Permanent Stainless Steel Anchorage Point for Concrete, Solid Masonry and Steel Constructions

Transcription

1 ABS-Lock X / X - SR Permanent Stainless Steel Anchorage Point for Concrete, Solid Masonry and Steel Constructions The ABS-Lock X system was developed to provide both a secure single anchorage point for individuals and to act as an end anchor in safety systems. The material is manufactured from corrosion-proof steel. The ABS-Lock X system is tested in accordance with EN 795, classes A and B, and can also be installed as an end or intermediate anchorage point in concrete or steel as part of a safety system in accordance with EN 795, class C, up to a max. load of 15 kn. When installing in either wood or trapezoidal sheeting a max. force of 12 kn may be induced. The Lock X is licensed as a single anchorage point for 3 individuals and can be used for up to 10 people in conjunction with a cabling system (Lock SYS I). L = 40 mm M16 thread L = max. 300 mm above the structural surface Thermal insulation, paneling etc. L = Insulation thickness Page 1 of 16

2 INSPECTION PRIOR TO USAGE: The recommendations for the usage of other products in conjunction with this product must be observed. The anchorage point must be free from damage with no evidence of corrosion. The concrete must be unflawed and have no obvious cracks. The anchorage point must be in good working order without any wear or tear or deformation. The anchorage point must not be used if the above criteria are not fulfilled. Important: This anchorage point must be subjected to an annual inspection by an expert under observance of the manufacturer s instructions. This examination is important as the user s safety depends on the effectiveness and durability of the equipment. SAFETY REGULATIONS: Never mount the anchorage point on a wall with a strength class less than C20/25 (B25). Never use the anchorage point for transporting materials. Wherever possible do not work above the anchorage point. (please refer to the lanyard operating manual): This product may be used as a single anchorage point by max. 3 individuals: This product may only be used by appropriately instructed and trained personnel. Both prior to and during usage thought should be given as to how rescue measures can be carried out effectively and expediently. The anchorage device may not be modified in any way whatsoever. During usage attention should be paid to ensuring one has a firm footing (beware of things one can fall over) This product must be used with connectors (in accordance with EN 362) and personal fall protection equipment (e.g. lanyard with fall absorber according to EN 354 and EN 355, guided type fall arrester with a flexible anchor in compliance with EN or a self-retracting lifeline in accordance with EN 360). Following a fall the product must be taken out of service and examined by the manufacturer. Do not expose the anchorage point to chemicals or other aggressive substances. If in doubt, please contact the manufacturer. If there are any doubts as to the safety of the anchorage point it should be immediately taken out of service and sent to the manufacturer for inspection. Page 2 of 16

3 It is absolutely vital to ensure that there is sufficient clearance below the user s feet. Should a person secured by the anchorage system fall, it is important to allow for the ensuing deformation of the anchorage system (up to 300 mm) when calculating the required restraining distance (fall absorber stretch, cable expansion and the fact that the lanyard slips along the body). Please also heed the user manuals of any other fall arrest PPE used. Health restrictions (cardiovascular diseases, the taking of medicines) can negatively impact the user s safety when working at heights. If there are any doubts regarding the user s physical condition, please consult a doctor prior to usage. Children and pregnant women should not use the system. An emergency rescue plan must be in place covering all the possible emergency situations which could arise during work. IMPORTANT The various mounting situations all require that the anchor eyelet is secured. This is done by tightening the ring nut up to the nut until it touches the serrated lock washer. Additionally, a screw fixing media (e.g. Loctite) should be used. For all other cases one should contact the manufacturer. PLEASE NOTE We recommend using a temporary anchor cable between the individual anchors (e.g. ASK 8) if no permanent stainless steel cable has been mounted (e.g. Lock SYS cabling systems) Page 3 of 16

4 INSTALLATION The schematic construction of the Lock X with supporting tube and the Lock X-SR is the same for all installation substructures - the only difference being the type of mount used. INSTALLATION USING REINFORCED SUPPORTS Lock X with supporting tube Lock X - SR 1. Ring nut 2. M16 nut 3. M16 seal 4. Small washer 5. Force absorber Mounting surface (illustration: doweled into concrete): In concrete or steel Mounting surface: Supporting tube 6. 36mm spacer ring 7. Base plate On wood or trapezoidal sheeting max. 500 mm protrusion Variable base plate ** How installation is done on the various surfaces is described on the following pages ** Page 4 of 16

