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SAFETY ENGINEERING CABLE SAFE DATA SHEET

Copyright © 2016 Safety Engineering Products Limited. All Rights Reserved.

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CONTENTS

‘CABLESAFE’ HORIZONTAL LIFELINE 03

MEMBRANE POST 04

333/400 TOP FIX RIVET POST 06

STANDING SEAM 08

TRADITIONAL POSTS 10

TENSIONER WITH TENSION INDICATOR DISK 11

CORNER BRACKET 90° 12

INTERMEDIATE BRACKET 13

8MM STAINLESS STEEL WIRE ROPE 14

VARIABLE CORNER BRACKET 15

TRAVELLER DEVICE 16

SAFE WORKING PRACTISES 17

INSTALLATION 18

GUIDANCE 20

SYSTEM EXAMINATION AND TEST 23

WARRANTY 24

CONTACT 25

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‘CABLESAFE’ HORIZONTAL LIFELINE Employing a horizontal flexible anchor line

The ‘CableSafe’ System can be fitted to all types of roof sheet by the use of several differently designed posts. These include Composite, membrane, standing seam, concrete, internal steel structure. It may be possible to fit to other roof types with consultation from the Installer or Manufacturer.

• All anchor Posts have been tested to comply with BS EN 795 Class A2

• ‘CableSafe’ System complies with BS EN 795 Class C

Every installed system will be designed for purpose, with calculations being carried out ensure that it is of acceptable design for the system to work correctly. In some cases calculations may be required for the integrity of structural support that the ‘CableSafe’ anchor devices or structural anchors will attach to. These anchors are to be installed to the strict adherence to BS 7883 and the manufacturer’s instructions. The anchors may be at up to a 10m centre in any one run when using the ‘CableSafe’ Horizontal Lifeline.

Once your ‘CableSafe’ System has been installed it will be commissioned for use by the installing contractor, they will clearly mark up the system and provide the building manager with the operating and maintenance manual.

All fixtures and fittings are specific to the type of structure that is being installed to, these may be Aluminium rivets, Stainless Steel Toggle Bolt, Aluminium Clamp or resin anchor.

APPLICATIONS

PERFORMANCE

DESIGN

COMMISSIONING

FIXTURES & FITTINGS

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TECHNICAL DATA SHEETMEMBRANE POST

The ‘Cablesafe’ Membrane post is designed for fitting to membrane roof types. This is done by the use of mechanical fittings through the insulation down to the metal or ply deck.

‘Cablesafe’ uses its own in house manufactured Toggle bolt.

Features of the Toggle Bolt

• All Stainless Steel Construction

• Integrated EPDM Bonded washer

• M8 X 1.25 Coarse Pitch, with Hex head

• Bolts supplied varying lengths to allow for insulation depth, this is achieved also by use of the set screw design

As well as the EPDM Bonded washer on each toggle bolt, the top attachment thread is supplied with an EPDM bonded washer to ensure the top of the post is sealed once any system components are attached.

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The post is fitted by attachment through the insulation, this can be done on initial roof construction or retro fitted. The post is then sealed using sections of membrane roof sheet to seal the post in.

The post can also be fitted with a weather cowl for added protection.

The PVC coated post option also allows for this procedure to be carried out with a wide range of membrane materials.

The use of dished mounting holes for the toggle bolts allows for the post to slightly embedded in the insulation and for the head of the toggle bolt to be in the dished recess, minimising potential trip hazards.

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TECHNICAL DATA SHEETMEMBRANE POST *CONTINUED

The post has been tested to conform with: BS EN 795 :1996.

This is achieved by the use of the internal shock absorbing element that is within the post. This enables the load to be absorbed by the post should a fall occur.

The post can be fixed to roofs that have a angle of 15 °. Ensuring the post can be fitted to the most common roof types.

