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Kee Line Installation for Aerospace Manufacturer

Discover how Harcon replaced an outdated lifeline with a new Kee Line system — a cost-effective, compliant solution for safe roof access.

Case Study PDF

The Client

Our client is a world-leading aerospace manufacturer dedicated to developing innovative jet engine technologies that are transforming flight and driving the aviation industry toward a more sustainable future.

At its advanced facility in Bristol, the company focuses on composite technology — developing lightweight fan blades and fan cases that significantly reduce aircraft weight. These innovations improve fuel efficiency and lower emissions, helping the aviation sector take measurable steps toward environmental responsibility.

The state-of-the-art facility was designed to operate with low energy consumption and minimal emissions. Automated manufacturing methods, precision engineering, and responsible material use ensure that every process maximises efficiency while reducing waste. As part of a wider corporate goal, the organisation has pledged to achieve net zero emissions across all operations by 2030.

The Brief

While the facility’s design reflected the highest standards in technology and sustainability, there were challenges in maintaining safe roof access for essential maintenance and inspection work.

An exclusion zone had previously been implemented around several skylights on the roof to restrict access to fragile and unprotected areas. However, over time, the maintenance team began to experience roof leaks near the perimeter of this exclusion zone. Although the roof required urgent repair, safe access to these areas was limited due to the deteriorated state of the existing fall protection system.

The existing lifeline system, which had been installed some years earlier, was in poor condition and no longer met current safety or compliance standards. When assessed, the cost of repairing the old system was found to be significantly higher than installing a new Kee Line system from scratch.
The client’s goal was clear — to remove the failed system and replace it with a modern, compliant, and cost-effective fall protection solution that would enable maintenance teams to safely access the roof while ensuring full legislative compliance.

The Solution

Harcon Services was appointed to design and install the new fall protection system. As with every project, our process began with a detailed on-site survey and risk assessment. This evaluation allowed our team to fully understand the site layout, roof structure, and the specific safety requirements for future maintenance access.

Following the survey, we recommended the installation of a Kee Line horizontal lifeline system around the roof perimeter. Kee Line is an advanced, permanent fall protection system designed to provide continuous, hands-free safety for those working at height. Its modular components allow for flexible installation on a variety of roof types while maintaining full compliance with UK safety standards.

Our proposed plan included:

  • Removal of the existing failed lifeline system, ensuring all old fixtures were safely decommissioned.
  • Installation of a new perimeter Kee Line system using clamped components — eliminating the need for roof penetrations and preserving the building envelope.
  • Supply of new Kee Travellers to provide secure, efficient movement along the lifeline system for workers using standard PPE.
  • Full inspection and testing of the installed system to ensure compliance with the Work at Height Regulations and BS EN 795 standards.

Once the quotation was submitted, the proposal was approved by the client’s project team. The installation was scheduled to ensure minimal disruption to ongoing operations within the facility.

The Outcome

The completed project provided the client with a robust, cost-effective, and fully compliant fall protection system. The outdated and unsafe lifeline was completely removed, replaced by a modern Kee Line system that offers secure access for maintenance personnel.

Key benefits achieved include:

  • Cost-effective solution: Installing a new Kee Line system proved more affordable and efficient than repairing the deteriorated system.
  • Safe and compliant roof access: Maintenance teams can now safely reach areas previously restricted by the exclusion zone to perform essential repairs.
  • Non-penetrating installation: The clamped design ensures no damage to the roof membrane, preserving the integrity of the structure.
  • Improved user experience: The new Kee Travellers allow smooth movement along the lifeline while ensuring users remain securely attached.
  • Long-term reliability: The Kee Line system delivers a durable, low-maintenance safety solution built to perform for years.

With the new system in place, the facility’s maintenance teams can confidently carry out repairs and inspections in full compliance with work-at-height safety legislation.

Harcon Services continues to support the client with ongoing discussions about extending fall protection coverage to other roof areas, including the installation of additional systems to safeguard unprotected roof lights.

Harcon - Case Study - Kee Line Installation for Aerospace Manufacturer 2

Conclusion

This project demonstrates Harcon’s expertise in delivering end-to-end fall protection solutions tailored to each client’s unique needs. From the initial consultation and site survey through to installation and certification, Harcon ensures that every system provides maximum safety, compliance, and long-term value.

By installing a new Kee Line system, we helped our client overcome a major access challenge, eliminate risks, and maintain their commitment to operational excellence and employee safety.

At Harcon Services, we understand that every site is different — and we pride ourselves on designing and installing bespoke systems that keep people safe while protecting the integrity of every building.

If your facility requires a reliable, compliant, and cost-effective fall protection system, contact Harcon Services today to arrange a site survey and expert consultation.

Harcon - Kee Line Installation for Aerospace Manufacturer

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Discover how Harcon replaced an outdated lifeline with a new Kee Line system — a cost-effective, compliant solution for safe roof access.

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