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Carbon Revolution

Carbon Revolution – Access and Height Safety System Installation

Background

Carbon Revolution, based in Geelong, Australia, is a pioneer in the production of lightweight carbon fiber wheels and other innovative automotive components. As the company expanded its manufacturing processes and facilities, ensuring the safety of employees working at height became a priority. With increased operational demands, the necessity for a reliable and effective height safety system was crucial to protect staff and maintain productivity.

Problem Statement

Prior to the installation of a new access and height safety system, Carbon Revolution faced several challenges associated with accessing elevated areas within its manufacturing facility. The existing access systems lacked proper safety measures, which raised concerns regarding the risks of falls and related incidents. The absence of adequate guardrails and structured access pathways exacerbated these challenges, making it essential to implement a comprehensive safety solution.

Objectives

1. Enhance Safety: Improve safety for employees accessing elevated production areas and equipment.
2. Ensure Compliance: Align with Australian height safety regulations and standards.
3. Facilitate Efficient Maintenance: Provide safe and easy access for maintenance personnel to perform their duties without risk.

Solution

To address the identified issues, Carbon Revolution undertook the installation of a comprehensive access and height safety system, which included the following components:

1. Caged Ladders:

• Installation of Caged Ladders: Multiple caged ladders were installed in various locations to provide safe access to elevated platforms and service areas. The caging ensures that workers have a secure ascent and descent, reducing the risk of falls.

2. Access Platforms:

• New Access Platforms: Sturdy access platforms were constructed at key high-access points, allowing maintenance staff to reach equipment securely. These platforms were designed with anti-slip surfaces and proper load-bearing capacity.

3. Guardrails:

• Installation of Guardrails: Permanent guardrails were placed around elevated access points, providing fall protection for personnel working near edges. These guardrails enhance safety and comply with Australian safety standards.

4. Walkway Systems:

• Fibre Walkway Systems: Durable walkway systems were installed to create safe passageways between various elevated areas. These walkways minimize the risk of slips and falls by providing stable walking surfaces.

5. Fold Down Guardrails:

• Fold Down Guardrails: Innovative fold-down guardrails were incorporated into the design of platforms and access areas, allowing for flexible use while maintaining safety when required.

6. New Access Hatch:

• Access Hatch Installation: A new access hatch was integrated into the design, providing easy and secure access to elevated areas for maintenance tasks while protecting against unauthorized entry.

Implementation Process: The installation process was meticulously planned to minimize disruption to Carbon Revolution’s manufacturing operations. Close collaboration among the Builder and facility management ensured that all systems were installed efficiently and met regulatory requirements.

Results

• Significant Reduction in Workplace Incidents: Since the implementation of the height safety system, Carbon Revolution has reported a dramatic decrease in safety incidents associated with working at heights.
• Regulatory Compliance Achieved: The newly installed systems comply with Australian safety standards, reinforcing the company’s commitment to safety and employee welfare.
• Enhanced Operational Efficiency: Maintenance personnel noted improved access to equipment, which has streamlined maintenance processes and reduced downtime.

Conclusion

The installation of the access and height safety system at Carbon Revolution effectively addressed previous safety concerns related to working at height. With the addition of caged ladders, access platforms, guardrails, walkway systems, fold-down guardrails, and an access hatch, the company has created a safer, more efficient work environment for its employees.

Modular Ladder Systems

TechLine’s range of industrial and commercial grade fixed rung ladder systems provide effective access to elevated areas and deliver high level safety for maintenance personnel accessing rooftops, ceiling spaces and maintenance platforms.

Used in conjunction with complementary handrails, fall protection cages or vertical fall arrest systems, TechLine offer a complete building access maintenance solution. Robust and lightweight, TechLine’s ladders are manufactured to Australian Standards, being robotically welded with high-grade aluminum for precision perfect finish. A wide range of fixing, brackets and ladder modules deliver solutions for all roof types and elevated access applications. Available ex-stock to meet demanding lead times, our modular fixed ladder systems can be powder coated to suit your buildings aesthetics.

Guardrail & Walkway Systems

Permanent and controlled access, guardrails and walkways offer the highest level of safety for employees and contractors working at heights.

TechLine’s guardrail systems deliver maximum fall protection and permits a continuous barrier for maintenance personnel working at heights. Our roof access guardrail systems are manufactured with high-grade aluminium for applications on any roof surface, with permanent or fold down options to suit the aesthetics of the building.

TechLine’s walkway systems provide a designated access path in potentially unsafe environments. Ideally suited for roof deck areas where frequent access is required, our walkway systems, available in high-grade aluminium or fibreglass, are manufactured with advanced grip surface for maximum traction. Walkways also protect roof surfaces from damage and leaks that occur as a result of frequent foot traffic from maintenance personnel.

Solutions provided

Systems Used