Published on: June 16, 2026
Balancing Architecture and Fall Protection
Hazard: Facility maintenance staff faced leading-edge fall exposures while servicing rooftop units near precast concrete parapets. Additionally, the precast panels required mounting methods that would not crack the concrete substrate.
Solution: A custom, 112-linear-foot hybrid guardrail configuration combining parapet-mounted Kee Klamp sections and freestanding, non-penetrating KeeGuard systems.
Benefits: Provided OSHA-compliant perimeter protection, resolved dissimilar metal corrosion risks between aluminum rails and galvanized mounts, and preserved the roof’s waterproofing integrity.
The Challenge: Navigating Substrates and Material Constraints
During the construction of the new Indianapolis Animal Care Services facility, general contractor F.A. Wilhelm Construction needed to secure the roof perimeter for maintenance crews servicing rooftop units. The project presented strict architectural and structural boundaries.
The city specified an aluminum rail construction to support long-term building aesthetics and material longevity. However, anchoring aluminum directly to standard galvanized steel base mounts creates a galvanic corrosion risk due to the contact of dissimilar metals. Furthermore, the building features precast concrete parapet walls, which required a precise, highly calculated anchoring approach to prevent fracturing or cracking the concrete panels during installation.
The Process: Engineering Ingenuity and Trade Synchronization
To overcome the material incompatibility, the FLS engineering team developed a specialized hybrid mounting configuration. Technicians treated galvanized mounting boots with bituminous paint, creating an insulating protective barrier that isolated the aluminum railing from the galvanized base mounts and stopped corrosion before it could start.
Timing was also critical. The guardrail installation had to occur within a narrow logistical window: after the heavy rooftop units were crane-lifted into place, but before final facility handover to prevent damage from other trades.
To keep the project on its tight late-September schedule, FLS project managers worked directly within F.A. Wilhelm’s ProCore project management environment to provide municipal inspectors with real-time access to technical submittals and “As-Built” updates. FLS accelerated the procurement phase by organizing an urgent drop shipment of components directly to the installation crew’s local lodging and coordinating a local hardware pickup to ensure zero downtime upon arrival.
The Solution: Hybrid Safety Infrastructure
FLS deployed a two-man installation team that completed the 112-linear-foot safety footprint in just two days. The safety infrastructure consists of:
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Dual-Mounting Footprint: The system seamlessly transitions between 40 feet of permanently fixed, parapet-mounted guardrails and 72 feet of freestanding, non-penetrating KeeGuard sections.
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Preserved Building Integrity: The freestanding components utilize counterweights to provide collective fall protection without penetrating the roof membrane or compromising the facility’s waterproofing.
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Adaptive Field Problem-Solving: When the originally planned 60-foot lift became unavailable, FLS adjusted and secured an 80-foot articulating boom lift through United Rentals, maintaining the project timeline without interruption.
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Certified Handover: The project concluded with a complete third-party audit of the “As-Built” drawings and the delivery of full warranty documentation to the city.
Summary: A Long-Term Compliance Partnership
By addressing the unique material and structural challenges of the site, FLS delivered an industrial-grade safety solution that honors the architectural requirements of the Indianapolis Animal Care Services facility. Proactive scheduling and transparent communication with F.A. Wilhelm Construction ensured that the project was completed on time, within budget, and without safety incidents.
To maintain compliance and asset integrity, the facility is enrolled in the FLS safety lifecycle program, with the first municipal safety recertification and annual inspection scheduled for September 2026.
Ready to enhance safety and efficiency at your facility? Contact Flexible Lifeline Systems for a comprehensive safety audit and let our team of experts help you find the perfect solution for your work at height.
