INSTALLATION INSTRUCTIONS - Vandernet

INSTALLATION INSTRUCTIONSRoofSafe Anchor & CableInstallation Instruction Number: 21Always read and follow the warnings and instructions for use© Copyright Capital Safety Systems Ltd 2013THE ULTIMATE IN FALL PROTECTION

RoofSafe Anchor & CableContentsGUIDELINES FOR INSTALLATION 3TOP FIX INSTALLATION 4TOGGLE INSTALLATION 5CONCRETE INSTALLATION 6COMPONENT INSTALLATION 8BASEPLATE DRILLING 9HEX SWAGING 10THESE INSTRUCTIONS ARE AN AID TO TRAINING.ONLY TRAINED PERSONNEL SHOULD ATTEMPT TO INSTALL A ROOFSAFE ANCHORS SYSTEM.Issue Date: 18/04/2013 Issue No: 32

RoofSafe Anchor & CableGuidelines for InstallationDetailed below are examples of typical components used in a RoofSafe Anchor system along with the tools required for installation.It is advisable to read through these instructions before beginning the installation.TYPICAL TOOL LISTGeneralHeavy duty drill with a hammer action facility32mm Auger drill bit or wood drill bit and extension bar for cuttingthrough the roof insulation materialMarker penSteel Ruler/Tape MeasurePair of plastic pipe cuttersPen TorchKnifeTorque wrench with a range of 0-50Nm (calibrated)Hex driver to torque wrench adaptor13mm Socket for use with the torque wrenchSocket to drill adaptorAlcohol Solution/WipesRA 6mm Hex Drive Bit (9600044)**RA Removal Spanner (9600043)**Standing Seam Anchor19mm Socket for use with the torque wrench3/16” hex driverTrapezoidal Anchor8.2mm HSS Drill BitToggle FixPowerbird Industrial Rivet Gun (7241102)**Powerbird Jaws (7241105)**Powerbird Nose Piece (7241106)**RA Baseplate Drilling Jig (9600046)**Concrete Anchor12mm HSS Drill Bit The drill bit must be long enough to penetratethe roof construction and concrete14mm HSS Drill Bit The drill bit must be long enough to penetratethe roof construction and any screedBlow pumpFlat FileHack sawLump hammerRA Concrete Setting Tool (7241112)**Eyebolt Testing Kit (7241125)**Plywood board (18mm x 500mm x 500mm) for distributingtest loadDepth Gauge Rod (knitting needle) long enough to reach deckthrough insulation** these tools are available for purchasefrom Capital Safety.Prior to installation of the product please ensure that:1) You have received training from Capital Safety.2) You have all of the appropriate personal safety equipment to complete the task safely.DON’T USE TOOLS UNTIL INSTRUCTED TO DO SOThe component list below shows typical RoofSafe Anchor components. Your order is system specificand may not feature all of these components.ROOFSAFE ANCHOR & CABLE COMPONENTS7241136 - RA Baseplate 405x405 H7241137 - RA Baseplate 405x405 BL7241138 - RA Baseplate 350x440 H7241139 - RA Baseplate 350x440 BL7241140 - RA Baseplate 550x450 BL7241141 - RA Module End / Corner Top Fix7241142 - RA Module Intermediate Top Fix7241143 - RA Module End / Corner Bitumen7241144 - RA Module Intermediate Bitumen7241145 - RA Module End / Corner PVC7241146 - RA Module Intermediate PVC7241147 - RA Module End / Corner All Membrane7241148 - RA Module Intermediate All Membrane7241161 - RA System Eye and Pin7241162 - RA 90º Corner7241163 - RA 45º Corner7241164 - RA Variable Corner7241165 - RA Intermediate Bracket7241166 - RA Throw Plate Kit7241167 - RA Single Point Eye EMEA7241204 - RS Maxi Clamp Z x47241205 - RS Mini Clamp Z x47241206 - RS Maxi Clamp E x47241207 - RS Mini Clamp E x47241208 - RS Maxi Clamp U x47241209 - RS Mini Clamp U x47241180 - Concrete Anchors 150mm x 47241181 - Concrete Anchors 300mm x 47241182 - RA Toggle Fixing 150mm x 47241183 - RA Toggle Fixing 300mm x 47240166 - Uni 8 8mm Hex Swage Tensioner 0.8kNIssue Date: 18/04/2013 Issue No: 37240211 - 8mm 7 x 7 Stainless Steel Cable7234011 - Uni 8 8mm Hex Swage Toggle3

