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GCT Duct Installation

Zenith has recently completed the design & installation a bespoke access platform to the uppermost section of a GCT duct.

The platform was designed by Zenith Consultants, the Group’s in-house structural engineering department.

The platform, with a combined weight of approximately 30 tonnes, was built from the 310m level to facilitate extensive cladding repairs to the GCT Duct commencing at the 327m level. The scaffold support loading proved to be too high for standard tubes and couplers and therefore a fabricated support arrangement was designed and installed.

As a multi-disciplined contractor, our ability to design and install temporary access solutions and then to successfully affect all necessary repairs to structures at height, means that our customers do not have to engage with numerous contractors. This ‘one stop shop’ approach has kept Zenith at the forefront of the industry and our specialist capabilities are being called upon by the world’s leading cement companies.


Since 2013, Zenith Structural Access Solutions Limited has continually been awarded the contract, by Cemex, to carry out major inspection, maintenance and repair projects at their Rugby Cement Plant in Warwickshire during their typical 6 week shutdown period.

Zenith is a multi-disciplined contractor thereby significantly reducing the number of interfaces with other contractors, providing the client with just one point of contact during critical shutdown timeframes from structural engineering to on-site execution. In addition, we provide a safe, comprehensive bespoke access solution that saves significant time and money. Our services include:

  • Access Specialists (Steeplejack, IRATA Rope Access, Cradles & Internal/External Platforms, Alimak Hoists as well as Traditional Scaffolding)
  • Inspections (Condition & Structural Surveys, NDT, & Weld Testing)
  • Design & Install steelwork modification
  • Specialist lifting
  • Fall Arrest Systems (Bespoke)
  • Containment Netting
  • Concrete Repairs
  • Cladding Repairs
  • Welding
  • Refractory Repairs
  • Painting
  • Cleaning (Difficult Access Areas)
  • Silos (Concrete & Steel)
  • Vessels
  • Bunkers, Hoppers & Cyclones
  • Ductwork (particularly long run)
  • Downcomers (PHT)
  • Cabling, Cable Trays & Lighting
  • Cement Kiln

Hope Cement Works, Derbyshire.

Zenith Structural Access Solutions Limited was awarded the contract, by Hope Construction Materials, to install a temporary by-pass steel stack braced to the concrete chimney windshield to enable internal brickworks to be carried out whilst allowing the plant to continue operation.

The design, supply and installation of the temporary bypass stack was performed in-house by Zenith to the client’s specification. The bypass stack aspect of the project comprised the following key stages of site installation works:

  • Make connections to existing ducts.
  • Install lateral supports.
  • Install main support steelwork.
  • Install bypass stack.
  • Install bypass ductwork and connect to existing duct connections.

On our website we have a timelapse video of the entire project.

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