Ropepro recently worked with GMHS to deliver to a major Melbourne water utility Rope Access maintenance to the roof structure within tankage at their facility at St Albans, Victoria.

Recent upgrade works to torsion rods within the roof structure of the tank required mechanical work as well as re-coating work to be carried out in difficult to reach areas of the roof structure of the tank. Due to the fact these works were required to be carried out within a tank, within strict time parameters coupled with the tactile nature of the task, Rope Access and work positioning techniques were selected as the most appropriate method of access for this work as opposed to other forms of access including Scaffold and Elevating Work Platform (EWP).

Ropepro has successfully assisted GMHS to deliver these works previously in 2018, however, when carrying out work in hazardous environments such as this, the pre-task assessment and control of these hazards and subsequent risk is still a major element of the overall project. Due to the nature and location of this work, the assessment of risk, the development of risk controls, Safe Work Method Statements (SWMS) and documented Rescue Plans required extensive consultation and input from various stakeholders and involved parties

At the task execution stage, this detailed level of planning ensures careful consideration of all elements of the work and provides clear instruction and work methodologies for the crews carrying out the work. Due to the dynamic nature of this work, the experience and skill of the work teams executing this task is paramount to the successful completion of a project such as this. Well done to all involved with this project to navigate a hazardous environment and successfully execute the project.

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The Richmond Recreation Centre features Melbourne’s oldest 50-metre swimming pool, with the centre first opening its doors as the “Richmond City Baths” in 1897.  Walking inside the centres’ front doors you find a magnificent orange coloured airplane-hanger-esque structure which contrasts beautifully against the aqua blue waters of the pool below.

Ropepro High Access Services were recently engaged by Total Ventilation Hygiene Pty Ltd (TVH Pty Ltd) to carry out routine maintenance and cleaning to the ducting which runs through the facility’s upper internal structure.  The temporary closure of the facility in-line with metropolitan Melbourne’s Stage 4 Restrictions has provided Ropepro and TVH Pty Ltd an opportunity to complete this scope of works during regular business hours while the facility is mostly vacant.  

The design of the facility and historical changes to Occupational Health and Safety Legislative requirements have made accessing the ducting via traditional forms of high access such as elevated work platform, scaffold or ladder very challenging. Roperpo have therefore worked in conjunction with TVH Pty Ltd and The City of Yarra to develop a safe system of work utilising industrial rope access methods.  Ropepro’s specialist, multi-disciplined, IRATA and ARAA trained technicians provide a safe, professional and innovative service with the ability to provide access solutions for almost any working environment.

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During the weeks and months leading up to the project commencement date, Ropepro worked closely with the AGL and Black Geo technical project management teams in the development of a Safe Work Method Statement and Rescue Plan to ensure the task hazards, risks and possible emergency scenarios were considered and controlled. These documents and plans required the flexibility to be reviewed and amended during the project to allow for emergent factors and hazards to be considered and controlled throughout the course of the project. Plans also needed to consider such potential scenarios as: air quality, communication between entrants and stand-by operatives, access to and treatment of a casualty or multiple casualties and the hauling or lowering of a casualty/ies through and out of the tunnel system whilst negotiating multiple hazards.

Prior to entry in to the Tunnel, anchor points were required to be installed in to the rock at the entrance of the tunnel to allow four abseilers to descend. Careful assessment of the rock was made by the Black Geo technical Engineers, Billy Burke and Nick Schofield, to ensure the rock was sound and suitable for use as a parent structure for the anchors. The Anchor points were then installed in to the rock face and load tested in accordance with manufacturer’s specifications and the Australian/New Zealand Standards.

An emergent hazard that was identified prior to entry was the presence of residual water at the head and entrance of the Tunnel. Although water had been isolated from the tunnel there was still the presence of water entering and falling through the tunnel during the inspection which created slip, trip and fall hazards as well as noise and communication hazards. By extension, another hazard that was identified was the risk of hypothermia due to the tunnel entrants being constantly exposed to cold water and cold temperatures for up to 3 hours at a time.

