Project: Height safety system design & installation
Location: 1 Lobethal Road, Lobethal SA
Client: Fabrik
Client need
The Fabrik team needed a comprehensive height safety system upgrade on the Fabrik Blanket Building in South Australia to improve safe roof access, support the installation of a new solar system on the building’s sawtooth roof, and ensure full compliance with current Australian Work Health & Safety (WHS) requirements and relevant Australian Standards.
The project addressed several pre-existing access and fall-protection risks, providing maintenance staff and contractors with safe, controlled access to rooftop plant and services through a fully engineered roof access system.
Key challenges
Prior to the upgrade, roof access and movement across the Blanket Building presented several serious safety and height safety compliance risks. Key issues identified included:
1. Limited safe access to roof areas
Existing access points were not designed for regular maintenance. Personnel were required to transition onto the roof from scissor or boom lifts, with no compliant fall protection in place.
2. No permanent fall protection
No permanent fall arrest or restraint systems were installed, leaving workers exposed to fall hazards near roof edges.
3. Uncontrolled movement across the roof
Without defined walkways or designated access routes, maintenance personnel walked directly on roof sheeting, significantly increasing the risk of slips and missteps, which could lead to serious injury.
4. Fragile roofing risks
Areas of the roof included materials that required controlled access to prevent loading damage or fall-through risks. The sawtooth glazing windows are not fall-rated, and as such, the installation of a safe roof access system, including a static line and designated walkway was essential to mitigate the risk of falls from height.
5. Non-compliance with current standards
The existing measures did not meet current WHS legislation or the relevant Australian Standards for safe work at heights, creating operational and legal risk for building management, contractors, and maintenance personnel.
A comprehensive safety solution
We designed and installed a custom height safety system, that maintained full compliance with AS/NZS 1657. We controlled every aspect of the project, from design to manufacturing and install, to retain high standards of quality and compliance. The solution comprised the following components:
Roof access & movement
The design and installation of a complete access system in accordance with AS/NZS 1657, which included:
- A change of direction ladder to the northern elevation providing safe, easy access to the two-storey roof
- to northern elevation providing safe, easy access to the two-storey roof
- Roof access ladder and transition points to allow safer movement from building access points onto each section of the sawtooth roof
- An aluminium modular roof walkway system installed to create designated safe access routes across all four sections of the sawtooth roof
- Handrail protection installed along all walkway sections to provide passive fall protection.
Fall protection system
- Engineered static line system installed on all four roof sections to allow safe, continuous attachment for personnel working near the edges
- Certified roof anchor points installed in accordance with AS/NZS 5532 to support both fall restraint and fall arrest systems.
Improved safety and compliance
The new system significantly improved safety for all personnel accessing the rooftop, delivering:
- Controlled and designated access pathways across all four sawtooth roof sections
- Permanent fall protection systems including static lines and certified anchor points
- Reduced risk of slips, trips, and uncontrolled roof movement
- Safe, maintainable access for routine inspections and contractor visits
The installation brought the Fabrik Blanket Building into full alignment with the current Australian Standards (AS/NZS 1657, AS/NZS 1891, AS/NZS 5532), as well as WHS working-at-heights requirements and best-practice height safety compliance design for industrial facilities.
Most importantly, the install of this custom system significantly reduces work-at-height risks for all personnel and ensures that facility managers fulfill their legislative requirements to protect workers. The project also supports the long-term management of rooftop solar infrastructure, making height safety inspections easier to conduct.
Does your building need a height safety upgrade?
We deliver fully engineered height safety systems across South Australia, including all installation and ongoing safety compliance support. Book a compliance assessement with our team today.