5 MOUNTING ON STEEL CONSTRUCTIONS BOLTING WELDING CLAMPING 4x 10 mm stainless steel bolts 4x M10 stainless steel nuts 4x stainless steel spring washers 4x M10 stainless steel threaded bolts 8x M10 stainless steel nuts 8x stainless steel spring washers 1. Place Lock X on the steel girder using the bore holes in the base plate as a template. 2. Drill through the steel girder at the marked spots (11mm) and insert the mounting bolts. 3. On the underside slip on the spring washers and the nuts and tighten accordingly. 1. Put the Lock X into position and have it welded into place by a trained welder Put the Lock X into position and fix the counter plate using the four M10 threaded bolts. 2. Tighten the counter plate up using nuts and spring washers on both sides. Page 5 of 16

6 MOUNTING IN CONCRETE DOWELING IN USING HEAVY DUTY DOWELS 4x ABS Lock BA 10x90 mm heavy duty stainless steel dowels CONCRETING IN CEMENTING IN USING CEMENT ANCHORS 4x M10x125 V2A anchor rods 4x M10 V2A nuts 4x M10 V2A spring lock washers 1. Position the X using the base plate bore holes as a template. 2. Drill four 10 mm diameter holes for the dowels ensuring that the minimum bore depth of 80 mm is observed. 3. Clean out the bore holes very thoroughly, blowing out the debris. 4. Hammer the heavy duty dowels in and use a torque of 40 Nm to tighten them up. 1. The base plate must be positioned at least 60 mm down into the substructure, or: The base plate is positioned below the reinforcement 1. Drill a hole approx mm deep, bore diameter 12 mm. 2. Clean out the bore hole The drill holes must be clean and dry. Brush out the holes at least twice and then blow out the debris two times. Do not use the anchorage point until the cement has set! 3. Fill the bore holes with cement until they are about ¾ full. 4. Put the Lock X in place and screw it all the way in by turning it approx. 3-4 times. 5. Make sure you observe the cement setting times specified in the instructions. 6. Once the cement has hardened screw the anchor rods tightly onto the base plate using the spring lock washers and the M10 nuts and a torque of 40 Nm. Page 6 of 16

7 MOUNTING IN CONCRETE DOWELING INTO REINFORCED CONCRETE SUSPENDED CEILINGS 4x ABS M10 anchors for suspended ceilings 4x ABS M10x60 screws 4x M10 spring lock washers INSTALLATION USING ANCHOR RODS FOR SHALLOW BORES (approx mm) 4x M10x100 stainless steel anchor rods 4x M10 stainless steel nuts 4x M10 stainless steel spring lock washers Protruding anchor rods can be shortened after installation mm 1. Put the X into position using the base plate bore holes as a template. 2. Drill four 16mm diameter holes for the expansion dowels Important: Drill in the areas where the web is at its thinnest!! 3. Hammer the expansion dowels in so that they do not protrude. 4. Put the Lock X-SR in place and screw it into the expansion dowels using the screws and spring lock washers. 5. Tighten using a torque of 30 Nm until the dowels have been forced apart as far as possible. 1. Drill a hole approx. 55 mm deep for the Lock X or resp. 65 mm deep for the Lock X-SR, bore diameter 12 mm. 2. Thoroughly clean the bore hole The drill holes must be clean and dry. Brush out the holes at least twice and then blow out the debris two times. Do not use the anchorage point until the cement has set! 3. Fill the bore holes with cement until they are about ¾ full. 4. Put the Lock X in place and screw it all the way in by turning it approx. 3-4 times. 5. Make sure you observe the cement setting times specified in the instructions. 6. Once the cement has hardened screw the anchor rods tightly onto the base plate using the spring lock washers and the M10 nuts and a torque of 40 Nm. Page 7 of 16