Through careful planning, consultation and execution by the project teams across several coordinated groups the inspection was carried out successfully and without incident in what proved to be a unique and challenging environment. The Geo technical Engineers were able to safely access the Tunnel under the Supervision of Rope pro site Supervisors to record accurate information relating to its condition to the satisfaction of our customer, AGL.

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Ropepro recently assisted Sugar Australia with the removal of redundant pipework within their Refinery at Yarraville, Vic. The identified pipework was no longer in use and presented a safety hazard if left in situ. Site Management therefore determined the removal of the pipework should be carried out. The challenge with removing the pipework was primarily that the area immediately surrounding the pipework was quite restricted, preventing the use of scaffolding or Elevating Work Platform (EWP) as methods of access. After consultation between Ropepro and Sugar Australia project managers, it was determined that Rope Access methods would be a viable solution to execute the task.

During several weeks leading up to the project commencement date, Ropepro worked closely with the Sugar Australia project management team in the development of a Safe Work Method Statement, Rescue Plan and a Lift/Lowering Plan to ensure the task hazards, risks and possible emergency scenarios were considered and controlled.

One aspect of the task that was identified as a hazard was the rigging. There was no suitable anchor points located on the roof area directly above the work zone. Therefore, ropes were rigged from steel structure within the building itself and exited through windows on either side of the work zone. By using both sets of ropes a Rope Access Technician was then able to safely access the lateral path of the pipework using a long rope transfer technique.

Using the above method, a hauling/lowering system in conjunction with a load cell was independently installed above the pipework. By incorporating a load cell in to the haul/lowering system we could monitor the weight of the load at all times to ensure the load did not exceed the load capacity of the equipment being used to support the pipework. Once the pipework was connected to the hauling/lowering system and supported, the flange connections were able to be disconnected and the pipework lowered to grade safely. Using this method the pipework was able to be safely removed in manageable loads.

Sugar Australia Reliability Engineer Zac Ludowyk had these comments regarding the project:

“Being my first time managing a rope access job, any concerns I had about the prospect of contractors abseiling down our heritage listed refinery building were quickly dispelled in our first meeting. Upon meeting the Rope Pro team I knew I was in safe hands. The degree of planning that went in to the job to identify the specific risks and control measures was quite impressive.The success of the job can be attributed to this. The documentation was thorough and submitted well ahead of the job for review. I particularly appreciated the expertise and attitude of the team members – nothing was rushed, safety first. I highly recommend Rope Pro for any troublesome access situations, and will not hesitate to have them back at Sugar Australia.”

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Ropepro recently assisted the Woolworths Group with removal of cladding within their new automated Distribution Centre in Dandenong South, Victoria.

The challenge Woolworths encountered was at the completion of the Construction phase, cladding between the highbay and the Operator platforms were left in place due to the challenging nature of removal, altering the designed airflow, trapping heat during the summer months, posing a health and safety issue for their employees. As the facility is now operational, the cladded wall itself, some 12mtrs high by over 100mtrs wide, was surrounded in state-of-the-art robotics, conveyors and machinery, restricting all access by Scaffold, Elevated Work Platform (EWP) or Cranes. The only way of accessing the large panels of cladding would be to climb the building’s structure to a position above each panel, and that is where Ropepro came in.

Ropepro developed a safe system of work utilising advanced rope access methods and were able to successfully execute the safe removal of the cladding by installing a lifting and lowering system above each panel.  The system could then be used to attach to each sheet and take its weight before the remaining fixings were removed and the panel safely lowered to grade. Ropepro worked closely with Woolworths  representatives s over a four week period leading up to the proposed commencement date to ensure the proposed methods of access, work and rescue capability aligned with the high standards of Quality and Safety expected during a project such as this.

