7m Access Cat Ladder – Bund Access Safety Design

Key Contributions

• Applied sheet metal design techniques in SOLIDWORKS to model and flatten components for precise fabrication, improving manufacturability and fit-up.
• Engineered a modular structure featuring pre-formed safety cages, bolted connections, and adjustable ladder brackets for quick site installation.
• Validated design compliance with relevant safety standards and internal site access policies.
• Produced comprehensive fabrication drawings detailing sheet metal folds, welds, and assembly interfaces.
• Developed RAMS documentation (Risk Assessment & Method Statement) to ensure safe handling and installation on site.

Outcome & Impact

• Delivered a fully compliant, easy-to-install access solution that enhanced safety for operators and maintenance personnel.
• Reduced on-site installation time by 25% through a modular sheet metal design approach.
• Improved fabrication efficiency and repeatability by standardizing ladder and cage sections.
• Strengthened the company’s safety record and operational accessibility standards.

Skills

1. Sheet Metal Design & Fabrication

Applied advanced sheet metal design techniques in SOLIDWORKS to develop modular ladder sections, safety cages, and landing platforms.

Generated flat patterns and bend allowances to ensure precise fabrication and assembly alignment.

Optimized material use through efficient nesting and component standardisation.

2. Structural & Safety Engineering

Performed load and deflection assessments to ensure structural integrity under live and static conditions.

Integrated working-at-height safety standards and ergonomic access principles throughout the design.

Designed structural interfaces for secure wall, bund, and platform mounting.

3. CAD & Technical Documentation

Produced detailed 3D models, fabrication drawings, and assembly documentation for manufacturing teams.

Coordinated with fabricators to validate weld details, bracket geometry, and sheet thickness prior to production.

Created clear installation sequence diagrams to simplify site assembly.

4. Compliance & Risk Management

Developed comprehensive RAMS (Risk Assessments and Method Statements) to ensure safe installation procedures.

Ensured design compliance with BS EN ISO 14122 (Safety of Machinery – Permanent Means of Access to Machines).

Delivered documentation supporting CDM (Construction Design and Management) compliance for the project.

5. Collaboration & Project Delivery

Worked cross-functionally with site engineers, installers, and project managers to align design with operational needs.

Provided on-site design support during installation, adapting solutions based on real-time feedback.

Ensured on-time, compliant delivery with zero safety incidents during implementation.