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Material: All Grade 304 Stainless Steel for Post

Fixing materials as specified earlier

Finish: Natural Stainless Steel / PVC Coated (RAL 9007)

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TECHNICAL DATA SHEET333/400 TOP FIX RIVET POST

333/400 TOP FIX RIVET POST

The ‘Cablesafe’ 333/400 top fix rivet post is designed for fitting to trapezoidal roof types. With a crown centre of 333 or 400mm. This is done by the use of Rivets.

‘Cablesafe’ uses the Bulb-tite® range of rivets.

Features of Rivet:

• (Upon installation the rivet body folds into 3 separate legs, creating a large load bearing area, and minimising the possibility of damage to the parent materials)

• Integral EPDM sealing ring ensures fastening is weather resistant

As well as the EPDM sealing ring the post is fitted with a synthetic rubber based high performance strip sealant. Designed for use on steel and aluminium.

The strip gives a air tight seal to comply with Building Regulations approved document part L standard

Bulb-tite® range of rivets

333/400 Top fix Rivet Post

EPDM sealing ring

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TECHNICAL DATA SHEET333/400 TOP FIX RIVET POST

The post has been tested to conform with:

BS EN 795 :1996, with the exception that the static load test was increased from the current 10kN to 12kN (which is proposed to be the standard from late 2012).

This is achieved by the use of the internal shock absorbing element that is within the post. This enables the load to be absorbed by the post should a fall occur.

The post can be fixed to roofs that have a angle of 15 °. Ensuring the post can be fitted to the most common roof types.

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Material: All Grade 304 Stainless Steel for PostFixings material as specified earlier

Finish:Natural Stainless Steel / Polyester Powder Coating (Goose Wing Grey)

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TECHNICAL DATA SHEETSTANDING SEAM

The ‘Cablesafe’ Standing Seam post is designed for fitting to Standing Seam roof types. This is done by the use of mechanical fittings that clamp on to the seam and do not puncture or pierce the roof sheet.

Cablesafe’ uses an Aluminium Clamp for means of fixing.

• Features of the Clamp

• Aluminium Construction with Stainless steel bolts

• M10 Fixing Bolts

• Easy installation by means of Allen key.

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TECHNICAL DATA SHEETSTANDING SEAM

The post is fitted by attachment to seam of the roof sheet, this can be done on initial roof construction or retro fitted.

Because the post attachment does not pierce the roof sheet there is no need to weather proof any of the roof sheet afterwards, saving time and costs.

The posts spans the width a roof panel, in-between two Standing Seams.

The post has been tested to conform with:

BS EN 795 :1996, with the exception that the static load test was increased from the current 10kN to 12kN (which is proposed to be the standard from late 2012).

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This is achieved by the use of the internal shock absorbing element that is within the post. This enables the load to be absorbed by the post should a fall occur. The post can be fixed to roofs that have an angle of 15 °.

Ensuring the post can be fitted to the most common roof types.

Material: All Grade 304 Stainless Steel for PostFixing materials as specified earlier

Finish:Natural Stainless Steel /Powder coated to any RAL Number

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TECHNICAL DATA SHEETTRADITIONAL POSTS

The Stainless Steel traditional post is designed to be fixed with M12 studding to various surfaces and materials. All manufactured from Gr 304 Stainless steel and Tested to En795-1996 Class A anchor point. The post is available from 50mm to 500mm in height.

Popular for use on concrete roofs and fixing to existing steel work when retrofitted.

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Material: All Grade 304 Stainless Steel

Finish:Mill Finish Stainless Steel / Electro Polished / Powder Coated

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TECHNICAL DATA SHEETTENSIONER WITH TENSION INDICATOR DISK

The ‘Cablesafe’ System uses Tensioner that has a tension indicating disk. The disk will rotate freely once a force of 80 Kg is exerted up on the indicator.

The tensioner is a swage fitting, while the indicator body attaches by a M12 bolt with a castle nut and split pin.