Woolworths’ site Commissioning Manager, Tony Care had these comments regarding the project ” Through the process of seeking a safe and viable solution, we engaged several independent parties over many months, with no success. As the well-being of our employees is our priority, we continued to seek alternatives, and with the help of Google, I found Ropepro. Within a few days, Ropepro Operations Manager Kyle Roberts, attended site and immediately gave us a level of confidence on viable options. To ensure complete safety, Kyle arranged onsite demonstrations of how his team would complete the works, gaining full support from the site safety teams. The work was completed entirely as planned and without incident, a credit to both Ropepro and the Woolies teams for a joint effort”.

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Ropepro recently assisted Melbourne Water with maintenance to the roof structure within tankage at their St Albans Water Tank Farm in Victoria.

Recent upgrade works to torsion rods within the roof structure of the tank required mechanical work to be carried out in difficult to reach areas of the roof structure of the tank. Due to the fact these works were required to be carried out within a tank, within strict time parameters coupled with the tactile nature of the task, Rope Access and work positioning techniques were selected as the most appropriate method of access for this work as opposed to other forms of access including Scaffold and Elevating Work Platform (EWP).

Advanced rigging techniques and specialised rigging devices were also employed to allow materials and equipment to be safely and efficiently mobilised to each work area within the roof structure.

When carrying out work in hazardous environments such as this, the pre-task assessment and control of the these hazards and subsequent risk is a major element of the overall project. Due to the nature and location of this work, the assessment of risk, the development of risk controls, Safe Work Method Statements (SWMS) and documented Rescue Plans required extensive consultation and input from various stakeholders and involved parties. Ropepro worked closely with Melbourne Water representatives over several months leading up to the proposed commencement date to ensure the proposed methods of access, work and rescue aligned with the high standards of Quality and Safety expected during a project such as this.

At the task execution stage, this detailed level of planning ensures careful consideration of all elements of the work and provides clear instruction and work methodologies for the crews carrying out the work. Due to the dynamic nature of this work, the experience and skill of the crew executing this task is paramount to the successful completion of a project such as this. Ropepro’s disciplined team of Rope Access Technicians and Supervisors have a broad range of skills and experience that can be drawn on to navigate hazardous environments and execute project deliverables whilst maintaining high standards of health and safety.

Through careful and considered planning, clear instruction and disciplined yet innovative execution, this project was completed safely, under time and under budget.

Project Manager within the Waterways and Land Delivery division at Melbourne Water, Nick Lauer, had these comments regarding the project  “The engrained standard of professionalism and safety culture at Ropepro was evident through the high quality consultation and planning through to execution which ensured the safe, timely and cost effective delivery of the St. Albans Tank project. Ropepro will be my first point of contact for future high access rope works”.

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Ropepro recently assisted Meridian Energy Australia in annual inspection and routine maintenance of access Ladders within a number of their Wind Turbine Towers in South Australia.

Although most modern Wind Turbines now have lifts within them to allow easy access to platforms within the towers and all the way to the Nacelle, they are still required to have access ladders in case of emergency lift breakdown or access to internal tower sections between platforms.

The access Ladders commonly found within Wind Turbine Towers are typically “Single-Stile” or “Twin-Stile” Rung Type Ladders that are installed in conjunction with an in built vertical Fall Arrest system. This system allows the climber to freely climb up or down the Ladder and “Lock off” if the user were to lose their grip or slip from the Ladder arresting their fall.

According to AS 1657-2013 Fixed platforms, walkways, stairways and ladders – Design, construction and installation, the maximum height a rung type Ladder can be is 3.5m, beyond which a Fall Protection system must by installed which, in turn, must comply with AS/NZS 1891.4:2009 Industrial fall-arrest systems and devices – Selection, use and maintenance.

Annual inspection and maintenance of access Ladders and the fall protection systems that accompany them are not only a legal requirement but they are also critical to safe use and operation of the equipment. By carrying out regular inspection and maintenance in accordance with the manufacturers specifications and the applicable standards, any defects can be identified and corrective actions can be implemented in a timely manner to ensure the integrity of the equipment.

Regular inspection is also valuable as any relatively minor defects can be noted and monitored over time to observe any advancement of the defect to an unacceptable condition.

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