8 MOUNTING IN WOOD WOODEN RAFTERS + PANELING 8x 6.5x64mm FABA screws with washers 2x 6.5x150mm FABA screws with washers WOODEN PANELS ONLY 28 x 6x60mm round-head screws with washers Ø6mm WOODEN RAFTERS ONLY 4x 6.5x150mm FABA screws with washers min. 60 mm 1. Position the Lock X so that both central bore holes in the base plate are on top of the wooden rafter. 2. Screw the 150mm screws into the rafter through the central base plate bore holes. 3. Screw the 8 64mm screws into the paneling through the outer bore holes of the base plate. 1. Check to make sure that the paneling is in good condition. 2. Position the sealant mat directly over the wooden paneling. Important: Remove any thermal insulation. 3. Place the Lock X on the mat and use the 28 screws to secure it by screwing them through the mat. Important: Do not forget to use the washers with the screws. 4. Only for use on paneling which is at least 24 mm thick! Important: In all other cases please consult the manufacturer min. 100 mm 1. Position the Lock X on the rafter and secure it using the 150mm screws. Important: Do not forget to use the washers with the screws. Page 8 of 16

9 ARRANGEMENT OF THE ROOF SUPPORTS FOR ABS-LOCK X Roof edge max. 7.50m 2) max. 7.50m 2) Roof edge min. 2.50m / max. 5.00m 1) Roof edge max. 7.50m 2) min. 2.50m / max. 5.00m 1) Roof edge 1) The values specified above serve only as a guide 2) The values specified above apply to using anchorage points on their own without a permanent cabling system Page 9 of 16

10 TRAPEZOIDAL SHEETING / SANDWICH PANELS DIRECTLY ON TRAPEZ. SHEETING 1x ABS-Lock X installation set (1x ring nut+nut+serrated lock washer; 4x toggle bolt+screw+ seal+washer) SANDWICH PANELS 1x ABS-Lock X installation set (pls. refer to Directly on Trapez. Sheeting ) WITH THERMAL INSULATION ON TOP 1x ABS-Lock X installation set (pls. refer to Directly on Trapez. Sheeting ) 4x spacer tubes 4x M8 threaded extensions 1. Mark and drill the four holes for securing the ABS- Lock X using the ABS-Lock X as a template for drilling. 2. The bore holes must be drilled centrally and have a diameter of 20mm. 3. Using the sealant material supplied eliminates the need for further waterproofing (assuming the surface upon which the ABS-Lock X is installed is smooth and flat!) 1. Installation is done in exactly the same was as for trapezoidal sheeting without insulation. 2. First insert the spacer tubes into the holes drilled through the thermal insulation material. 3. Push the Lock X with its thread extension and toggle bolt through the tube and then tip the bolt head as described on the following page. Details on how to secure the toggle bolt can be found on the following page! Important: This anchorage point may be used on tin rooves with as little as 0.5 mm thickness! Page 10 of 16

11 INSTALLATION INSTRUCTIONS - CONTINUED When installing on sandwich elements 1 any thermal insulation material/ 2 wadding underneath has to be removed (possibly also applies to trapezoidal sheeting). To do this remove the respective thermal insulation below the raised bead using a drill or similar tool (possibly using suction), then insert the toggle bolt through the 20mm diameter bore hole. Then shake the bolt violently (possibly using a spanner) so that the toggle mechanism is triggered. As the thread protrudes approx. 5 millimeters, as shown in Step 1, the bolt head is prevented from tipping 180 degrees. This guarantees that the bolt can no longer be removed. Plastic washer Seal (rubber) Important!! The end of the screw protrudes approx. 5 mm out of the brass shaft Seal (rubber) is lying flat on the surface Bore diameter 20mm 5mm protrusion prevents tilting (if nec.) removal of the thermal insulation 3 you can using some pliers until it will not 4 ** Wrong ** (approx mm) Now pull the screw upwards as hard as go any further, leaving it protruding from the Lock X base plate by about 40-45mm (when using standard 70mm screws). The released toggle bolt is now held in place underneath the metal sheeting by the washer. **Correct** 40-45mm Important: It is absolutely essential to ensure that the toggle bolt is lying flat right up against the metal. Should the toggle bolt be wedged in at a vertical angle the screw can only be pulled out a few millimeters Now the screw can be tightened using a torque of 10 Nm without causing the toggle bolt to rotate Important: Please ensure that the toggle bolt is lying flat! On no account should it get caught up or be wedged into the sides of the trapezoidal sheeting as this would prevent the anchor from providing adequate protection! **IMPORTANT** The toggle bolt must lie flat After installing the toggle bolt the anchorage point should be pulled and shaken violently in all directions to check that it has been installed correctly. Page 11 of 16