RoofSafe Anchor & CableTop Fix InstallationSTANDING SEAM INSTALLATION01020304Ensure the seam is correctly formedprior to installing the anchor.Attach the clamps and positionthe anchor.Slide the inserts into position.The inserts should be flush with themain body of the clamp.05060708Torque the bolts to 30Nm.Torque set screws to 15Nm.Fit the top module into the baseplateand torque to 40Nm.Anchor installation is complete andready for the system components tobe secured.TRAPEZOIDAL INSTALLATION01020304Stick the scapa tape over the holeswhich align with the roof crowns.Clean the fixing area with alcoholsolution/ wipes and place postin position.Drill through the first hole in the baseplate using an 8.2mm drill bit.Rivet down the first hole to the roof.05060708Drill and rivet the opposite corner.Drill and rivet through theremaining holes.Fit the top module into the baseplateand torque to 40Nm.Anchor installation is complete andready for the system components tobe secured.Issue Date: 18/04/2013 Issue No: 34

RoofSafe Anchor & CableToggle Installation01020304Mark out the fixing positions of theanchor on the roof membrane. Besure toggles will fix into the crownson metal deck.Whilst the baseplate is inposition, mark positions throughthe toggle inserts.Using a 29mm (1.14”) diameterbi-metal hole saw, drill through theinsulation and through the metal orplywood deck.Clear away the debris.05060708Measure the depth of the hole to thetop of the metal or plywood deck.Mark alignment tube and toggle foaminsulation with the measurement fromstep 5 and cut.Insert alignment tubes into the holes.Slide the toggle into the hole as shown.09101112Once it has dropped through,the toggle should fall.Pull upwards to lock the togglein place.Repeat steps 8 to 10 for theremaining toggles.Whilst holding the toggle insert, usea hand drill (18v recommended) and13mm hex driver to drive the toggleinto place.13141516This will lock the toggle as shown.Using a torque wrench,torque the toggles to 15Nm.Fit the RoofSafe Anchor module intothe baseplate and torque to 40Nm.The anchor is now installed and readyfor the application of waterproofingdetail and system components.Issue Date: 18/04/2013 Issue No: 35

RoofSafe Anchor & CableConcrete Installation01020304Mark out the fixing positions of theanchor on the roof membrane.Using the 29mm Auger or wood drillbit, drill through the roof membraneand the insulation material.Clear away the debris.Measure the depth of the hole.05060708Mark alignment tube and toggle foaminsulation and cut to length.Insert alignment tubes into holesSet the drill to ‘hammer’ action andusing a 12mm drill bit, drill a hole inthe concrete 50-55mm maximumdepth from the surface of the concreteroof structure.Note: If screed is present above theconcrete roof structure, drill through itwith the 14mm masonry drill bit, untilyou reach the concrete. Then revert tothe 12mm drill bit.09101112Using a blow pump, clean all of thedust and debris from the hole.Screw the threaded rod into the fixingsocket so that two full threads areprotruding out of the bottom end.Measure the depth of the insulationwith the steel ruler, plus the depth ofany screed.Mark the threaded rod with themeasurement taken in step 11, awayfrom the shoulder of the fixing socket(see above).Issue Date: 18/04/2013 Issue No: 36

RoofSafe Anchor & CableConcrete Installation13141516Insert into the hole in the concrete.Place the setting tool (7241112)over the threaded rod and on to theshoulder of the fixing. The settingtool should be resting on top of thefixing socket.Hit with a hammer to set the fixing untilthe mark made in step 12 is level withthe roof membrane.Screw the threaded rod downuntil it touches the bottom ofthe concrete hole.17181920Slide the toggle foam spacer over thethreaded rod.Test each fixing to a load of 5kN usingpull tester. See pull test instructions formore details.Place the baseplate in position.Place the toggle inserts over thethreaded rods.21222324Add the nut and tightento 15Nm.Cut off the excess threaded rod.File down any burrs to preventpenetration of the roof membrane.Fit the RoofSafe Anchor module intothe baseplate and torque to 40Nm.The anchor installation is now completeand ready for waterproofing detail andsystem component.Issue Date: 18/04/2013 Issue No: 37

RoofSafe Anchor & CableComponent Installation90°/45° CORNER01020304Remove M12 nut and washer.INTERMEDIATE BRACKETPosition the corner componentand align.Refasten nut and washer.Torque to 30Nm and replace nut cap.01020304Remove M12 nut and washer.Position the Intermediate componentand align.Refasten nut and washer.Torque to 30Nm and replace nut cap.VARIABLE CORNER01020304Remove M12 nut and washer.Position the Variable componentand align.ROOFSAFE SYSTEM EYE & PINRefasten nut and washer.Torque to 30Nm and replace nut cap.01020304Remove M12 nut and washer.SINGLE POINT EYE - EMEAPosition the System Eye componentand align.Refasten nut and washer.Torque to 30Nm and replace nut cap.01020304Remove M12 nut and washer.Position the Single Point Eyecomponent and align.Refasten nut and washer.Torque to 30Nm and replace nut cap.Issue Date: 18/04/2013 Issue No: 38

