INSTALLATION INSTRUCTIONS

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1 INSTALLATION INSTRUCTIONS RoofSafe Anchor & Cable Installation Instruction Number: 21 Always read and follow the warnings and instructions for use Copyright Capital Safety Systems Ltd 23 THE ULTIMATE IN FALL PROTECTION

2 Contents GUIDELINES FOR INSTALLATION 3 TOP FIX INSTALLATION 4 TOGGLE INSTALLATION 5 CONCRETE INSTALLATION 6 COMPONENT INSTALLATION 8 BASEPLATE DRILLING 9 HEX SWAGING 10 THESE INSTRUCTIONS ARE AN AID TO TRAINING. ONLY TRAINED PERSONNEL SHOULD ATTEMPT TO INSTALL A ROOFSAFE ANCHORS SYSTEM. Issue Date: 18//23 Issue No: 3 2

3 Guidelines for Installation Detailed 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 LIST General Heavy duty drill with a hammer action facility 32mm Auger drill bit or wood drill bit and extension bar for cutting through the roof insulation material Marker pen Steel Ruler/Tape Measure Pair of plastic pipe cutters Pen Torch Knife Torque wrench with a range of 0-50Nm (calibrated) Hex driver to torque wrench adaptor 13mm Socket for use with the torque wrench Socket to drill adaptor Alcohol Solution/Wipes RA 6mm Hex Drive Bit (96004)** RA Removal Spanner (96003)** Standing Seam Anchor 19mm Socket for use with the torque wrench 3/16 hex driver Trapezoidal Anchor 8.2mm HSS Drill Bit Toggle Fix Powerbird Industrial Rivet Gun (72411)** Powerbird Jaws (72411)** Powerbird Nose Piece (72411)** RA Baseplate Drilling Jig (960)** Concrete Anchor 12mm HSS Drill Bit The drill bit must be long enough to penetrate the roof construction and concrete 14mm HSS Drill Bit The drill bit must be long enough to penetrate the roof construction and any screed Blow pump Flat File Hack saw Lump hammer RA Concrete Setting Tool ( )** Eyebolt Testing Kit ( )** Plywood board (18mm x 500mm x 500mm) for distributing test load Depth Gauge Rod (knitting needle) long enough to reach deck through insulation ** these tools are available for purchase from 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 SO The component list below shows typical RoofSafe Anchor components. Your order is system specific and may not feature all of these components. ROOFSAFE ANCHOR & CABLE COMPONENTS RA Baseplate 4x4 H RA Baseplate 4x4 BL RA Baseplate 350x440 H RA Baseplate 350x440 BL RA Baseplate 550x450 BL RA Module End / Corner Top Fix RA Module Intermediate Top Fix RA Module End / Corner Bitumen RA Module Intermediate Bitumen RA Module End / Corner PVC RA Module Intermediate PVC RA Module End / Corner All Membrane RA Module Intermediate All Membrane RA System Eye and Pin RA 90º Corner RA 45º Corner RA Variable Corner RA Intermediate Bracket RA Throw Plate Kit RA Single Point Eye EMEA RS Maxi Clamp Z x RS Mini Clamp Z x RS Maxi Clamp E x RS Mini Clamp E x RS Maxi Clamp U x RS Mini Clamp U x Concrete Anchors 150mm x Concrete Anchors 300mm x RA Toggle Fixing 150mm x RA Toggle Fixing 300mm x Uni 8 8mm Hex Swage Tensioner 0.8kN Issue Date: 18//23 Issue No: mm 7 x 7 Stainless Steel Cable Uni 8 8mm Hex Swage Toggle 3

4 Top Fix Installation STANDING SEAM INSTALLATION Ensure the seam is correctly formed prior to installing the anchor. Attach the clamps and position the anchor. Slide the inserts into position. The inserts should be flush with the main body of the clamp. Torque the bolts to 30Nm. Torque set screws to 15Nm. Fit the top module into the baseplate and torque to 40Nm. Anchor installation is complete and ready for the system components to be secured. TRAPEZOIDAL INSTALLATION Stick the scapa tape over the holes which align with the roof crowns. Clean the fixing area with alcohol solution/ wipes and place post in position. Drill through the first hole in the base plate using an 8.2mm drill bit. Rivet down the first hole to the roof. Drill and rivet the opposite corner. Drill and rivet through the remaining holes. Fit the top module into the baseplate and torque to 40Nm. Anchor installation is complete and ready for the system components to be secured. Issue Date: 18//23 Issue No: 3 4

5 Toggle Installation Mark out the fixing positions of the anchor on the roof membrane. Be sure toggles will fix into the crowns on metal deck. Whilst the baseplate is in position, mark positions through the toggle inserts. Using a 29mm (1.14 ) diameter bi-metal hole saw, drill through the insulation and through the metal or plywood deck. Clear away the debris. Measure the depth of the hole to the top of the metal or plywood deck. Mark alignment tube and toggle foam insulation with the measurement from step 5 and cut. Insert alignment tubes into the holes. Slide the toggle into the hole as shown Once it has dropped through, the toggle should fall. Pull upwards to lock the toggle in place. Repeat steps 8 to 10 for the remaining toggles. Whilst holding the toggle insert, use a hand drill (18v recommended) and 13mm hex driver to drive the toggle into place This will lock the toggle as shown. Using a torque wrench, torque the toggles to 15Nm. Fit the RoofSafe Anchor module into the baseplate and torque to 40Nm. The anchor is now installed and ready for the application of waterproofing detail and system components. Issue Date: 18//23 Issue No: 3 5

