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Kee Line, Kee Walk & Modular Step Unit Installation for Wind Tunnel Roof Access

APS Safety Systems installed Kee Line, Kee Walk and modular step units to deliver safe, compliant roof access for a specialist wind tunnel facility.

Case Study PDF

The Client

Our client is a leading global engineering, construction, and professional services company, delivering innovative solutions across infrastructure, transportation, energy, environmental, and industrial sectors. With extensive experience managing complex engineering projects throughout the UK and internationally, the organisation is recognised for its technical expertise, collaborative approach, and commitment to sustainability.

Supporting projects from concept through to design, construction, and operation, the company specialises in delivering technically demanding facilities where precision, safety, and performance are critical. Their reputation for engineering excellence has seen them appointed to some of the UK’s most prestigious infrastructure and construction projects.

One such project was the development of a state-of-the-art wind tunnel facility at Silverstone. Designed to support the next generation of high-performance automotive engineering, the facility plays a vital role in aerodynamic testing and vehicle development within one of the world’s most demanding motorsport environments.

Kee Line, Kee Walk & Modular Step Unit Installation for Wind Tunnel Roof Access - APS 2

Background

The wind tunnel forms part of a cutting-edge engineering campus dedicated to advancing automotive performance through world-class aerodynamic research and testing. The highly specialised facility enables engineers to evaluate vehicle performance under controlled conditions, helping to optimise efficiency, stability, and speed.

Unlike conventional industrial buildings, the wind tunnel presented several unique challenges. Powerful airflow generated within the tunnel meant that any loose components could present a significant safety risk and potentially compromise testing activities. In addition, lighting and electrical systems were installed through the roof structure, requiring safe and reliable access for ongoing inspection and maintenance.

To support the long-term operation of the facility, a permanent roof access solution was required that would provide safe working at height while integrating seamlessly with the specialist engineering requirements of the building.

The Brief

APS Safety Systems was appointed to design a safe access solution that would allow maintenance personnel to reach rooftop lighting, electrical installations, and other key equipment safely and efficiently.

The solution needed to address several critical requirements, including:

  • Providing safe access across the roof for planned maintenance activities.
  • Ensuring operatives remained protected while working at height.
  • Preventing any loose objects from entering the wind tunnel during maintenance.
  • Providing secure access to roof-mounted electrical and lighting installations.
  • Integrating with the building’s specialist design without affecting the operational performance of the facility.
  • Delivering a permanent, low-maintenance solution that complied with current working at height legislation.

Given the technical complexity of the project, APS carried out a comprehensive site survey to fully understand the operational requirements before developing a bespoke roof access strategy.

The Solution

Following detailed consultation with the project team, APS Safety Systems designed and installed a complete roof access solution incorporating Kee Line horizontal lifeline systems, Kee Walk walkway systems, and modular step units.

Each element was selected to address a specific aspect of the client’s maintenance requirements while working together as one integrated safety system.

Kee Line Horizontal Lifeline System

The Kee Line system provides continuous fall protection across the roof, allowing maintenance personnel to remain connected while moving safely between work areas. This significantly reduces the risks associated with working at height while providing unrestricted access to essential plant and equipment.

Kee Walk Walkway System

Kee Walk was installed to create clearly defined maintenance routes across the roof. The anti-slip nylon tread provides excellent grip in all weather conditions while protecting the roof surface from unnecessary wear caused by regular foot traffic. The designated walkways also help direct operatives safely around the facility.

Modular Step Units

To safely navigate changes in roof level, APS installed modular step units that provide secure, permanent access between varying elevations. These systems improve safety while reducing the need for temporary access equipment during routine maintenance.

Throughout the design process, particular attention was given to ensuring that lighting and electrical installations could be accessed safely without introducing loose components into the wind tunnel. Every element of the system was carefully integrated into the building’s structure to maintain the performance and integrity of this highly specialised facility.

The installation was completed efficiently and in close collaboration with the wider project team, ensuring minimal disruption to the construction programme while maintaining the highest standards of quality and safety.

The Outcome

The completed installation provides a comprehensive, permanent roof access solution that enables maintenance teams to safely access every required area of the wind tunnel roof.

By combining Kee Line, Kee Walk, and modular step units into one integrated system, APS has significantly improved both safety and operational efficiency.

Key benefits delivered include:

  • Permanent, compliant roof access for maintenance teams.
  • Continuous fall protection while working at height.
  • Safe access to roof-mounted lighting and electrical systems.
  • Clearly defined maintenance walkways reducing slip risks.
  • Permanent access between varying roof levels.
  • Reduced risk of accidental damage to sensitive equipment.
  • Durable, low-maintenance systems designed for long-term performance.
  • Minimal impact on the operational performance of the wind tunnel.

The success of the project demonstrated APS Safety Systems’ ability to develop innovative solutions for technically demanding environments where conventional roof access systems would not have been suitable.

The quality of the installation and collaborative approach adopted throughout the project also strengthened APS’s relationship with the client. As a result, APS has already secured opportunities to support additional specialist wind tunnel projects, including two further developments and another significant project in Italy.

Conclusion

This project demonstrates APS Safety Systems’ ability to deliver bespoke height safety solutions for some of the UK’s most technically challenging engineering environments. Through detailed consultation, innovative design, and expert installation, APS developed a roof access solution that supports both worker safety and the operational requirements of a world-class engineering facility.

With more than 30 years of experience and over 1,800 successful projects completed across the UK and beyond, APS Safety Systems continues to deliver tailored roof access, fall protection, and height safety solutions for commercial, industrial, and specialist engineering sectors.

If your project requires a bespoke roof access or fall protection solution, contact APS Safety Systems today to arrange a site survey and speak with one of our height safety specialists.

Kee Line, Kee Walk & Modular Step Unit Installation for Wind Tunnel Roof Access - APS Safety

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APS Safety Systems installed Kee Line, Kee Walk and modular step units to deliver safe, compliant roof access for a specialist wind tunnel facility.

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