Installing Safe Access Systems for PV Maintenance at Central Way (July 2025)
1. Challenge
Tri Construction Ltd was nearing completion of a major new-build project at Central Way, featuring a brand-new Kingspan roof system with rooftop solar PV arrays. The client’s brief—received via tender—provided basic layout drawings but no specification. A key requirement was the inclusion of a walkway and mansafe system to allow operatives safe and compliant access to the PV panels for ongoing maintenance.
Complicating matters, any solution had to be fully compatible with Kingspan roofing to avoid voiding the manufacturer warranty—a common risk with aftermarket roof safety systems.
2. Solution Design
Think Worksafe collaborated closely with approved supplier Bettersafe to design a fully compliant system tailored to the unique roof profile. Working within the tender parameters, Think Worksafe produced technical drawings at all project stages, ensuring traceability and alignment with the client’s evolving construction programme.
The proposed solution included:
- Axxesswalk non-slip aluminium walkways to provide structured, secure footpaths across the PV zones
- Axxessline horizontal lifeline system, offering full fall restraint for users tethered while traversing the roof
Both products are Kingspan-approved, meaning their installation does not compromise the roof’s warranty—a critical requirement for Tri Construction’s client handover process.
3. Execution (3 Days in July 2025)
A dedicated Think Worksafe team completed the full install over three consecutive days:
- Day 1 – Site induction; layout review and equipment staging
- Day 2 – Installation of Axxesswalk walkways following production-line sequencing; fixings checked for alignment and spacing
- Day 3 – Lifeline system tensioned, tested, and tagged; full system handover with operational briefing to client site reps
The project ran without disruption to the wider site schedule. Think Worksafe coordinated closely with other contractors to minimise overlap and ensure safe working zones throughout.
4. Health, Safety & Compliance
All work followed the Work at Height Regulations 2005, with Think Worksafe operatives fully trained and accredited for rooftop safety installations. The Axxesswalk system’s anti-slip surface and elevated structure ensures safe traversal above rooftop undulations and delicate PV cabling.
The Axxessline system was installed with permanent fall restraint anchoring, maintaining user positioning and preventing exposure to unprotected roof edges.
All installations were tested to manufacturer specification, with certification issued upon completion.
5. Results
Warranty-protected solution – By specifying Kingspan-approved products, Think Worksafe guaranteed the roof’s warranty remained intact post-installation.
Safe and easy access – The Axxesswalk and Axxessline systems create an intuitive, low-profile access route that keeps all users in restraint, even during extended rooftop works.
Rapid delivery – Completed in 3 days, the installation allowed Tri Construction to move seamlessly into their final commissioning phase.
Minimal disruption – The install was carefully phased to avoid conflicts with adjacent roof works, scaffolding, and electrical teams.
6. Lessons Learned
Approved compatibility matters – Early identification of warranty-safe components saved potential delays and costly redesigns.
Drawing-led delivery – Producing install drawings at each stage helped all stakeholders visualise scope and avoid errors in layout or fixing positions.
Less is more – A simple, modular system (walkway plus lifeline) covered all access needs without unnecessary complexity.
Collaborative approach wins tenders – Working hand-in-hand with Bettersafe during the bid phase positioned Think Worksafe as a solution provider, not just an installer.
7. Client Feedback & Next Steps
With the system now operational, Tri Construction has invited Think Worksafe to provide similar access safety solutions for future builds where rooftop PV is specified. Follow-up reviews are scheduled at 6 and 12 months to assess system usage and potential needs for expansion.