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1. Tensioner body 316 stainless steel

2. Tensioner bar 316 stainless steel

3. Indicator body 316 stainless steel

4. Indicator disc plastic

5. M12 x 45 split pin bolt stainless steel

6. Split pin stainless steel

7. M12 castle nut stainless steel

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TECHNICAL DATA SHEETCORNER BRACKET 90°

‘Cablesafe’ uses a one piece 90° corner bracket for negotiating corners within the system design. This allows for smooth, continuous movement of the traveling device around the corner with the user not requiring detaching from the system.

The corner bracket incorporates a 8mm base which allows for rigidity of the base area while the tube supports are allowed to collapse in the event of a fall.

The Corner Bracket 90° is tested as part of the ‘Cablesafe’ System to BS EN 795 :1996

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Material:-All Grade AISI 316 Stainless Steel

Finish:Electro-polished Stainless Steel

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TECHNICAL DATA SHEETINTERMEDIATE BRACKET

The ‘Cablesafe’ Intermediate bracket is designed to act as a positioning unit to keep the cable located where it is required, while allowing the traveling device to pass over.

The unit also deforms in the event of a fall which acts as part of the energy absorbing element of the system.

The Intermediate Bracket is tested as part of the ‘CableSafe’ System to BS EN 795 :1996

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TECHNICAL DATA SHEET8MM STAINLESS STEEL WIRE ROPE

The ‘Cablesafe’ System uses a 8mm wire rope to act as the horizontal anchor line.

The wire rope is tested and certified to meet the required standard of BS EN 12385 / 2002.

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Finish: AISI 316

Tensile Strength of wire: 1570N/mm²

Minimum Breaking Load: 4200Kg

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TECHNICAL DATA SHEETVARIABLE CORNER BRACKET

The Variable Corner Bracket is designed so that with the use of a pipe bender the extended arms of the Bracket can be bent up to 45° on each arm.

The Variable corner is supported with side piece plate stitch welded, which supports the strain incurred when acting as a corner but allows for deformation in the event of a major fall

The Variable Corner Bracket is tested as part of the ‘CableSafe’ System to BS EN 795 :1996

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TECHNICAL DATA SHEETTRAVELLER DEVICE

The ‘CableSafe’ Traveller device is a solid one piece device, the user is attached to this by means of a Karabiner and then shock absorbing lanyard to themselves.

The Traveller negotiates all components within the ‘CableSafe’ System, meaning the user does not need to disconnect from any part of the system. Allowing for a complete hands free approach, ensuring the user can concentrate on the job at hand.

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a) Before any work is carried out a full risk assessment and method statement should be carried out.

b) A suitable rescue plan should be produced, as well as the ability and knowledge to carry out any procedure.

c) Any personnel working at height must be suitably trained.

d) Ensure that you have all equipment required for the task, if not see your supervisor.

e) Check all equipment being used is correctly marked, labelled and serviceable.

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a) This anchorage device is for use only within limitations and scope laid out within this manual.

b) This system is for use with only equipment that complies to the EN standard that is relevant to that piece of PPE.

GENERAL

FUNCTIONS

SCOPE

Warning-Given the hazardous nature of working at height is important that any one doing so is in good health and physical condition. Any one with underlying health issues should contact a medical health practitioner to assess if there are any issues with them working at height.Please read and understand these instructions fully before any work is carried out. This instruction manual should be retained for further reference

I. SAFE WORKING PRACTISES

a) This system is designed for use in an external and internal capacity.

b) For use in all environments. (Although any concerns should be raised with Safety Engineering Products Ltd)

c) In the Temperature range of –20C to +50C

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a) It is recommended that before any work is carried out a full survey of the site is carried out. This is to ensure that the following requirements are met

b) The Installer must be confident that any concrete, membrane or metalled structure being used will support the impact forces that may be imposed on it.

c) The allowance for fall clearance has to be considered, to avoid injury. Also taking into account if a expanding energy absorbing lanyard is in use on the system.

d) If the system is sold in another country. That there are suitable instructions in the language of that country.

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Loadings applied to horizontal and inclined cable systems are a function of:

a) Number of users falling / restraining simultaneously and also.

b) The fall arrest / restraint characteristics of ancillary equipment (e.g. lanyards etc.) Shock absorbing lanyards which have a peak tear out force greater than 6kN are not permitted.

