Kee Guard Installation for Manufacturing Facility in Dublin

The Client

Skyway was engaged to deliver an upgrade to safety-at-height systems at a large manufacturing and packaging facility located in Clondalkin, West Dublin. The site operates as part of a wider international organisation supplying corrugated packaging solutions to multiple sectors, including agriculture, food and beverage, healthcare, and general manufacturing.

The facility employs a significant workforce and operates within a fast-paced production environment where safety, compliance, and operational efficiency are critical. As part of a wider building project at the site, the client required a comprehensive review and upgrade of existing working-at-height safety systems.

Skyway - Kee Guard Installation for Manufacturing Facility in Dublin - Case Study 3

The Brief

The client contacted Skyway to review and upgrade their existing safety-at-height equipment at the Clondalkin facility. The objective was to ensure all roof and elevated access areas were fully compliant with current Irish and EU working-at-height regulations while also improving usability for ongoing maintenance activities.

The site required a combination of safety systems, including:

Fixed access ladders
Cable-based fall protection systems
Guardrail edge protection
Kee Covers to protect roof openings and fragile areas

As the project progressed, the scope of works evolved several times. Through multiple calls and meetings, Skyway worked closely with the client to assess different options and refine the design to achieve the safest, most practical, and cost-effective solution.

The brief ultimately focused on delivering a fully compliant, integrated safety system that supported routine maintenance, reduced risk, and aligned with the operational demands of a live manufacturing environment.

The Solution

Site Survey and Assessment

Skyway began the project with a detailed on-site survey, assessing existing safety provisions, roof layouts, access routes, and risk areas across the facility. The survey also considered how frequently different roof zones required access and which form of protection would be most appropriate in each area.

This detailed assessment enabled Skyway to move beyond a single-system approach and instead design a solution tailored to the site’s specific requirements.

Hybrid System Design

Following consultation and technical review, Skyway proposed a hybrid safety solution combining several proven systems to provide comprehensive protection across the facility. The final design included:

Kee Guard guardrail systems to deliver collective edge protection along roof perimeters.
Kee Line lifeline systems in areas where flexible, continuous fall protection was required.
Kee Covers installed over roof openings and fragile zones to prevent fall-through risks.
Fixed ladders to ensure safe vertical access to roof and elevated areas.

This blended approach ensured that each risk area was protected using the most appropriate system, improving safety outcomes while avoiding unnecessary complexity or cost.

Skyway produced a robust technical design package, including layout drawings, system specifications, and compliance documentation. The design was refined through ongoing consultation to ensure full alignment with the client’s safety standards and operational needs.

Installation and Delivery

Once approved, Skyway’s internal design and installation teams coordinated the delivery of the works. Having all disciplines in-house allowed Skyway to maintain full quality control, respond quickly to site conditions, and deliver the project efficiently.

The installation was carefully planned to minimise disruption to ongoing manufacturing operations. All systems were installed in accordance with manufacturer guidance and relevant safety standards, followed by inspection and certification to ensure full compliance.

Skyway - Kee Guard Installation for Manufacturing Facility in Dublin - Case Study 2

The Outcome

The completed installation delivered a robust, compliant, and future-proof safety-at-height solution for the Clondalkin facility.

Benefits to the Customer

Improved Safety and Compliance: The new Kee Guard, Kee Line, and Kee Cover systems provide comprehensive fall protection, ensuring personnel can work safely at height in full compliance with current regulations.

Enhanced Maintenance Access: Permanent safety systems and clearly defined access routes allow maintenance teams to carry out inspections and servicing more efficiently and with reduced risk.

Cost-Effective, Long-Term Solution: The hybrid design maximised safety while reducing unnecessary installation and long-term maintenance costs, delivering strong lifecycle value.

Efficient Project Delivery: Despite several scope changes during the planning phase, the project was delivered smoothly through close collaboration and clear communication.

Ongoing Collaboration: The success of this project has led to continued collaboration, with additional safety system installations planned in the coming months.

Conclusion

This Kee Guard installation demonstrates Skyway’s expertise in delivering bespoke, integrated safety solutions for complex manufacturing environments. By adopting a consultative approach and tailoring the system to the site’s evolving needs, Skyway delivered a solution that improves safety, ensures compliance, and provides long-term operational value.

From initial survey and design through to installation and certification, Skyway provided a complete end-to-end service, supporting the client in creating a safer working environment without compromising productivity.

If your organisation is reviewing its safety-at-height systems or planning upgrades as part of a building project, Skyway can help.

Contact Skyway today to arrange a site survey and discover how we can deliver a compliant, future-proof safety solution for your facility.

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Skyway delivered a compliant Kee Guard installation at a Dublin manufacturing facility, improving roof safety, access, and long-term maintenance efficiency.

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