PUDDING MILL LANE

Our team recently completed an interesting and technically challenging project at Pudding Mill Lane, where we worked with a new client to install a fixed CAT ladder to provide safe access to a sump pump room. The existing access arrangements were not ideal, presenting potential safety risks for anyone entering or exiting the area. The installation of the new ladder was therefore an essential improvement, ensuring compliance with access and egress safety requirements and creating a more secure working environment for ongoing maintenance activities.

The project presented several logistical and technical challenges from the outset. The sump pump room is located within a confined area, meaning that careful planning and precise execution were vital. Our engineers carried out a detailed site survey before starting work, developing a step-by-step plan to manage the limited working space and safely handle the installation of the 7.5-metre ladder. Coordination with the client and site stakeholders was key throughout, ensuring that all health, safety, and operational requirements were met.

The main scope of works included the design, approval, and installation of a 7.5-metre CAT ladder, supplied in two sections to facilitate handling and assembly in the restricted area. The ladder design was reviewed and approved by RFLI (Rail for London Infrastructure) before installation, confirming full compliance with relevant standards. Once on site, our team carefully aligned and bolted the two sections together, ensuring a secure and seamless connection. To fix the ladder to the concrete structure, we used Hilti chemical fixings, selected for their proven strength and reliability in structural applications.

To go above and beyond standard requirements, we carried out pull tests on all ladder fixings rather than the 20% sample rate typically required by specification. This provided complete assurance of the integrity and performance of every fixing point, demonstrating our commitment to safety and quality workmanship.

Given the density of reinforcement (rebar) within the concrete substrate, drilling presented its own set of difficulties. Using our extensive range of small tools and specialist drill bits, our engineers were able to penetrate the reinforced concrete cleanly and achieve the necessary depth for the chemical anchors. Their skill and attention to detail ensured that no rework was needed and that installation could proceed smoothly.

In addition to the ladder installation, we also fitted new metal mesh flooring within the sump pump room. This provided a robust and anti-slip walking surface, further enhancing the safety of personnel working in the area.

Throughout the project, our site team maintained a strong focus on safety, communication, and quality. Despite the challenging working conditions, all works were completed on schedule and without incident. Upon final inspection, both the RFLI engineers and the TfL Pumps team expressed their satisfaction with the quality of the installation and the professionalism of our team on site.

The successful completion of this project at Pudding Mill Lane demonstrates our ability to deliver complex installations in constrained environments, combining practical engineering solutions with meticulous planning and an uncompromising approach to safety.