GENERAL

LOADINGS

II. INSTALLATION

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For horizontal and inclined fall arrest cable systems where more than one person is to be attached during use, it has been shown that precisely simultaneous impacting loads are almost impossible. However, where two or more users are allowed for on a fall arrest horizontal system, it is assumed that two users will not impact simultaneously and individually exert the peak arrest forces associated with their personal fall arrest equipment (e.g. shock absorbing lanyards, retractable lanyards, etc.) In addition, if there are more than two users allowed on the system, it will be assumed that each remaining user (beyond the two already catered for) exerts a force of 1kN additional to the dynamic load produced by the dual fall.

For example, if P(kN) is the peak dynamic arrest load associated with the equipment in use, then the following dynamic loads should be applied in the system design:

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LOADINGS

END ANCHORS

II. INSTALLATION

a) Loadings on end anchorages are the direct result of the cable tension arising from fall arrest loadings. End loads can be controlled by the inclusion of the shock absorber, depending on the type of system. These extend under predetermined loads and allow additional extension of the system thus reducing end loads.

b) End loads are also controlled by the spacing distance of the intermediate anchorages. It is recommended that intermediate spacing of between 3 metres and 10 metres can be used. The intermediate spacing’s are not to be greater than 10m. It is essential that adequate ground clearance is available and rescue techniques are accounted for, due to large wire deflections.

No of Users Assumed Arrest Load (kN)

1 P

2 P + 1

3 P + 2

4 P + 3

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These notes are for guidance for any installers of the ‘CableSafe’ system, please note that these directions are for recommendation purposes only. All systems should follow industry best practise and the installers’ individual professional discretion.

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NOTE

STATIC LINE / WIRE CABLE

III. GUIDANCE

The type of static line wire to be used is:

• Stainless steel 8mm 7x7 strand grade 316

END FITTING / SWAGE FITTINGS

a) The different types of End Fitting are

• Line Tensioner with disk

• Line Tensioner without disk

• Swage fork end

• Threaded terminator

b) In each system you will have at least two of these components, as one will be swaged on either end of the cable. Any of these components can be attached to the end fitting mounting.

c) The first bite of the swage should be begun 60mm from the mouth of the fitting with a spacing of 2 - 3mm between the swages. Minimums of 3 swages are to be applied, with the swage jaws being closed to the full extent. Care must be taken that the press contact is limited to the tubular section of the swage and not the solid bar area.

d) With any swage fitting it is vitally important to ensure that the 8mm wire cable goes at least 60mm inside the fitting. This can be done with a cautionary check of inserting the cable. Marking the point where the mouth of the fitting is on the cable. Remove the cable and measure from the mark to the end of the cable. To ensure at least 60mm of depth has been achieved.

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a) With a hand winch, load-cell and a cable gripping device load one system termination to the predicted maximum tension (not greater than 15kN for 7x7 cable).

A Hydrojaw test rig is recommended for this.

b) Maintain the applied load for 3 minutes and then release.Thoroughly examine the following:The swaged connection for ‘slip’,The cable for damage,All associated structures for damage/signs of failure,

c) Re-test each system termination as above until all terminations have been tested.

d) Re-tension the system to 80kgf.

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PROOF LOAD OF END FITTINGS

END FITTING MOUNTING

III. GUIDANCE

90° CORNER UNIT

The main types of end fitting mountings are the:

• Shark fin

• 2 Hole connector Plate

• 3 Hole connector plate

• Or point to attach on the structure

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6 The 90° Corner Unit is used when the system is being designed to negotiate a 90° corner. The corner unit must be affixed to suitable structural work or anchorage device for it to take the forces impacted on it as if it were an end anchor. The unit can be used as a internal or external angle.

