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Stack of bespoke steel covers of picture of hotel next to a beach

Delivering a tailored access solution to PI Beach Club

  • Island Site Developments

  • PI Beach Club, Bahamas

  • Access cover

Project background

We were approached to support the P I Beach Club development in the Bahamas following an initial enquiry received in July 2025. The request was for a number of recessed access covers, with limited technical detail provided at the outset.

Working proactively, the Wrekin team applied their experience to develop a best-fit solution, initially proposing UK-manufactured deep recessed access covers designed to accept concrete infill, manufactured to the specified sizes and performance requirements.

As the project progressed, close collaboration with the client team became critical. Further information requests followed, including individual lid weights to allow the client to calculate the total infill weight. When concerns were raised about manual handling and overall lid weight, Wrekin responded by re-engineering the solution, proposing twin-part covers and frames to significantly reduce individual lift weights.

Stack of bespoke steel access covers

Engineering Challenges and Collaboration

During a technical review meeting involving Wrekin, procurement, and technical representatives, it became clear that site conditions had evolved. Installed elements beneath the access trays conflicted with the original strengthening design, requiring a revised approach without compromising performance.

Working closely with Wrekin’s fabrication team, an alternative strengthening method was developed. By replacing flat bar reinforcement with parallel flange channel (PFC) sections, the required loading performance was achieved with a shallower build-up. This adjustment necessitated a return to single-piece lids, which was agreed with the project team following a revised quotation.

A further challenge arose around the handling of the heavier one-piece lids. To address this, Wrekin designed a smaller secondary access solution, incorporating a removable “peep hole” within selected covers. This allowed routine access without the need to remove the full lid, improving usability and safety on site.

Paul Thompson

This project is a great example of how early engagement and collaboration can shape the right solution. We worked closely with Island Site Developments to develop a design that met both the structural requirements and the realities on site.

Paul Thompson

Wrekin Products Ltd

Outcome

The final solution combined robust performance with practical site considerations, balancing structural requirements, access needs, and manual handling concerns. Detailed drawings were produced and approved, and the bespoke access covers were manufactured to meet the project’s specific demands.

Through responsive communication, technical flexibility, and collaborative problem-solving, Wrekin delivered a tailored access solution that supported the successful progression of the P I Beach Club project.