Catwalk Installation - Assembling and Installing a 30-Metre Catwalk Across Three 20m Silos

Week 8 recap: a 30-metre catwalk was installed across three 20m silos using modular assembly, precision lifting, and controlled crane operations.

Project Progress – Connecting the Structures

By Week 8, all three 17m silos had reached full height. With structural construction complete and inspections signed off, attention turned to one of the most visually striking elements of the project: installing a 30m catwalk linking the three 20m high silos. ailed planning, coordinated lifting operations, and precise alignment at height.

Day 1 – Site Preparation and Planning

Before any lifting began, the team carried out detailed preparation and safety planning.

The catwalk was designed and fabricated in four sections, each approximately 7.5 metres long. This modular approach allows for safer, more controlled lifting operations.

On the ground, the team:

Laid out all four sections
Checked side trusses, cross braces, and grating panels
Verified handrail components and fasteners against drawings
Confirmed lifting points and rigging plans

Every connection was reviewed before assembly began.

Day 2 – Pre-Assembly of Catwalk Sections

Each catwalk module was assembled at ground level. Sections were square-checked for alignment, temporarily bolted for lifting stability and prepared with lifting slings for crane operations.

By the end of the day, all four sections were assembled and staged in lifting order.

Day 3 – Lifting the First Two Sections

Favourable weather conditions allowed lifting to proceed safely.

The first two sections were installed between Silo 2 and 3 following a strict procedure:

Final rigging and balance check
Controlled crane hoist to roof height
Use of tag lines to prevent rotation
Alignment with pre-installed mounting brackets
Bolting into place with high-strength galvanized fixings

The first section was installed smoothly. The second required minor adjustment due to a light crosswind but was secured successfully by mid-afternoon.

All bolts were torque-marked, and level checks were completed before work concluded for the day.

Day 4 – Completing the Span

Attention then turned to the connection between Silo 1 and 2.

Sections three and four were lifted and installed using the same controlled methodology. With three silos aligned in a row, maintaining perfect positioning was critical. Even slight deviation at one joint could affect the full 30-metre span.

Once secured, the complete elevated walkway connected all three silos. Final splice plate connections were completed, and alignment was verified using laser levels.

Day 5 – Grating, Handrails and Final Commissioning

With the primary structure in place, finishing components were installed, including:

Galvanized floor grating panels
Saddle clip fixings for secure, non-slip access
Handrails and toe boards bolted to pre-drilled posts

The final day focused on inspection and commissioning. The client joined the team for a full walkthrough, during which safe access routes, harness anchor points, and maintenance considerations were reviewed.

Standing 20 metres above ground level, the completed catwalk provided a robust and safe access route linking all three silos.

Week 8 Summary

Week 8 represented a highly coordinated operation requiring precise lifting, careful alignment, and strict safety control. The completed 30-metre catwalk now connects all three silos, providing long-term operational access and maintenance capability.

This phase showcased not only engineering precision but also the strength of detailed planning and teamwork at height.