Location: Skelton Grange Energy-from-Waste Facility
Scope of Work: Touch-up painting of ACC steam ducts, turbine ducting, diagonal supports, undersides and ACC fans outside the boiler hall.
Team Deployment: IRATA-qualified rope access technicians supervised by iCATS-trained supervisor.
Access Method: MEWP (cherry picker) and rope access, with IRATA-qualified technicians.

Overview:

Think Access was engaged to carry out the full application of a uniform topcoat paint system to the Air-Cooled Condenser (ACC) at an energy-from-waste facility. The scope required the identification and rectification of paint defects across a complex network of elevated steam ducts, turbine connections, diagonal structural supports, ACC fan housings and associated pipework. All works were delivered in accordance with relevant specifications and industry best practice.

A pre-contract site survey carried out and identified inconsistencies in paint colour and poor application quality across the ACC ducting, indicating that the existing finish did not meet the required standard. Think Access was appointed to remediate these deficiencies and achieve a consistent, compliant topcoat across all surfaces.

The Challenge:

The project presented several access, logistical and environmental challenges:

• The ACC structure comprises a complex arrangement of large-diameter steam ducts, diagonal bracing members, elevated turbine connections and fan housings, all requiring paint application to difficult-to-reach undersides and curved surfaces.
• A combination of MEWP (mobile elevating work platform) and rope access techniques was required to reach the full extent of the structure, with certain areas accessible only via rope access due to geometry and obstruction.
• Paint supply logistics required careful planning: on at least one occasion the team cleaned and prepared the work area while awaiting paint delivery before commencing application.
• Works were carried out on an operational industrial site requiring daily coordination with the client representative, strict access controls and a maintained clean work environment throughout.
• The scope included internal areas of the ACC structure as well as external pipe runs outside the boiler hall, requiring the team to adapt rigging and access configurations across different zones on the same project.
• All works were subject to daily client sign-off, with records maintained digitally via the GetKonnected cloud platform, providing the client with real-time visibility of progress, operatives and site activity.

The Solution:

Think Access deployed an IRATA-qualified rope access team supervised by an iCATS-trained technician working across multiple days throughout the project duration. Access was provided by a combination of rope access rigging and MEWP operations with the team adapting their approach to suit each distinct area of the structure.

Phase 1 – Steam Duct Underside

The initial mobilisation focused on the section of steam duct running from the turbine across to the flue gas treatment (FGT) plant with particular attention to the underside of the duct which represented the most difficult access challenge. The team began painting this section using rope access allowing close-range application to all surfaces including curved undersides inaccessible to MEWP platforms.

Phase 2 – Turbine Ducting and ACC Vertical Sections

Over three working days the team systematically progressed through the remaining ducting areas. On the first day equipment and paint were gathered, point-of-work task sheets were completed and painting of the turbine ducting commenced. The second day saw completion of the middle vertical ACC ducting section and progress to one third of the large ducting running from the turbine. The third day completed three quarters of the turbine top and sides before the team stood down at midday.

Phase 3 – External Pipe Runs and Rope Rigging

The team returned to work on the pipes outside the ACC building painting along the pipe runs and addressing areas requiring touch-up. Ropes were rigged ahead of the following day’s operations demonstrating proactive programme management.

Phase 4 – ACC Diagonal Supports and Undersides

Over four consecutive working days the team completed the steam duct section running from the turbine to the ACC, began painting the two diagonal bracing members, completed one diagonal in full and progressed to the undersides and tops of the ACC structure. Daily client notes confirm systematic progression through the scope with the team checking for missed patches and ensuring consistent coverage across all surfaces.

Phase 5 – ACC Fan Touch-Up and Close-Out

The final phase of works focused on the ACC fans located outside the boiler hall. The team blocked the working area, completed all required touch-up painting and cleared materials before leaving site. Client sign-off was obtained confirming completion.

Results:

The project was delivered across the agreed programme with all areas of the ACC painting scope completed to the required standard. Key outcomes included:

• Works carried out on an operational EfW facility with minimal disruption to site operations throughout the project duration.
• Full topcoat paint system applied uniformly across all ACC steam ducts, turbine ducting, diagonal supports, undersides, tops and external fan housing areas.
• Paint defects and colour inconsistencies identified during the pre-contract survey fully remediated, with all surfaces achieving the specified finish.
• Access delivered safely across a complex multi-level industrial structure using a combination of MEWP and rope access, with no incidents throughout the project.
• Daily client sign-off obtained throughout, with all site activity logged digitally via the Think Access cloud platform GetKonnected, providing a fully auditable project record.
• All materials, PPE and plant supplied by Think Access, including MEWP hire where required, with no additional procurement burden on the client.

Safety & Compliance:

All works were carried out in full compliance with Think Access’s safe system of works. IRATA-qualified technicians operated under the supervision of an iCATS-trained supervisor throughout. MEWP pre-use inspections were completed prior to each day’s operations. All tools used at height were tethered. PPE was supplied and worn correctly at all times. Point-of-work task sheets were completed daily before works commenced.

All activities were recorded on the GetKonnected digital platform, providing the client with live access to operative details, equipment logs, daily activity reports and sign-off records throughout the project.

Have a Challenging Access Requirement?

Whether working at height on complex industrial structures, in restricted access zones or on operational facilities, our IRATA-qualified rope access and MEWP teams are ready to deliver safely, on programme and with full digital documentation. For painting, inspection, maintenance or access solutions, get in touch for a no-obligation consultation.