At Walker Rubber, our mission goes beyond manufacturing rubber products; we’re here to provide practical, long-lasting solutions for real-world problems. Whether it’s sealing a marine hatch or fixing uneven ground, we take pride in working closely with clients to design and deliver the right outcome.
In this case, we were approached by a major UK construction contractor working on behalf of a high-profile coastal safety organisation. They needed our help to address a health and safety hazard on a lifeboat station slipway as part of a major construction project – and they needed a solution fast.
Who is the customer and what did they require?
Our customer is a respected UK-based construction firm known for delivering complex public and private sector projects with professionalism and zero-defect precision.
As part of a multi-million-pound lifeboat station construction project, the team noticed that the join between the concrete slab (where the lifeboat sits before launch) and the slipway ramp was uneven. This misalignment was creating a significant trip hazard, which was not just inconvenient, but potentially dangerous for those operating around the lifeboats.
They need a custom rubber extrusion that would:
- Bridge the gap between the concrete slab and the slipway
- Provide a flush surface to reduce the risk of trips and injury
- Be tough enough to withstand foot traffic and harsh coastal conditions
They knew what they needed in theory and had an idea of what it might look like, but weren’t sure how to make it happen in practice – which is where Walker Rubber came in.
What solution did Walker Rubber provide?
The first step was to take detailed measurements of the site of the area, which were provided by the client. Once we understood the physical environment, we looked into the exact extrusion profiles that could meet the need.
We decided to adapt a weighbridge seal extrusion – a profile originally designed for industrial applications – by modifying the shape to suit this specific use case. We narrowed the protruding section to ensure it would fit and anchor into the gap securely, while also flattening the top to create a smooth and safe surface for foot traffic.
Process:
- Collaborative design: The client's design team had feedback on our initial proposal, so we worked closely with them to tweak the design and ensure it met both safety and usability needs
- Custom rubber extrusion: We used our in-house custom tooling and rubber extrusion capabilities to produce the modified profile
- Vulcanisation: To enhance durability and performance, we vulcanised the extruded profiles, making them more resistant to weather and temperature changes, and overall, more hard-wearing
Materials:
- EPDM: Given the harsh conditions the part would be exposed to daily, we selected EPDM because its chemical make-up makes it highly resistant to damage from sun and weather exposure
Were there any challenges?
As with many of our projects, there was a high degree of collaboration involved. The contractors and client-side designers had different views from our initial concepts, which sparked a constructive back-and-forth. Together, we iterated the profile design quickly and effectively, using our experience to adjust and improve the solution.
Thanks to our team’s familiarity with similar applications, we were able to turn around the first proposal within hours. That speed, combined with decades of manufacturing know-how, helped the project move forward without delay.
What was the result?
The result was robust, tailored rubber extrusion that successfully filled the gap between slipway and slab, mitigating the trip hazard and creating a safer working environment for lifeboat staff.
The solution we provided met the technical requirements of the application: able to reduce risk before tackling the demands at sea, and to withstand exposure to cold, wet, salty conditions.
Most importantly, it solved a real safety issue, something both the contractor and the end-client were highly satisfied with.
Need a custom rubber extrusion fast?
Whether it’s a new-build project or a retrofit challenge, Walker Rubber has the expertise and flexibility to provide the right solution. From initial sketches, to fully extruded, bonded and tested rubber parts, we’re ready to get hands-on with your toughest rubber requirements.
Call us on 01603 904371 or use our contact form. We're ready to help.