throughout the programme. All rope access, dropped-object, hot works and LOTO controls functioned as planned.
• Daily client representative sign-off obtained via the Get Konnected platform, providing a fully auditable record of all site activity.
• Site handed back clean: roof swept clear of all swarf and debris, patch plates fitted to all cut penetrations, all scrap material removed to ground level.
• All workmanship warranted for twelve months from the date of completion, in line with Think Access Group terms and conditions.

The project was delivered on a fixed-price basis and signed off by the client representative following a walk-around on the final day, with two minor snags identified and rectified on the day. Full manager verification was completed through Think Access’s internal quality process.

Cladding at height? We’ve got it covered.

IRATA-qualified rope access specialists delivering safe, efficient cladding installation and remedial works wherever others can’t reach. Zero disruption. No compromise.