Case Studies

Factory Access Catwalk and Integrated Maintenance Platforms


Client: UK Packaging Manufacturing Facility

Delivered by: RHW Engineering

Services: Design, Manufacture & Installation of Access Catwalk and Maintenance Platforms

The Project


RHW Engineering recently completed the design, manufacture, and installation of a bespoke access catwalk connecting two office areas within a busy packaging manufacturing facility. The new catwalk not only provides safe and efficient personnel access between offices but also integrates maintenance platforms for essential duct inspection and servicing.

This project formed part of a factory improvement and production upgrade, where RHW Engineering supported the client with multiple access, equipment integration, and health and safety improvements

The Improvements/ Expansion:


To effectively have a direct route, joining each office accommodation via a new overhead bridge section between the offices. Spanning over the factories 24/7 waste management system.

The client needed:

  • A safe and permanent access solution between offices.
  • Installation during live operations with minimal disruption to the baler house.
  • The structure to also act as joint access for inspection and servicing of ducting systems.

Additionally, the new structure had to meet stringent health and safety standards, reduce unnecessary factory floor traffic, and fit within tight spatial constraints.

The Solution


Design and Planning

RHW Engineering’s design team conducted comprehensive on-site surveys to assess existing infrastructure, utilities, and spatial limitations. This proactive approach allowed the team to develop a structurally efficient, modular design that could be installed safely and quickly with minimal interruption to production.

Structural Design and Fabrication

  • Minimal footprint design: A bridge platform supported by three goalpost frames preserved valuable floor space within the baler house.
  • Lightweight modular structure: The catwalk was fabricated from medium-weight steel beams, designed for strength and ease of installation in confined areas.
  •  Galvanised open-mesh flooring for secure footing. Selected to allow natural light penetration from existing ceiling lights.

Integrated maintenance access: Two additional pier platforms were attached alongside the catwalk to provide safe inspection zones near the ducting system.

All components were manufactured and certified to BS EN 1090-2:2018+A1:2024 standards, ensuring full compliance for steel structures.

 

Installation


The installation was completed with zero unplanned production downtime. With space at a premium and limited forklift access, the team utilised chain blocks and Genie lifts to position the components. RHW installed the catwalk in two stages—on either side of the central support frame—allowing the baler system to remain fully operational throughout.

The result was a permanent, multi-purpose access system completed safely, efficiently, and on schedule.

Results & Benefits


  • Improved Safety: Reduced personnel traffic across the production floor and safer access for duct maintenance.
  • Operational Efficiency: Installation completed without halting production.
  • Optimised Space: Compact, goalpost-supported design maximised available floor area.
  • Compliance & Durability: Fully certified to BS EN standards, providing a robust long-term access solution.

Conclusion


This project showcases RHW Engineering’s ability to design and deliver bespoke access solutions within complex, operational manufacturing environments. By combining innovative design, precision fabrication, and meticulous installation planning, RHW provided the client with a durable, compliant, and efficient access catwalk that supports ongoing production and maintenance needs.