Rooftop Catwalk System/Crawling Boards

Safety of workers on roofs of A.C.Sheets has assumed high priority due to serious risks involved; often resulting in fatal accidents. Factory inspectorates, all over India, have made stringent rules to provide “SOME” safety system compulsory. Ours is the “ONLY” easy to use, light to carry system available exclusively for roof top work. We pioneered this system in 1980.

  • This roof top safety system has been recognised by Factory Directorates under the respective Factories Rules.
  • It also conforms to the proposed IS specifications.

The basic principle of this system is to distribute the load of the workers on the system and transferring it to the purlin structure, avoiding concentrated load on the fragile A.C.Sheets.

After occurrence of any roof top accidents, “an occupier” faces a chain of unwarranted events, like downtime, production losses, compensations, legal costs, loss of morale of other roof workers & litigations. The unfortunate worker, who inadvertently steps on a weakened sheet, due to it’s deceptive look, may get his compensation from the contractor who employs him or through his insurance cover. But, a “Prime Employer”, can not avoid rigorous penalties & proceedings for lack of adherence of Safety Provisions as per demands of prevalent Factories Rules.

Our system has been awarded many “Merit Awards” like N.R.D.C. & of various Chambers of Commerce & Industries for its innovativeness & simplicity in its usage. Yet, our biggest reward is the satisfaction of protecting precious human lives. So far, we have supplied over 4,600 Sets of this system to various establishments all over India. This safety system is surely useful & economical too. It offers immunity from post accident worries & botheration.

  • We have a 20 minutes film on VCD which spells the utility, application & necessity of this system which is available Free Of Cost.
  • We manufacture Sets suitable for Corrugated type Roof sheets as well as, suitable for Semi-Corrugated, i.e. Trafford type Roof sheets

We are aware, after lapse of our earlier Patent, competition has emerged for this product. They have compromised SAFETY to cut down the cost. It is observed that the Purchase Departments often compare basic price difference only. Some have tried to copy our earlier design. They have manufactured without knowledge of its operation and the rooftop problems. But, do they have answers to the problems, roof workers face, on rooftop? ALAS, NO. As an after sales service, we offer a live demonstration for the effective & correct use of our system, once procured if so required, on nominal charges. Our team of Demonstrators train the concerned people.

It is rightly said “There is hardly anything in the world that A MAN cannot make a little worse and sell a little cheaper. Those who consider PRICE only are this man’s LAWFUL PREY.”

WE have experienced during marketing of our product Fabricare Roof Top Catwalk System, that at some places the departmental roof workers or that of the CONTRACTOR’s, tend to avoid the use of the system, though available. Here are some of the excuses given by them and the solutions thereof:

