Access Solutions Providing Comprehensive Rooftop Safety
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Project Challenge
The manufacturing facility operated critical rooftop equipment across multiple building levels and roof slopes, creating significant safety hazards for maintenance teams who previously relied on temporary ladders and unsafe walking routes between equipment. The complex rooftop environment included varying elevation changes, equipment clearance requirements, and multiple fall hazard zones that required comprehensive safety solutions without compromising the building's roof warranty through penetrations.
The facility's 24/7 production schedule meant that rooftop equipment maintenance was essential for continuous operations, but existing access methods posed serious safety risks and potential WorkSafe compliance issues. The installation needed to accommodate future equipment modifications and expansions while providing permanent, weather-resistant access that could withstand the demanding industrial environment. Additionally, the solution required integration across different roof types and slopes while maintaining consistent safety standards throughout the facility.
Key Challenges:
- Provide safe access across complex multi-level rooftop environment with varying equipment clearances
- Eliminate fall hazards while maintaining 24/7 access for critical production equipment maintenance
- Install comprehensive access system without roof penetrations that could void building warranties
- Accommodate future equipment modifications and facility expansions within integrated safety network
- Ensure full AS1657 compliance across diverse roof types and elevation changes
Solution
Con-form Group's integrated EasyAccess© system provided a complete safety solution combining walkways, guardrails, and stairs in a unified access network. The modular aluminium construction enabled rapid installation across the facility's complex rooftop layout, with walkways spanning equipment clearances, stairs navigating elevation changes, and guardrails providing fall protection at all hazard points. The entire system installed without roof penetrations, preserving warranty coverage while exceeding AS1657 safety requirements.
The prefabricated components arrived ready for assembly with foolproof connections, enabling installation teams to complete the extensive 500-metre access network efficiently without disrupting production operations. The raised walkway sections provided optimal clearance above process equipment while stairs created safe transitions between building levels, all integrated with continuous guardrail protection to eliminate fall hazards throughout the facility.
Solution Benefits:
- Integrated walkway, stair, and guardrail system provided comprehensive rooftop safety coverage
- Zero roof penetrations preserved building warranty while exceeding AS1657 compliance requirements
- Modular design enabled efficient installation of 500+ metres without production disruption
- Raised walkway sections maintained optimal equipment clearance for ongoing maintenance access
- Future-ready modular construction accommodated facility expansions and equipment modifications
Services Rendered
Con-form Group provided complete turnkey delivery for this complex multi-component access installation, with specialized safety engineering teams designing integrated walkway routes that optimized maintenance workflows while ensuring comprehensive fall protection coverage. Our design team developed detailed shop drawings that coordinated walkway spans, stair transitions, and guardrail placement across the facility's complex rooftop environment. The project included extensive coordination with facility management to maintain production schedules while implementing the safety infrastructure essential for ongoing operations.
Services Included:
- Comprehensive safety engineering design integrating walkways, stairs, and guardrails across complex rooftop environment
- Detailed shop drawings optimizing maintenance access routes while ensuring AS1657 compliance coverage
- Manufacturing facility project management maintaining 24/7 production operations during installation
- Custom manufacturing of modular EasyAccess© components with prefabricated connections and anti-slip surfaces
- Professional installation delivering integrated safety systems with zero roof penetrations
- AS1657 compliance verification and safety testing across all walkway, stair, and guardrail components
- Comprehensive 25-year warranty coverage on all aluminium access system components
Building
The project was completed at a food processing and manufacturing facility in regional South Australia.
November 3, 2025
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