How one Inspector at KAEFER Completed 45,000 Scaffold Inspections Using SMART Inspector

When you’re responsible for inspecting scaffolding across some of the UK’s busiest industrial sites, efficiency isn’t just a nice-to-have, it’s essential.

For Dan Shirley, Scaffold Inspector at KAEFER, digital inspections have transformed the way he works. Over the past three years, Dan has completed an incredible 45,000 scaffold inspections using SMART Inspector, eliminating paper records, speeding up inspections and giving both KAEFER and its clients instant access to inspection information whenever it’s needed.

Recently surpassing 6,000 inspections completed within SMART Inspector in 2026, Dan shared how moving away from traditional paper-based inspections has changed his day-to-day workflow.

Scaffold inspector using SMART inspector from SMART Scaffolder

25 Years of Scaffolding Experience

Dan has worked in the scaffolding industry for almost 25 years, building extensive experience across industrial, commercial and residential projects. His career began at Coryton Oil Refinery, before moving into industrial scaffolding, housing developments, street works and television projects. Despite describing himself as “a bit of a technophobe”, Dan found adopting SMART Inspector surprisingly straightforward.

“I found it pretty straight forward, especially as I’m a bit of a technophobe.”

With support from his site manager during implementation, he was quickly completing inspections digitally. This reflects one of SMART Inspector’s biggest strengths, it’s designed to be intuitive for experienced scaffold inspectors, regardless of their technical confidence.

Better Planning Across Large Industrial Sites

Managing inspections across large industrial sites means knowing exactly which scaffolds require inspection each day. Before using SMART Inspector, planning involved paperwork and manually checking inspection records.

Today, Dan simply opens SMART Inspector and immediately knows:

Which scaffolds require inspection
Where they’re located
Their previous inspection history
The quickest route around site

As Dan explains:“Makes my life so much easier as I have the site I visit records at the touch of a button, and which scaffolds are due for inspection that day. So planning my route around site is much quicker.”

For inspectors covering large industrial facilities, these time savings quickly add up.

Replacing Paper F91 Forms

One of the biggest changes for Dan has been saying goodbye to traditional paper inspection forms. When asked what he couldn’t imagine going back to, his answer was immediate:“Filling out F91s in paper form.”

Instead of returning to the office to process paperwork, inspections are now completed digitally at the workface.

The result is:

Less administration
Faster inspections
Improved record keeping
No duplicated data entry

Finding Scaffolds Faster with Photos

One of Dan’s favourite SMART Inspector features is the ability to attach photographs directly to scaffold inspections.

While photos improve reporting, they also make locating scaffolds significantly easier on large sites.

As Dan explains: “Time saved locating scaffolds due to the picture helping locate them so much easier.”

Visual identification removes unnecessary searching and helps inspectors move efficiently between structures.

Inspection Records Available Instantly

Industrial clients often require scaffold inspection records at short notice.

With SMART Inspector, Dan can produce digital inspection records immediately.

He highlighted this as one of the software’s biggest advantages: “Being able to produce inspection records as requested for our clients very quickly and on demand.”

Having inspection data stored securely in one place means compliance information is always available whenever clients, site managers or auditors need it.

Eliminating Paper Benefits Everyone

Beyond improving efficiency, moving to digital inspections has also reduced paper usage considerably.

Dan summed up one environmental benefit simply: “Environmentally, no more paper.”

Replacing thousands of paper F91 forms each year not only saves time but supports more sustainable site operations.

Managing 45,000 Inspections Over Three Years

Completing 45,000 scaffold inspections in just three years is a remarkable achievement.

When asked how he manages such a high inspection volume, Dan credited SMART Inspector’s digital workflow.

“Purely the fact there is no more paperwork and all inspections can be done at the work face.”

By removing paperwork from the process, inspectors spend more time inspecting scaffolding and less time completing administration.

Supported Every Step of the Way

Introducing new technology only works when it’s backed by good support.

When asked about his experience with the SMART Scaffolder team, Dan’s response was straightforward:

“Very good.”

Reliable support helps organisations adopt digital inspection software with confidence.

Would Dan Recommend SMART Inspector?

When asked what he would tell another company considering SMART Inspector, Dan didn’t hesitate.

“Why are you not already using SMART Inspector!!!!??”

Asked to describe SMART Inspector in just three words, he chose:

Quick. Easy. Efficient.

Those three words neatly summarise why thousands of scaffold inspections are now being completed digitally every week.

Why KAEFER Uses SMART Inspector

For Dan and KAEFER, SMART Inspector has delivered measurable operational benefits:

Over 45,000 scaffold inspections completed digitally
Elimination of paper F91 inspection forms
Faster planning across large industrial sites
Immediate access to inspection history
Photo attachments for easier scaffold identification
Instant inspection reports for clients
Reduced administration time
Improved environmental performance through paperless inspections

SMART Inspector enables inspectors to focus on keeping scaffolding safe and compliant, rather than managing paperwork.

Frequently Asked Questions

What is SMART Inspector?

SMART Inspector is SMART Scaffolder’s digital scaffold inspection app, part of the SMART Manager suite. Enabling inspectors to complete inspections electronically, attach photographs, schedule inspections and instantly generate compliance reports.

Can SMART Inspector replace paper F91 forms?

Yes. SMART Inspector digitises scaffold inspections, removing the need for paper F91 forms while creating secure digital inspection records.

Is SMART Inspector suitable for large industrial sites?

Absolutely. As demonstrated by KAEFER’s use of SMART Inspector across busy industrial sites, the software helps inspectors efficiently manage high inspection volumes and complex scaffold inventories.

How many scaffold inspections can SMART Inspector manage?

SMART Inspector scales from small contractors to major industrial organisations. In this case, it supports the completion of over 1 million digital scaffold inspections every year.

Ready to Transform Your Scaffold Inspection Process?

If your organisation is still relying on paper inspection forms, discover how SMART Inspector can help you improve efficiency, reduce administration and maintain instant access to compliance records.

Contact SMART Scaffolder today to arrange a SMART Inspector demonstration and see how digital scaffold inspections can transform your workflow.