  1. It takes more time for completing the job with the System in assigned time.
    Practice makes a man perfect. After sufficient practice, fast work is possible. Hence, it will be required to compel the workers to use the system as and when they have to work on roof top. Thus the workers will have enough practice of using the system. Besides, it should be noted that nothing comes out of nothing. In this case, if the management wishes to protect valuable life of it’s worker with the system, it should allow some extra time initially.
  2. Non-availability of each and every accessory of the system, playing a specific role.
    This happens due to absence of required procedure in preserving the set after its use and ensuring receipt of all the material back in the stores. Responsibility should be fixed for acknowledged issue and receipt of ALL material issued earlier. The issuing authority will also have to mention its destination where the system is being carried and the names of the person/persons to whom the system is issued. The leader of the users should be held responsible and warned that he would be answerable if any of the accessories is missing.
  3. Inadequate time for completion of job in assigned time frame.
    Considering time required for completion of a particular job with use of the system, schedule should always be planned in advance accordingly. If manpower is less and quantum of work is more, work should be assigned well in advance, or else, provide required manpower with adequate systems.
  4. Poor-transportation for carrying a system to a far off work place from the stores.
    Necessary means should be provided to carry the system if the work place is far away from stores. In absence of means to carry the system, workmen are mentally tired with the thought of carrying the system on the shoulders all the way from stores to a far off working place.
  5. Damaged Parts of the system - hence useless to serve the desired purpose.
    All the users are required to be well trained in careful handling & storage (all parts well oiled and greased wherever required) of system.
  6. System made available is inadequate, vis-à-vis the number of gangs asked to work.
    If area of roof is huge and at a time number of gangs are deputed or expected to carry out maintenance job, at least 2 sets per gang are required to be provided. Wherever this is being religiously observed successfully the above problem gets solved. The workers are united. If it is revealed to them that one crew only is going to be protected being shortage of the sets, all the workmen refuse to use the system.
  7. Normal human tendency : Resist any newly introduced things, not traditional.
    Workers are required to be convinced about they being direct beneficiaries and not the management in use of the system and to be educated about the risks involved in absence of the safety system. If it is made mandatory, workers will have to use the system and their reluctance will be seen to be gradually disappearing.
  8. Ignorance about the proper method/knowledge of application of the system
    Live demonstration and proper training program should be arranged for benefit of all the concerned with roof maintenance work. This helps each and everybody to understand the method of application for variety of jobs to be done on roof, in ideal or adverse conditions. This training can be imparted in India by the pioneers, M/s. Katalist Consultants Pvt. Ltd., manufactured by their associate concern M/s. Fabricare, Pune.
  9. Normal tendency of almost every individual, of thinking himself to be different and that nothing can go wrong with him, even if he doesn’t observe safety rules.
    This is a psychological phenomenon and nobody can answer why one should think himself to be different. This is required to be emphasized on minds of such workers that everybody, who is careless and doesn’t observe safety norms, can fall prey.
  10. Work entrusted on contract basis : Contractors resist the idea of using the safety system.
    • When the work is entrusted to a contractor, he neglects use of the system. His main cause of refusal of work with the system is the rate given is always on per square meter for water- proofing and per number for changing of sheets and purlin bolts. Contractors employ workers for this job and try to carry out maximum work in minimum possible time to save on payments to workers. Contractors are aware that the system is a bit time consuming and hence he will require more days to complete the job and thereby will not be able to save on payments to workers. Generally roof maintenance job is given on contract basis. Management therefore, should consider this problem and increase the rate considerably to encourage the contractor to instruct his workers to use the system. Besides, the contractors are aware that in case of any mishap, the “Occupier” is ultimately responsible. It is heartening experience that industries which are strict about safety, having made the use of the system mandatory, have increased the rate to motivate the contractors to use the system. In such industries the contractors are observed to be using the system even for a smallest job.
    • Contractors or the contractor’s workers go on changing every year. Thus new workers may not know the method of use of the system. Obviously, therefore, the use of the safety system is avoided. Occupier, hence, considering the problem, cannot make the use of the system mandatory. In such case, one or two departmental persons should be trained enough about use of the safety system. Such trained persons will always be available on hand to the industries to educate the new workers.
  11. ) If threaded portion of purlin bolts is entirely damaged due to corrosion.
    For successful clamping of the system threaded portion of the bolts should necessarily be good. Many times, some of the bolts are rusted with threads entirely damaged. However, it is never observed that all the bolts at a time are rusted. Hence some bolts with good threads are available for clamping. Saddles of the ladders are provided with sliding arrangement. The user therefore can slide the saddles accordingly to avail such bolts for clamping. In highly corrosive atmosphere the life of the bolts is short and the same get corroded very fast. In such case some of the initial specific bolts should be changed to enable making base with required clamping. Once base is ready, by making use of the base, further job of water proofing or replacement of sheets can also be done by changing specific bolts to make the same available for clamping. The same method can be adopted for changing all the bolts of the roof. To understand the method training from the manufacturers of the safety system should be arranged. Polymer coated bolts and polymer accessories are manufactured by us at Pune. Use of such accessories will help the corrosion prone industries to protect the bolts and threading portion from rusting.
