Gas Refinery Unit Project

Project Overview

Our customer designs and fabricates structural modules for offshore gas refineries. These large units are assembled onshore before being transported to their final destination at sea. Safety is a critical factor during both construction and long-term operation, with requirements for fall prevention, durable walkways, and secure access systems.

Key requirements included:

• A durable handrail system with kick plates for protection on all levels.

• Open mesh walkways to provide slip-resistant, solid access routes.

• Custom access ladders ranging from 1000mm to 4000mm, fitted with protective hoops and self-closing gates.

Did You Know?

Several UK refineries date back to the 1920s, including Fawley, Grangemouth, and Stanlow. Others, such as Pembroke, Lindsey, and Humber, were built post-WW2. Today, refineries not only process crude oil but also recycle materials like used cooking oil, animal fats, and plastics into fuel.

Kite’s Contribution

Kite Group supplied a full safety package tailored to the structural module:

• ModiFix Handrail System: Galvanised, laser-cut uprights with precision slots allowed horizontal rails to pass through directly, eliminating the need for multiple clamp fittings. This provided a sleek, cost-efficient, and environmentally friendly design.

• Kick Plate System: Installed along edges for added fall prevention.

• Open Mesh Panels: Supplied for slip-resistant, durable walkway surfaces across all levels.

• Custom Galvanised Access Ladders: Manufactured in bespoke sizes (1000–4000mm) with protective hoops and self-closing gates for secure vertical access.

By combining these systems, Kite delivered a robust, low-maintenance safety solution that protected engineers during assembly and ensured long-term operational safety offshore.