Wienerberger Weatherproof Working Tunnel

Project Overview

Wienerberger Ltd., a leading manufacturer of construction materials including bricks and clay blocks, required a safe and weather-protected access solution over a live conveyor system at their West Sussex production facility. The conveyor, a critical part of daily operations, needed to remain in use while still allowing safe access for maintenance and operational staff.

Amphibian Scaffolding was contracted to design and install both a secure access gantry and a full shrink-wrapped enclosure over the conveyor. The solution allowed continuous, safe access while protecting both personnel and machinery from weather and airborne debris.

Project Scope & Objectives

The main goal was to create a robust, weatherproof working tunnel over the conveyor line to ensure safe and easy access for maintenance staff, without interrupting production. The key deliverables included:

• Scaffold gantry constructed above and around the conveyor
• Full shrink wrap encapsulation for weather protection and containment
• Anti-slip working surfaces and safe pedestrian access routes
• Compliance with site-specific health and safety regulations
• Zero interference with conveyor operation

Key objectives:

• Protect sensitive machinery and staff from the elements
• Create a clean, controlled environment around an active production area
• Provide a superior alternative to standard debris netting
• Ensure durable, long-term weather resistance throughout the project lifespan

Execution & Delivery

The project began with a site consultation and risk assessment to understand the limitations of working over a live conveyor system within an industrial manufacturing environment. Our solution was engineered to meet both access and containment needs without compromising ongoing operations.
Execution highlights:

• Custom scaffold gantry built over and around the conveyor belt, allowing uninterrupted operation
• Full shrink wrap applied to create a sealed, weather-tight enclosure
• The wrap provided excellent protection against wind, rain, and dust—ensuring safe working conditions year-round
• Installation completed swiftly and safely, coordinated closely with site management to avoid production downtime
• Walkway included toe boards, handrails, and clear signage for pedestrian safety.

By opting for shrink wrap over traditional debris netting, Wienerberger gained a longer-lasting, tighter seal that provided significantly improved protection, reduced flapping/noise in windy conditions, and offered a cleaner, more professional appearance.

Outcome

The project was delivered efficiently and without disruption to factory operations. The access gantry and shrink-wrapped tunnel allowed staff to safely manage and monitor the conveyor system, even during adverse weather conditions.
The choice of shrink wrap proved particularly valuable for dust control and durability—critical in a heavy-duty manufacturing setting like Wienerberger’s. The client was pleased with the results, particularly the neat finish and reliability of the installation.

This project showcased Amphibian Scaffolding’s ability to deliver intelligent, high-performance access and containment solutions in active industrial environments.