Providing safe access around a working animal feed processing site required a scaffold solution that could deal with two very different challenges at once.
For this project, we installed a temporary internal scaffold staircase inside a concrete silo, along with an external scaffold tower to reach feeder cladding for inspection and repair.
Because the work involved deteriorated internal concrete, a curved silo structure, and the need to maintain safe operations around an active production environment, the scaffold design had to be practical, stable, and carefully planned from the start.
Client Profile
This project was carried out at an agricultural and industrial storage facility operating as part of an animal feed processing site. The client needed safe access for maintenance works to address deteriorated internal concrete within the silo, while also reaching external feeder cladding that required inspection and repair.
The access arrangement had to support maintenance activity both inside and outside the structure without causing unnecessary disruption to ongoing site operations. With feed production continuing around the work area, the scaffold also needed to be installed in a way that protected access routes, reduced interference, and maintained a safe working environment throughout the project.
Scope of Work
We supplied and installed a temporary internal scaffold staircase to provide safe entry and vertical access within the concrete silo. Alongside this, we built an external scaffold tower to give the maintenance team secure access to the feeder cladding on the outside of the structure.
The scaffold package included:
- An internal scaffold staircase for safe access inside the silo
- An external scaffold tower for cladding inspection and repair
- Modular scaffold components suited to both internal and external working areas
- Guardrails and toe boards to improve collective fall protection
- Non-slip working platforms for safer footing
- A scaffold arrangement adapted to suit the curved shape of the silo
By combining internal and external access within one coordinated scaffold solution, we were able to give the client practical access to each work zone while keeping the structure stable and the layout efficient.
Timeline & Team
The project was completed over 2 to 3 days by a team of 3 to 4 scaffolders. All works were programmed in coordination with the client’s ongoing feed production schedule so the maintenance team could access the required areas without unnecessary delay.
Because the site remained operational during the scaffold works, sequencing and communication were important throughout. The installation was planned to fit around live site activity, allowing the scaffold to be erected safely while keeping disruption to surrounding operations to a minimum.
Key Challenges
This project presented a number of structural and operational challenges that required a careful scaffold design.
One of the main issues was the poor condition of the internal concrete surfaces. Direct access against damaged areas was not suitable, so the internal staircase had to provide a stable route and safe working access without relying on compromised surfaces for support.
The curved form of the silo created another challenge. Standard scaffold arrangements often need adjustment when working around rounded structures, so the scaffold had to be adapted carefully and tied securely to maintain strength and stability throughout the installation.
The project also required access both inside and outside the same structure. That meant the solution needed to combine two separate but coordinated scaffold arrangements: one for internal vertical access and another for external maintenance access to the feeder cladding.
There was also the operational side of the site to consider. Because work was taking place close to active feed systems, the scaffold installation had to be planned carefully to maintain safe access routes, protect the surrounding area, and reduce disruption to the client’s day-to-day operations.
Our Solution
To meet the client’s requirements, we installed a temporary internal scaffold staircase that created a safe and controlled access route within the concrete silo. This provided the maintenance team with dependable internal access while avoiding direct reliance on deteriorated surfaces.
Externally, we erected a scaffold tower to provide efficient access to the feeder cladding for inspection and repair work. The external scaffold was arranged to suit the working area and tied securely to maintain stability around the curved silo structure.
Using modular scaffold components allowed us to adapt the design to both the internal and external conditions on site. This gave the client a joined-up access solution that worked across multiple maintenance areas while remaining practical, safe, and efficient to use.
Health & Safety
Health and safety were a key part of the project, particularly given the poor internal concrete condition, the shape of the silo, and the need to work around ongoing feed production operations.
Before installation began, the access requirements, scaffold layout, and support arrangements were considered carefully to ensure the scaffold would provide safe working conditions both inside and outside the structure. The internal staircase was set up to give a stable access route, while the external scaffold tower was tied and configured to maintain safe use around the curved silo.
Key safety measures included:
- Stable internal scaffold access to avoid unsafe contact with damaged concrete
- Secure ties and adapted scaffold design to suit the curved structure
- Guardrails and toe boards to improve edge protection
- Non-slip platforms for safer movement and working underfoot
- Planned work sequencing around operational feed systems
- Coordination with the site team to maintain safe access and minimise disruption
By taking a structured and site-specific approach, we were able to provide a scaffold arrangement that supported the maintenance works safely and effectively from start to finish.
The Outcome
The completed scaffold gave the client safe internal access for inspection and repair of deteriorated concrete within the silo, while the external tower provided efficient access to the feeder cladding for maintenance works. The combined arrangement allowed both parts of the project to move ahead safely and in a controlled manner.
The project delivered:
- Safe access for internal concrete inspection and repair
- Efficient external access for cladding maintenance on the feeder system
- Minimal disruption to ongoing site operations
- Zero safety incidents during the scaffold works
By tailoring the scaffold design to the structure and the operational demands of the site, we helped the client complete essential maintenance work safely and with minimal interference to production activity.
Client Testimonial
“The scaffold structure provided safe and practical access both inside the silo and to the external feeder cladding. The team delivered a well-planned solution that allowed our maintenance work to be completed efficiently.”
Project Summary
This project highlights our ability to provide practical scaffold access for specialist agricultural and industrial maintenance works. By installing an internal scaffold staircase alongside an external scaffold tower for concrete silo maintenance, we gave the client a safe and effective way to reach damaged internal surfaces and external cladding areas, helping the work proceed efficiently, safely, and with minimal disruption to the wider site.
