Project Snapshot
Industry
Heavy Manufacturing / Large-Scale Industrial Plant
Facility Profile
Multi-acre plant with an extensive network of EOT (Electric Overhead Traveling) cranes
Core Risk
Regular near-miss incidents during EOT crane operation, inspection and maintenance at height
Solution Deployed
Overhead Horizontal Lifeline System for EOT Crane runways and maintenance platforms
Scope
3,000 metres of lifeline installation across the facility, including a 400-metre high-heat processing zone
Standard Compliance
Engineered and installed in line with EN / ANSI fall protection standards, and compliant with BIS (Bureau of Indian Standards) requirements
Certifications
ATEX certified — safe for use in potentially explosive atmospheres
Material Rating
Fire-resistant lifeline construction, suited to high-heat and thermally hazardous industrial zones
The Challenge
Our client operates a large manufacturing facility spread across several acres, with an extensive network of EOT (Electric Overhead Traveling) cranes running the length of the plant. These cranes require regular inspection and maintenance, which means technicians and operators are routinely working at height, close to the crane runway and along narrow maintenance platforms.
Over time, the client’s safety team observed a recurring pattern: near-miss incidents during crane maintenance and movement along the runway. None had yet resulted in a serious injury, but the frequency was rising, and the client recognised that without a structured fall protection system in place, it was only a matter of time before a near miss became a fatality.
Concerned about the safety of their workforce, the client approached Indian Inovatix to assess the site and recommend a reliable, code-compliant solution for working at height around EOT cranes.
Our Approach
Our team conducted a detailed on-site survey of the plant, mapping every EOT crane runway, maintenance platform and access route where personnel were exposed to fall risk. The survey looked at crane travel paths, platform layout, structural anchor points, and environmental conditions across different zones of the plant — including a section that ran through an extreme-heat processing area.
Based on the survey findings, we recommended an Overhead Horizontal Lifeline System purpose-built for EOT crane runways and platforms. This system allows maintenance personnel to move freely along the crane pathway while remaining continuously connected to a certified anchor line, arresting any fall before it can result in injury.
We submitted a full survey report along with our proposed solution. After reviewing the report, the client confirmed they wanted the exact system we had recommended, with no changes to scope or specification.
The Solution: Overhead Horizontal Lifeline for EOT Cranes & Platforms
Execution: Installation Across 3,000 Metres, Including a 400-Metre Heat Zone
Once the order was confirmed, we moved quickly to dispatch materials and mobilise our installation team. The scope covered 3,000 metres of overhead lifeline across the plant — one of the larger single-site installations we have undertaken.
The most demanding stretch of the project was a 400-metre section running through the plant’s high-heat processing zone. Installing overhead anchor points and lifeline runs in sustained extreme-heat conditions is challenging for any installation team, and it also raises the risk profile of the installation work itself.
Our installation team planned this section carefully — sequencing the work, using appropriate PPE and heat-safety protocols for our own team, and adjusting work windows to manage exposure — so that the lifeline could be installed to full specification without compromising the safety of our own installers. The fire-resistant construction of the lifeline itself meant the system was engineered to withstand the very conditions our team was working in, giving the client confidence that the system would hold up long after handover, not just during installation. Despite the environmental challenge, the project was completed and handed over on schedule, with no safety incidents during installation.
Results & Impact
Since installation, the client's maintenance team uses the overhead horizontal lifeline system as a routine part of working on and around the EOT cranes. Feedback from the client has been consistently positive:
The system is easy to use and does not restrict the natural movement technicians need while working along the crane runway.
No discomfort has been reported during extended use.
Near-miss incidents along the crane pathway have reduced since the lifeline was installed.
In the event of a slip, the fall arrest system is designed to stop the person from falling, converting what could have been a serious incident into a non-event.
The client has raised no complaints since handover, and the system continues to operate as part of their standard safety infrastructure.
Conclusion
This project reflects the core purpose behind everything we design at Indian Inovatix: minimising incidents during work at height and building genuine safety awareness on the industrial Workspace. By combining a thorough on-site survey with a purpose-engineered Fall Protection system — and by delivering it on time even through a challenging high-heat installation zone — we helped our client turn a recurring near-miss risk into a controlled, protected work environment for their maintenance teams.
Indian Inovatix has been engineering fall protection systems for over 50 years, from the first vertical fall arrest system in 1979 to over-the-head horizontal lifelines installed since 1993. Our Fall Protection systems are BIS-compliant, ATEX certified for hazardous and explosive atmospheres, and built from fire-resistant materials — giving clients in heavy industry, oil & gas, and high-heat processing environments a single system that meets both safety and regulatory requirements. This case study is one example of how that experience translates into safer industrial workplaces across India.
