Location: Westfield Energy Recovery Facility, Lochgelly, Fife, Scotland
Scope of Work: Application and certification of intumescent fire protection coating system to structural steelwork across 42 locations within the plant.
Team Deployment: IRATA-qualified rope access technicians and IPAF-certified MEWP operators, working under a nominated rope access supervisor.
Access Method: Primary access via boom-lift MEWPs fitted with anti-entrapment devices; IRATA rope access deployed as a contingency for areas outside MEWP reach.

Overview:

A principal contractor required specialist intumescent coating application and certification to structural steelwork at an operational energy recovery facility in Scotland. With live plant operations ongoing and a requirement to work at height across 42 identified locations including the boiler and turbine fire wall up to the 20m level, a combined approach using MEWPs and IRATA rope access provided the safest and most controlled method of delivering the works to the required fire protection specification.

The Challenge:

The scope required the application of a full intumescent coating system to structural steelwork across multiple locations throughout the facility. Structural steel relies on intumescent coatings as a critical passive fire protection measure. Applicators must apply each coat to precise dry film thickness tolerances to achieve the required two-hour fire rating, making application quality and documentation equally important to a successful outcome.

Working at height within an operational energy recovery facility introduced significant access and safety planning requirements. The team needed to take out daily permits, establish exclusion zones beneath all working areas, conduct daily pre-start task sheets and equipment inspections, and brief the full team on RAMS and rescue plans before each shift commenced. The boiler and turbine fire wall areas required work at the 20m level, where boom lifts could not safely reach every position, so the team supplemented MEWP access with IRATA rope access to cover the full extent of the works.

The Solution:

Think Access deployed a team of IRATA-qualified rope access technicians and IPAF-certified MEWP operators to carry out the full intumescent coating programme at Westfield ERF. The team arrived on site, discussed scope directly with the site representative, gathered materials and equipment, and proceeded to carry out the works in a structured and permit-controlled manner across consecutive days.

MEWPs fitted with anti-entrapment devices served as the primary access platform, with IRATA rope access used as a contingency where MEWP access was not achievable. The team applied the full coating system in accordance with manufacturer specifications: Firetex C69 primer at 25 microns dry film thickness, Firetex FX6002 intumescent intermediate coat to the dry film thickness required to achieve a two-hour fire rating, and Acrolon 7300 semi-gloss topcoat at 150 microns. As works progressed, the team carried out dry film thickness tests on all areas and logged all results and photographic records digitally for quality assurance and client verification.

Each day the team took out the required permits, briefed the team on objectives and safe systems of work, completed pre-start task sheets and carried out their work before surrendering permits, cleaning the work area and removing barriers at the end of shift. The team recorded and managed all daily activity through the GetKonnected platform, giving the site representative real-time visibility of operatives on site, equipment in use and progress across all 42 treatment locations. The site representative signed off each working day on completion, with the Think Access manager verifying and closing out each visit promptly thereafter.

Results:

Think Access delivered a complete and certified intumescent coating application programme across all 42 steelwork locations at Westfield Energy Recovery Facility. All works were applied to the specified dry film thickness and fire rating requirements, with full certification provided on completion. The project was delivered on a fixed-price basis, managed throughout via the GetKonnected digital platform, and signed off by the site representative on completion of the works, providing the principal contractor with a full and auditable record of all intumescent coating activity carried out.

Intumescent Coating Application by IRATA Rope Access: Built for Complex Sites

If you need intumescent fire protection coatings applied and certified on structural steelwork in hard-to-reach or operationally live environments, Think Access provides IRATA-qualified rope access teams and IPAF-certified MEWP operators ready to deliver safely, efficiently and to the highest professional standard.