RoofSafe Anchor & CableBaseplate Drilling01020304Clean the fixing area with alcoholsolution/ wipes.Position the sealing tape on the seams.Place the baseplate on the roof.Position the baseplate drilling jig on theplate as shown.05060708Mark all hole positions.Center punch the first hole.Drill through the baseplate androofsheet using an 8.2mm drill bit.Rivet down the first hole to the roof.09101112Drill and rivet the opposite corner.Drill and rivet throughthe remaining holes.Fit the top module into the baseplateand torque to 40Nm.The anchor is now installed and readyfor the top component.Issue Date: 18/04/2013 Issue No: 39

RoofSafe Anchor & CableHex SwagingOnly 8mm 7x7 construction stainless steel wire cable supplied by Capital Safety may be used for RoofSafe Anchor & Cable applications. The hex swage data is based on the results froman Izumi EP410 model hex swager with 7241122 10mm bite dies. For any other hex swaging system/machine the installer needs to verify that the minimum strength of the hex swage is38kN. Capital Safety offers a testing service, please contact us for more information.MEASURE & CUT CABLE01020304Remove the split pin from the tensionerand attach it to the Energy Absorber orsystem eye.Unscrew the stud by hand to fullyexpose the threads.Mark the tube at the depth of the hole(80mm from the end of the tube).Pull the cable tight and mark the cablewhere it lines up with the mark on thetube and then cut using appropriatesteel wire cable cutters.SWAGING05060708If required, uninstall the swage andinsert the cable into the tube and markwith tape/marker. Check it inserts tofull depth (80mm).Using the hex swager, make thefirst bite immediately after the solidsection (A) (see below). Each bite isapproximately 10mm wide.Following the table dimensions below,ensure the 6th bite finishes short of thechamfer section (B) (see below).Using a vernia, check the swagebite dimensions against the specifiedtolerance on the part.(Dimensions are in mm)CABLE HEX SWAGING TABLESWAGE DIES SWAGE BITES BITE GAP DIMENSION ACROSS FLATS7 X 7 CABLE 7241122 6 discontinuous 1mm - 1.5mm See etched markings on partPart number, batch number and swagebite dimensions are etched on the side ofthe swage part.Key:Etching - (xxxxxx xxxxxx)80mmABxxxxxx xxxxxxxxxxxx xxxxxxDimension across flatsBite GapIssue Date: 18/04/2013 Issue No: 310

EUROPE, MIDDLE EAST& AFRICAFranceLe Broc CenterZ.I. 1re Avenue – BP1506511 Carros Le Broc CedexFRANCEt: +33 (0)4 97 10 00 10f: +33 (0)4 93 08 79 70United Kingdom5a Merse RoadNorth Moons MoatRedditch, WorcestershireB98 9HL UKt: +44 (0) 1527 548 000f: +44 (0) 1527 591 000DubaiME Branch OfficePO Box 17789JAFZA, Dubai – U.A.Et: 00 800 999 55500f: +33 (0)4 93 08 79 70GermanyHagener Strasse 44, D-57489,Drolshagen,Germanyt: +49 (0) 2 76 18 33 82 29f: +33 (0)4 93 08 79 70GLOBAL LEADER IN FALL PROTECTIONCapital Safety is one of the world’s leading manufacturers of fall protection and rescue equipment,with decades of experience and a legacy of innovation.We understand the industries we serve and listen to the workers in the field. We employ the bestengineers to create innovative solutions and patent the products that keep workers safe at heightsaround the world. Capital Safety has the best quality and largest range of fall protection productsin the industry. But we’re more than a product company.We take an innovative approach in bringing our products to the field. We have created internationalpartnerships and a vast network of authorized distributors, certified installers and service centres.We offer on-site and in-house training.Look for complete solutions in our extensive line of DBI-SALA ® and Protecta ® products.CUSTOMER SERVICES00 800 999 55500information@capitalsafety.comwww.capitalsafety.comAll rights reserved. The material contained herein is copyrighted; no part of this publication may bereproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic,mechanical, photocopying, recording or otherwise without prior written permission from Capital Safety.