12 MOUNTING IN LIGHTWEIGHT CONCRETE, MASONRY etc. SECURING IN CASES WHERE THE INSTALLATION SURFACE DOES NOT ALLOW CEMENTING OR ANCHORING Anchorage point installation kit: 2x M16 stainless steel nuts 2x M16 stainless steel spring washers 1x M16 stainless steel ring eyelet Support rod installation kit: 1x Small M16 stainless steel washer 1x DM16 PA seal 1x Synthetic force absorber 1x Plastic centering ring 1x M16 stainless steel spring lock washer Order: 1. Ring nut 2. Spring lock washer 3. M16 nut 4. M16 seal 5. Small M16 washer 6. Force absorber 7. Centering ring 8. M16 nut 9. M16 spring lock washer 3 Ring eyelet Hall roof Lock X with threaded bolt and screwedon counter plate Bore hole 2 Counter plate Pull through the bore hole from above 1 Attach a rope to a threaded sleeve or similar and pull the Lock X up without its ring bolt 1. The Lock X is pulled upwards from above using, for example, a threaded sleeve and a rope. 2. The threaded bolt is passed through the bore hole and the second plate is used to counter the first. 3. After tightening it up using a torque of 70 Nm the supporting rod is then installed, also using 70 NM, and finally the ring eyelet, serrated lock washer and nut are attached. Page 12 of 16

13 MOUNTING AT THE ROOF APEX SCREWING INTO WOOD (MIN. 24 MM THICK) FOR ROOF PITCHES FROM 30 to 45 32x 6x40mm round-head screws GENERAL INFORMATION: The base plate is delivered ex factory with an angle of If the screws are firmly tightened up the base plate can also be adjusted to fit a range of 30 to Position the base plate in the center. 2. When tightening up the screws start with the top row and switch from one side to the other so that the base plate fits exactly. We recommend installing 2 screws in the top right row and 2 screws in the top left row and then continuing down accordingly. 30 to 45 Top row 3. Firmly tighten up the screws so that the base plate fits snugly. If necessary, the base plate can be bent where it forms an angle. 8 screws for each row Page 13 of 16

14 LABELING INFORMATION The anchorage device bears a label with the following information: Model: Manufacturer: Batch No.: Max. number of individuals allowed: Standard with release date: ABS-Lock X or ABS-Lock X -SR X XXXXX 3 individuals EN 795/A1:2001 Symbol pointing out that it is important to follow the instructions in the user manual: CE-symbol and ID No. of the notified office engaged in inspecting the PPE: DEKRA EXAM GmbH Dinnendahlstrasse Bochum Page 14 of 16

15 DOWEL LOG Date Location: Type of Dowel: Setting Depth: Bore ø: Concrete quality: (e.g.: C20/C25) The undersigned installation company herewith confirms that the dowels have been correctly implemented in accordance with the dowel manufacturer s guidelines. (Drill holes correctly cleaned, observance of the hardening times and processing temperature, distance of the dowels from the edge, surface check etc.) PHOTOGRAPHIC DOCUMENTATION Date: Location: Photos: (File Names) Responsible installation technician: Installation company Signature: Signature: Page 15 of 16

16 INSPECTION LOG Year of manufacture: Purchase date: Model description/ standard: Batch number: Date first used:: User name: Date Processing reason (routine examination or maintenance) Identified damage, maintenance work carried out etc. Name/ signature of a qualified person Date of the next routine inspection Page 16 of 16