Project Requirements and Site Conditions

The project involved the installation of a 43-metre-high automated warehouse racking system within a large distribution facility. As construction progressed, traditional elevated work platforms could no longer safely access the work area because the boom lifts were unable to reach through the completed racking structure.

Without an alternative solution, installation works risked delays, increased safety exposure and reduced productivity. The project required an innovative approach that would provide safe access at height while allowing installation activities to continue efficiently within the confined operating environment.

Rather than accepting the limitation, Rigsafe worked to engineer a purpose-built solution specifically for the project.

How Rigsafe Delivered the Work

Rigsafe designed and developed a custom aluminium flipper deck to overcome the site's unique access challenges and maintain safe installation operations throughout the project.

The engineered platform was purpose-built to operate within the warehouse structure, providing a stable working platform that could be safely positioned inside the completed racking. The design incorporated integrated rollers for efficient movement between work locations and fold-out handrails to provide continuous edge protection for personnel working at height.

The innovative system allowed installation crews to safely access previously unreachable work areas while significantly improving efficiency across the project. Throughout construction, the flipper deck became an integral part of the installation methodology and was used extensively to support the completion of the high bay racking system.

Rigsafe's scope included:

• Engineering and design of a custom aluminium access solution
• Specialist lifting and rigging
• Safe access planning for work at height
• Installation support for 43-metre-high warehouse racking
• Development of an innovative flipper deck system
• Integrated safety features including rollers and fold-out handrails
• Ongoing lifting and installation coordination throughout the project

The Result on Site

The custom-engineered flipper deck was used more than 1,200 times during the project, enabling the safe and efficient installation of the entire high bay racking system without incident.

By designing a practical solution to a complex site challenge, Rigsafe eliminated a critical access constraint, improved productivity and maintained safe working conditions throughout construction.

The project demonstrates Rigsafe's commitment to engineering-led problem solving, showing that when conventional methods are not suitable, our team has the expertise to develop innovative solutions that keep projects moving safely and efficiently.

Project highlights:

• Purpose-built engineered access solution
• Over 1,200 safe deployments
• Enabled installation where conventional boom lifts could not operate
• Improved efficiency and reduced project risk
• Completed without incident
• Demonstrated Rigsafe's innovation and engineering capability