Published on: July 15, 2025
Lone Star Spirits Shine Brighter (and Safer!)
Challenge: Ensuring worker safety during maintenance of an expansive solar panel array.
Solution: Installation of non-penetrating Kee Guard® Topfix standing seam safety railing.
Benefits: OSHA/ANSI compliant work at height and efficient maintenance.
Project Overview
Flexible Lifeline Systems (FLS) partnered with Fifth Generation Inc., the distillers of Tito’s Handmade Vodka, to implement a crucial safety solution at their Austin, Texas facility. Fifth Generation Inc. is a landmark in Texas, being the state’s first legal distillery and the sole current producer of vodka in the Lone Star State, widely known for Tito’s Handmade Vodka, which is distinctively crafted using traditional pot stills. This project involved the design and installation of Kee Guard Standing Seam rooftop guardrail, ensuring the safety of maintenance crews accessing a newly installed solar panel array on their production building roof.
The Hazard
The installation of a new solar panel array on Tito’s production rooftop introduced a significant safety challenge. Previously, the facility had no regular need for rooftop access. However, the solar array now occupies approximately 90% of the available rooftop footprint, bringing service crews within mere feet of an unprotected edge on all sides. This close proximity to the edge, coupled with the need for regular cleaning and servicing of the panels, classified the risk of falling and potential injury severity as “high.”
Initially, the customer considered a rooftop lifeline system, envisioning employees tying off. However, FLS’s expertise guided them to the realization that a passive guardrail system, specifically Kee Guard Standing Seam Metal Roof (SSMR), would be a more effective and safer solution for their needs.
The Solution
Flexible Lifeline Systems designed, engineered, and installed approximately 600 linear feet of Kee Guard Standing Seam rooftop guardrail around the full perimeter of the production building roof. This non-penetrating guardrail system was securely mounted on 40-inch wide spreader plates and fastened with S5 Clamps, ensuring the integrity of the standing seam metal roof.
The Kee Guard system provides 100% collective fall protection for workers, eliminating the need for individual tie-offs and ensuring safety for anyone on the roof. For safe and controlled access, double self-closing gates were strategically installed at one location. This robust and compliant system offers a continuous barrier against falls, allowing maintenance crews to safely service the solar array without personal fall arrest equipment.
The Benefits
The implementation of the Kee Guard® Standing Seam rooftop guardrail system at Fifth Generation Inc. provides several key benefits:
- Enhanced Worker Safety: The primary benefit is the significant enhancement of worker safety, eliminating the risk of falls during essential solar panel maintenance tasks.
- OSHA/ANSI Compliance: The Kee Guard system provides a fully compliant edge protection solution, meeting all relevant safety standards for rooftop work.
- Efficient Operations: Maintenance crews can now safely and efficiently perform their work on the rooftop, focusing on their tasks without the added stress of fall hazards.
- Non-Penetrating Design: The system’s non-penetrating attachment method preserves the integrity of the standing seam metal roof, avoiding potential leaks or damage.
- Long-term Safety Solution: As a passive system, Kee Guard requires minimal training for users and provides continuous, reliable protection, reducing ongoing management effort.