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a) The variable corner can be used to negotiate a change in direction of the system but not to the extent of 90°. The variable corner can be bent on site for angles up to 45°, on each extension of the arm.

b) The adjustment of the variable angle should be done using a pipe bender to avoid any damage being incurred to the tube. Once bent a traveller device should be run over the variable unit to ensure free movement. The installer should also thread a length of 8mm wire cable through the unit to ensure no damage has occurred internally.

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VARIABLE CORNER UNIT

INTERMEDIATE BRACKET

III. GUIDANCE

The intermediate bracket comes in two forms.

• Standard

• Heavy duty

Safety Engineering Products Ltd recommend that Heavy duty intermediates are to be used when the system is to be used in restraint or if the system is to be placed overhead. The bracket has two points where it can be attached to structural work either of these can be used. It is up to the installer to decide which way of mounting the bracket allows for smooth running of the system.

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a) Identify and remove from service the used harness and lanyard(s) (including retractable types).

b) Carry out inspection on mobile anchorage device. Return used mobile anchor device to Safety Engineering Products Ltd for examination or replacement if necessary.

c) Visually examine cable, intermediate and end anchorages. The cable must be replaced if there are any signs of damage (kinks, fretting, etc.) or if the severity of the fall was such as to produce end loads approaching 15kN.

d) Visually examine the end and intermediate anchorages. If the anchorages display signs of damage they must be replaced.

e) Carry out a proof load of all End Fittings.

f) Inspect all structural anchors, if any movement or uncertainty has arisen, carry out a axial proof test of 6Kn to that anchor.(Only for solid structural anchors, any designed to collapse or move after a fall should be replaced outright if any signs of deployment are shown.)

g) Issue new Test Certificate. The Test Certificate should itemisethe test/checks carried out on the system.

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IV. SYSTEM EXAMINATION AND TEST AFTER FALL ARREST / RESTRAINT (ALL SYSTEMS)

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WARRANTY‘CABLESAFE’ HORIZONTAL LIFELINEEMPLOYING A HORIZONTAL FLEXIBLE ANCHOR LINECLASS C SYSTEM

LIMITED WARRANTY AND LIMITATION OF LIABILITY

Each component of the ‘CableSafe’ System is warranted to be free from defects in material and workmanship under normal use and service. The warranty period is one year and begins on the date of shipment.

This warranty extends only to the original buyer or end-user customer of

a ‘CableSafe’ System authorized Installer and does not apply to any product which, in

Safety Engineering Products opinion, has been misused, altered, neglected, contaminated, or damaged by accident or abnormal conditions of operation or handling.

‘CableSafe’ System authorized resellers shall extend this warranty on new and unused products to end-user customers only but have no authority to extend a greater or different warranty on behalf of Safety Engineering Products. Warranty support is available only if a product is purchased through a ‘CableSafe’ System authorized installer or Buyer has paid the applicable international price. Safety Engineering Products reserves the right to invoice Buyer for importation costs of repair/replacement parts when product purchased in one country is submitted for repair in another country.

Safety Engineering Products warranty obligation is limited, at Safety Engineering Products option, to refund of the purchase price, free of charge repair,

Or replacement of a defective product which is returned to a ‘CableSafe’ System authorized installer within the

Warranty period.

To obtain warranty service, contact you’re ‘CableSafe’ System authorized installer to obtain return

authorization information or an inspection on the system.

Safety Engineering Products assumes no risk for damage in transit. Following

Warranty repair, the product will be returned to Buyer or ‘CableSafe’ System authorized installer, transportation prepaid (FOB Destination). If Safety Engineering Products determines that failure was caused by neglect, misuse, contamination, alteration, accident, or abnormal condition of operation or handling, by use outside the product’s

Specified rating, or normal wear and tear of mechanical components, Safety Engineering Products will provide an estimate of repair costs and obtain authorization before commencing the work. Following repair, the product will be returned to the Buyer or ‘CableSafe’ System authorized installer, transportation prepaid and the Buyer or ‘CableSafe’ System authorized installer will be billed for the repair and return transportation charges (FOB Shipping Point).

This warranty does not prejudice your statutory rights.

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