This project required a fully bespoke set of access solutions, including cat ladders, roof-edge balustrading, and a hop-up stair, to support safe maintenance access to plant and equipment on a healthcare facility roof. DG Scott were appointed to design, fabricate and install a series of custom components that could be safely installed without drilling into the roof and while navigating extremely tight and complex spatial constraints.
Background
The client required four bespoke cat ladders, roof-edge protection balustrading and a hop-up stair to provide safe access to plant, equipment and ducting located on the roof of a healthcare facility. Due to site limitations, tight gaps, and areas with restricted clearance, standard solutions were not viable, necessitating a fully customised fabrication approach from DG Scott.
The Challenge
The project presented several technical and logistical challenges:
1. No drilling or roof penetration permitted
All four ladders had to be installed on a roofing system that could not be drilled into or cut, ruling out conventional fixing methods. Two ladders needed to reach the flat roof of the mobile imaging unit, while the other two required access to ducting cleaning hatches.
2. Sloped roof and extremely restricted access
The section of roof beneath the ducting hatches was sloped at 20°, complicating ladder positioning and stability.
The ducting layout created additional challenges, including:
- A tight 90-degree bend
- Only 500mm of vertical clearance
- Ducting suspended on thin legs spaced at ~800mm, preventing placement of a ladder directly beside the left-hand hatch
A bespoke structural solution was essential to ensure safe access.
3. Requirement for roof-edge balustrading
The mobile imaging unit required roof-edge protection, but the same no-drill restrictions applied. A completely custom approach was needed to ensure safety without compromising the roof structure.
The Solution
DG Scott conducted a detailed site survey to capture measurements, assess restrictions and identify the safest load-bearing points.
Specialist Engineering & Design
- Fully bespoke cat ladders were developed to fit precisely within the sloped and confined roof space.
- Custom support structures were engineered to distribute loads without penetrating the roofing system.
- For the left-hand ducting hatch, where direct access was impossible, DG Scott designed a tailored offset system to allow safe, compliant cleaning access.
In-House Fabrication & Protective Finishing
All ladders, balustrades and hop-up components were designed and fabricated in-house.
Each item was galvanised for long-term durability in an exposed outdoor environment.
Non-Invasive Installation
DG Scott’s installation team used specialist fixing methods designed exclusively for delicate or protected roofing systems, ensuring no penetration of the roof while maintaining full structural stability.
The Outcome
DG Scott delivered a suite of highly customised access components that now provide safe, reliable and regulation-compliant access to:
- The mobile imaging unit
- Roof-edge working areas
- Ducting cleaning hatches
- Plant and equipment on the facility rooftop
Despite strict limitations and challenging site conditions, the team engineered a practical and durable solution that met all safety and operational requirements.
If you require bespoke access solutions for challenging or sensitive environments, contact DG Scott. Our engineering and fabrication specialists can design, manufacture and install fully tailored systems to meet your exact requirements. Contact us today.