Sutro Group was engaged to conduct a comprehensive maintenance project on the structural steel components of a large industrial facility. The project involved multiple areas, including the main frame, inside fan cells, rooftop supports, and stair/platform supports. Given the complexity and scope of the project, an initial pre-start assessment was conducted to ensure all areas were accessible and to identify the most efficient methods for completing the work.

The project scope included the preparation and painting of various structural steel components within the facility. This included hammering off scabs, grinding to remove surface rust, and applying paint. A four-man rope access team, supplemented by a groundman/MEWP operator, was assigned to ensure all areas were covered efficiently and safely.

Access difficulty: Some areas of the structure were challenging to access via rope, necessitating the use of a MEWP.

Extensive surface preparation: Various levels of rust and degradation required meticulous preparation to ensure a clean and paint-ready surface.

Complex structure: The intricate configuration of the structural steel demanded careful planning and execution.

Pre-start assessment

A one-day access trial was conducted to identify potential challenges and determine the feasibility of using rope access for all areas. This assessment revealed that some sections would be more effectively accessed using a MEWP.

Manpower allocation

A team of four rope access technicians, supported by a groundman/MEWP operator, was deployed. This setup ensured efficient completion of tasks while maintaining high safety standards.

Surface preparation

• Main frame: The main frame, split into square sections around each of the 40 fan cells, required detailed surface preparation. A combination of grinders with wire cup brushes and needle guns was used to remove rust and prepare the steel for painting.
• Inside the cells: Each of the 40 cells housing the fans required three days of work by two men, ensuring thorough preparation and painting.
• Rooftop supports: The rooftop sections, including vertical and floating horizontal steels, required careful rigging off the horizontals. Structural drawings were reviewed to plan the approach effectively.
• Stair and platform supports: The supports for stairs, ladders, and a central structure around piping also required preparation and painting.

Through meticulous planning, innovative use of access methods, and a dedicated team, Sutro Group successfully completed the structural steel maintenance project. The combination of rope access and MEWP operations ensured that even the most challenging areas were addressed efficiently and safely, delivering high-quality results that will stand the test of time.

By prioritising safety and leveraging advanced techniques, Sutro Group demonstrated its commitment to maintaining the integrity of our client’s assets, ensuring operational continuity and extending the lifespan of the facility’s structural components.

For more information on how Sutro Group can optimise your inspection processes, contact us today:

0800 069 9395
info@sutrogroup.co.uk