Case Study: Gurney Slade
Case Study Summary
Support Services Provider: Severn Access & Rescue Services
Services Provided: Industrial Rope Access Maintenance
Project Location: Gurney Slade Site in Radstock, Somerset, UK.
Task Summary
The task involved Severn Access & Rescue Services supporting a third-party contractor in conducting essential maintenance works at their Gurney Slade Site in Radstock, Somerset. The task involved replacing approximately 30 nuts and bolts on a critical pinch flange within the milling facility. Given the challenging access conditions and working-at-height requirements, rope access methods were employed to ensure operational efficiency and regulatory compliance.
Objectives
- Securely install 30 new bolts on a structural flange located in an elevated position within the mill.
- Conduct all work under UK Work at Height Regulations and in accordance with all safety procedures.
- Minimise the exposure of personnel to airborne dust generated by Marble and Limestone Filler residues during maintenance.
Specialist industrial rope access services were provided in the completion of the task.
Materials Involved
Two bulk materials of concern in the operational area were:
- Marble (Calcium Carbonate)
- Not classified as hazardous under CLP Regulation.
- Main risk: fine particulate dust that can irritate respiratory airways.
- Limestone Filler
- Also comprised of Calcium Carbonate and trace Quartz (SiO₂).
- Quartz is a known respiratory hazard when airborne in respirable form.
Both substances, while chemically stable and non-flammable, presented potential risks due to dust inhalation. Therefore, the RAMS accounted for these risks with appropriate respiratory protective equipment (RPE) and ventilation strategies.
Risk Assessment and Controls
Key hazards included:
| Activity | Hazard | Initial Risk Score | Control Measures | Residual Risk |
|---|---|---|---|---|
| Working at height | Fall from height | 20 (Very High) | IRATA-trained team, twin rope, MEWP backup | 5 (Low) |
| Dust exposure | Respiratory illness (Marble & Limestone) | 6 (Moderate) | RPE (FFP3), ventilation, limited exposure time | 2 (Very Low) |
| Dropped tools | Injury to persons below | 10 (Medium) | Tool lanyards, area exclusion zones, containment | 5 (Low) |
| Manual handling | Musculoskeletal injury | 6 (Moderate) | Load sharing, pre-planned routes, lifting aids | 4 (Low) |
All risk ratings were reduced to an acceptable level through mitigation strategies outlined in the RAMS.
Methodology
The work was executed using a two-person IRATA-qualified rope access team. The methodology followed a seven-step approach:
- Preparation and Site Setup
- A Level 3 IRATA Supervisor inspected all anchor points to EN 795 and BS 7883 standards.
- Twin rope systems were deployed, with backup fall arrest systems and tool containment protocols.
- Ascent and Positioning
- The technician ascended using prusiks and a chest-mounted rope grab, maintaining constant communication with the standby team.
- Bolt Installation
- A torque-controlled installation of 30 bolts was carried out, ensuring no tools or parts were dropped.
- All operations were performed hands-free using work positioning lanyards.
- Dust Control Measures
- Exposure to Marble and Limestone dust was mitigated through:
- Use of FFP3 respirators.
- Ventilation via open doors and natural airflow.
- Post-job equipment cleaning outdoors.
- Exposure to Marble and Limestone dust was mitigated through:
- Descent and Debrief
- Controlled descent on the twin rope system.
- Post-task inspection of bolt fittings and debriefing with the site supervisor.
Outcomes and Compliance
- The task was completed on 18th June 2025 without incident.
- All bolts were successfully secured and torque tested.
- No dust-related symptoms were reported by staff.
- Compliance was maintained with:
- The Control of Substances Hazardous to Health (COSHH) Regulations.
- IRATA ICOP standards for rope access.
- The REACH and CLP regulations governing substance use.
Conclusion
Our Gurney Slade case study demonstrates a successful integration of rope access, risk management, and COSHH-compliant procedures in an industrial setting involving potentially hazardous particulates. Through careful and metoculous project oversight by Severn Access and Rescue, the project was executed safely and in full alignment with UK regulations and best practice.
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