The brief
Following a request from Transport for London, the team undertook the overhaul and refurbishment of a manual travelling access gantry to improve the reliability, safety, and long-term operation of the system. The existing system had reached a point where the drive gear assemblies were showing wear, the outrigger arrangement no longer supported the close-access work required at the glass atrium areas, and the operating personnel needed structured training to continue using the gantry safely.
Gantry systems used for building maintenance are subject to the Provision and Use of Work Equipment Regulations 1998 (PUWER), which require work equipment to be maintained in efficient working order and good repair, and used only by people who have received adequate training. Where equipment has deteriorated beyond safe operational tolerances, continued use without remediation creates both a legal compliance risk and — more critically — the risk of equipment failure during live access operations at height. The brief was to bring the system back within safe operating parameters and establish a structured training and inspection regime going forward.
What we did
The existing manual drive gear assemblies were removed and replaced with upgraded taper lock bearings and new drive gears, restoring system performance and improving future maintainability. Taper lock assemblies provide a more secure and repeatable connection than the original components, improving load transfer across the gantry drive system and simplifying future maintenance intervals compared to the previous arrangement.
Following the overhaul works, the team supplied and installed replacement outrigger boards to provide safe and secure close access to the glass atrium areas. The upgraded outrigger arrangement is sized to support the inspection and cleaning works required at the atrium faces, allowing operatives to work in a fully restrained position without risk of overreach or unsupported access — addressing a key limitation of the previous setup.
In addition to the mechanical works, Sky Height Safety now provides structured operator instruction training for TfL engineers using the gantry system. The training covers pre-use inspection checks, safe travel and positioning of the gantry, correct use of personal fall protection equipment during access operations, and emergency procedures — meeting the requirements of PUWER Regulation 9 for information, instruction, and training in the use of work equipment. Training records are maintained and refresher sessions are scheduled to ensure continued competence across the operator group.
Following the overhaul, a full thorough examination of the gantry was completed and certification issued, confirming the system is fit for continued use and establishing the next scheduled examination date.
The outcome
The works extended the operational lifespan of the gantry system, restored safety margins for maintenance access operations, and ensured the system can continue to provide reliable access for ongoing building maintenance. The overhaul and certification process also gave TfL a documented compliance record for the asset — essential for managing work equipment obligations across a large and complex built estate.
With operator training in place, TfL engineers use the upgraded gantry confidently and consistently across their routine maintenance programme. Transport for London remain a current client — we continue to act on their behalf for operator instruction, periodic inspection, and any further upgrade or remedial works identified during the examination cycle.