Projects
Bespoke Overhead Track for The Port of Liverpool
The Client
Peel Ports Group is the UK’s second-largest port operator, overseeing seven ports, 24 terminals, and employing over 2,000 staff nationwide. Handling around 70 million tonnes of cargo annually—equivalent to 14% of the UK’s total market share—the group plays a pivotal role in supporting international trade and logistics.
The Port of Liverpool acts as a key gateway to the North’s industrial heartland, offering seamless rail, road, and sea connections to major UK and global markets. Within the port, the Alexandra Bulk Complex has undergone extensive redevelopment, transforming into a state-of-the-art bulk terminal capable of processing up to 850,000 tonnes of cargo per year, with further expansion already on the horizon.
The Brief
The Alexandra Bulk Complex comprises five large bulk warehouses and two berths, handling vast quantities of dry bulk materials every year. The warehouses provide more than 200,000sqm of storage space, divided into multiple bays and serviced by advanced handling equipment, including cranes, conveyors, and hoppers.
Given the operational scale and complexity of the site, employees frequently work at height — performing essential maintenance and operations on top of large equipment and elevated platforms. Peel Ports required a comprehensive fall protection solution that would safeguard workers, meet legal compliance standards, and integrate seamlessly into their busy working environment.
The Solution
Drawing on over a decade of expertise in Work at Height safety, Heightsafe’s in-house design team identified the Kee Track Overhead Rigid Rail System as the ideal solution for Peel Ports’ operational needs. The Kee Track system provides a continuous overhead fall arrest solution, designed to protect workers in areas with limited fall clearance. Engineered for durability and ease of use, the system offers exceptional safety without obstructing other ongoing activities. Its compact design means it can be easily retracted or left in place without interfering with loading, storage, or material handling operations.
Heightsafe’s specialist installation engineers securely fixed the Kee Track system to the roof’s steel purlins, ensuring long-term stability and full compliance with BS EN 795 and BS EN 7883 standards. The inertia reels were neatly mounted to maintain a clutter-free workspace and simplify access when required.
Upon completion, the system was fully tested, tagged, and certified to ensure complete compliance — ready for safe and reliable use by Peel Ports’ on-site teams.
The Outcome
Following installation, the Kee Track fall protection system has provided Peel Ports with a safe, efficient, and fully compliant solution for all Work at Height activities within their bulk warehousing facilities. The new system not only enhances on-site safety but also ensures that operational efficiency remains uncompromised. By significantly reducing the risk of fall-related incidents, Peel Ports has demonstrated its continued commitment to the highest standards of health and safety compliance across its operations.
Through annual inspection and recertification, carried out as part of Heightsafe’s ongoing Compliance Testing and Maintenance services, the system will continue to provide long-term reliability and peace of mind for years to come.
This project highlights Heightsafe’s ability to deliver bespoke fall protection systems that combine innovative design, robust installation, and long-term compliance support — enabling organisations across logistics, construction, and manufacturing sectors to maintain safer working environments at height.
Contact Us
To learn more about the Kee Track Overhead Fall Protection System, or to discuss a tailored Work at Height safety solution for your facility, contact the Heightsafe team today on 020 3819 7199 or submit an enquiry here.
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