6 Concrete Installation Mark out the fixing positions of the anchor on the roof membrane. Using the 29mm Auger or wood drill bit, drill through the roof membrane and the insulation material. Clear away the debris. Measure the depth of the hole. Mark alignment tube and toggle foam insulation and cut to length. Insert alignment tubes into holes Set the drill to hammer action and using a 12mm drill bit, drill a hole in the concrete 50-55mm maximum depth from the surface of the concrete roof structure. Note: If screed is present above the concrete roof structure, drill through it with the 14mm masonry drill bit, until you reach the concrete. Then revert to the 12mm drill bit Using a blow pump, clean all of the dust and debris from the hole. Screw the threaded rod into the fixing socket so that two full threads are protruding out of the bottom end. Measure the depth of the insulation with the steel ruler, plus the depth of any screed. Mark the threaded rod with the measurement taken in step 11, away from the shoulder of the fixing socket (see above). Issue Date: 18//23 Issue No: 3 6

7 Concrete Installation Insert into the hole in the concrete. Place the setting tool ( ) over the threaded rod and on to the shoulder of the fixing. The setting tool should be resting on top of the fixing socket. Hit with a hammer to set the fixing until the mark made in step 12 is level with the roof membrane. Screw the threaded rod down until it touches the bottom of the concrete hole Slide the toggle foam spacer over the threaded rod. Test each fixing to a load of 5kN using pull tester. See pull test instructions for more details. Place the baseplate in position. Place the toggle inserts over the threaded rods Add the nut and tighten to 15Nm. Cut off the excess threaded rod. File down any burrs to prevent penetration of the roof membrane. Fit the RoofSafe Anchor module into the baseplate and torque to 40Nm. The anchor installation is now complete and ready for waterproofing detail and system component. Issue Date: 18//23 Issue No: 3 7

8 Component Installation 90 /45 CORNER Remove M12 nut and washer. INTERMEDIATE BRACKET Position the corner component and align. Refasten nut and washer. Torque to 30Nm and replace nut cap. Remove M12 nut and washer. Position the Intermediate component and align. Refasten nut and washer. Torque to 30Nm and replace nut cap. VARIABLE CORNER Remove M12 nut and washer. Position the Variable component and align. ROOFSAFE SYSTEM EYE & PIN Refasten nut and washer. Torque to 30Nm and replace nut cap. Remove M12 nut and washer. SINGLE POINT EYE - EMEA Position the System Eye component and align. Refasten nut and washer. Torque to 30Nm and replace nut cap. Remove M12 nut and washer. Position the Single Point Eye component and align. Refasten nut and washer. Torque to 30Nm and replace nut cap. Issue Date: 18//23 Issue No: 3 8

9 Baseplate Drilling Clean the fixing area with alcohol solution/ wipes. Position the sealing tape on the seams. Place the baseplate on the roof. Position the baseplate drilling jig on the plate as shown. Mark all hole positions. Center punch the first hole. Drill through the baseplate and roofsheet using an 8.2mm drill bit. Rivet down the first hole to the roof Drill and rivet the opposite corner. Drill and rivet through the remaining holes. Fit the top module into the baseplate and torque to 40Nm. The anchor is now installed and ready for the top component. Issue Date: 18//23 Issue No: 3 9

10 Hex Swaging Only 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 from an Izumi EP410 model hex swager with mm bite dies. For any other hex swaging system/machine the installer needs to verify that the minimum strength of the hex swage is 38kN. Capital Safety offers a testing service, please contact us for more information. MEASURE & CUT CABLE Remove the split pin from the tensioner and attach it to the Energy Absorber or system eye. Unscrew the stud by hand to fully expose 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 cable where it lines up with the mark on the tube and then cut using appropriate steel wire cable cutters. SWAGING If required, uninstall the swage and insert the cable into the tube and mark with tape/marker. Check it inserts to full depth (80mm). Using the hex swager, make the first bite immediately after the solid section (A) (see below). Each bite is approximately 10mm wide. Following the table dimensions below, ensure the 6th bite finishes short of the chamfer section (B) (see below). Using a vernia, check the swage bite dimensions against the specified tolerance on the part. (Dimensions are in mm) CABLE HEX SWAGING TABLE SWAGE DIES SWAGE BITES BITE GAP DIMENSION ACROSS FLATS 7 X 7 CABLE discontinuous 1mm - 1.5mm See etched markings on part Part number, batch number and swage bite dimensions are etched on the side of the swage part. Key: Etching - (xxxxxx xxxxxx) 80mm A B xxxxxx xxxxxx xxxxxx xxxxxx Dimension across flats Bite Gap Issue Date: 18//23 Issue No: 3 10

11 EUROPE, MIDDLE EAST & AFRICA France Le Broc Center Z.I. 1re Avenue BP Carros Le Broc Cedex FRANCE t: +33 (0) f: +33 (0) United Kingdom 5a Merse Road North Moons Moat Redditch, Worcestershire B98 9HL UK t: +44 (0) f: +44 (0) Dubai ME Branch Office PO Box JAFZA, Dubai U.A.E t: f: +33 (0) Germany Hagener Strasse 44, D-57489, Drolshagen, Germany t: +49 (0) f: +33 (0) GLOBAL LEADER IN FALL PROTECTION Capital 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 best engineers to create innovative solutions and patent the products that keep workers safe at heights around the world. Capital Safety has the best quality and largest range of fall protection products in 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 international partnerships 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 SERVICES All rights reserved. The material contained herein is copyrighted; no part of this publication may be reproduced, 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.

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