  12. Threaded portion of bolts protruding above the roof not adequate for clamping the system.
    For installation and effective use of Roof Top Safety System adequate projection of purlin bolts protruding on roof is a must. But, some times it is observed that the bolt projection is inadequate and in such cases, for successful clamping of the system and thereby smooth working of the same, we are required to replace those with new ones with adequate projection. When the problem of inadequate projection is revealed at the “eleventh hour” replacement is not possible immediately. To overcome the problem temporarily, as a bridge gap arrangement, we have developed an accessory, called “PROJACE”. This accessory acts as an extension of the purlin bolts. This accessory is provided with the inside threading in bottom half and outside threading on top half. It is observed several times that threading portion of bolts protruding above the roof is less than 15mm. It should be 25 mm at least, as per the standard. It is also observed the over size bolts are used hence bolt projection above the roof is excess. It is, therefore, ideal for those who intend regular and strict use of Roof Top Safety System that the Civil Engineering Department should have information of the purlin sizes used in the industry and issue of the suitable bolts only for such purlins should be ensured. This is absolutely not difficult.
  13. Wind pressure is more, due to the height of the shed.
    Height of the shed or wind pressure has nothing to do with successful implementation of the system. Only if wind pressure is more management should not expect fast work if use of safety system is expected. In such wind pressure on high sheds work should be done slowly with the system with proper precautions.
  14. When purlin bolts are not installed as per the instructions of A.C. sheet manufacturers.
    The system is designed considering that the A.C. sheeting job is done properly, observing the instructions given by Sheet manufacturers. However, it is observed some times that such instructions given by Sheets manufacturers are overlooked and purlin bolts used for fixing the sheets are installed in a zig zag manner. It is, therefore, necessary for Civil Engineering/Maintenance Department who intend to be strict on using the safety system, to be kin on observing structural engineering standards and the instructions given by Sheets Manufacturers.
  15. Shed is covered with different type of sheets, i.e. Trafford & Corrugated type Sheets.
    Above position is observed very unusually. However, it is a fact that in some of the industries different type of sheets are observed to have laid on the same roof. There are two different systems suitable for A.C. Trafford & A.C. Corrugated sheets. Universal type system is not available owing to some technical limitations. If the industries have one set suitable particularly for one type, the same can not be used on other type of Sheets and hence the use is avoided. It is, therefore, required to make both type of systems available to the workers if different sheets are laid.
  16. Post accident, workers lose their confidence and hence are reluctant to climb on the roof
    Live demonstration and training with regard to use of Roof Top Safety is required to be arranged through experts in the field. This has been observed several times that such demonstration and training has often increased the confidence of the workers.
  17. Where use of Wind Ties is made.
    Many industries use Wind Ties so that the sheets should not fly off in excessive wind pressure or during cyclone. Wind Ties obstruct installation of ladders. There is no other solution at present to overcome this problem. Whenever the maintenance job is to be carried out on a particular shed where wind ties are used, wind ties are required to be removed temporarily. Once job is over the same should be installed once again.
    Above reasons/excuses are given by the maintenance/contractor’s workers for avoiding use of the Roof Top Safety System. This is our observation, during marketing of Roof Top Safety System, for last 20 years. It would be improper if it is not mentioned here that there are several industries in India today, which are successfully using this system. All the above obstructions in the way of using the system are needed to be painstakingly addressed & removed by the management.
  18. What is necessary is tremendous will to protect the lives of the workmen.
    We have efficient and experienced staff who can capably conduct live demonstration of use of Roof Top Safety System and can impart training to all the concerned with roof maintenance work. This demonstration and training has helped management remove initial resistance of the workers in using the system.
  • Indian Oil Corpn. Ltd.,
  • Hindustan Petroleum Corpn. Ltd,
  • Indian Railways, (Various Zones)
  • Bharat Heavy Electricals Ltd.
  • Grasim Industries Ltd.
  • Tamilnadu Newsprints and Paper Ltd.
  • Hindustan Motors Ltd.
  • Lakshmi Machine Works Ltd.
  • Ordnance Factories (Various Factories)
  • Bharat Earth Movers Ltd. (Various Plants)
  • MICO Ltd.
  • Bharat Electronics Ltd.,
  • Indian Rare Earths Ltd.,
  • Hindustan Zinc Ltd.,
  • Mining and Allied Machinery Corpn.
  • Godrej & Boyce Ltd.,
  • Glaxo Labrotories Ltd.,(Various Factories)
  • Roche Products Ltd.,
  • Hoechst India Ltd.,(Various Factories)
  • Larsen & Toubro Ltd.,(Various Factories)
  • MRF Ltd. (Various Factories)
  • J.K. Group
  • Bharat Aluminium Co.
  • Siemens (I) Ltd.
  • Bharat Heavy Plates & Vessels Ltd.
  • TVS Suzuki
  • Premier Automobiles Ltd.
  • Ceat Tyres
  • National Fertilizers Ltd.
  • Tribeni Tissues Ltd.
  • Mysore Paper Mills
  • Travancore Titanium Products Ltd.
  • Reliance Industries Ltd.
  • Hindustan Aeronautics Ltd. – All Divisions.
  • Ruchi Soya Ind. Ltd. Various Plants

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Contact Katalist Safety Systems

Mr. Jayprakash Sathe: +91 94225 47781
Mr. Abhay Khurjekar: +91 94230 09750