ManSafe Constant Force Post Bituminous Roofing Approved: T.Bissett Sheet 1 of 19
Materials Base plate mild steel, sheradized to 25μm min. Thickness, powder coated Insulating ring 30% glass filled nylon 66 Tube mild steel, sheradized to 25μm min. Thickness, powder coated Dome 316s stainless steel, electropolished Coil 316s stainless steel Yoke 316s stainless steel Axles 316s stainless steel Rollers 316s stainless steel Clinch nut 316s stainless steel Top washer 316s stainless steel Spreader plate 316s stainless steel Nuts & bolts marine grade a4 stainless steel Toggle guide 30% glass filled nylon 66 Toggle bolt A4/70 stainless steel Toggle bolt cap P.A 66 nylon Strength Initial yield force 2.7kN Continuous deployment force of 10kNB (typical) Ultimate strength after full deployment greater than 20kN Approval Tested in accordance with BS EN795 in classes A2 & C Quality control 100% visual inspection on all critical items 100% inspection gauging 100% visual inspection of sub and final assemblies Batch conformance tested to ultimate strength Approved: T.Bissett Sheet 2 of 19
Index For steel deck installation instructions see pages 3 to 7 For concrete deck installation instructions see pages 8 to 14 For timber deck installation instructions see pages 15 to 19 Approved: T.Bissett Sheet 3 of 19
Steel deck roofing systems Tool list 25mm hole saw latchways part no. 00797-00 Drive arbor std for 25mm hole saw latchways part no. 65010-02 Arbor extension for 25mm hole saw latchways part no. 65040-03 Counter bore latchways part no. 00795-00 Notes 1. For use as an end, corner or intermediate anchor as either part of a class c system, a class a2 anchor in a class c system or as a single point anchorage. The base plate is suitable for fixing to the following profile steel sheets with 0.7 mm nominal thickness: d19, d32s, d35, d46, d60 and d100. 2. Overall base plate base plate dimensions = 375 x 532 mm. 3. It is recommended that the posts be installed at a distance of 2m or more from any edge. However, the following edge distances are permissible: Eaves no less than 1m from the eaves. Ensure the post is installed back from the line of the first purlin and sheet stitching screws. Verge no less than 1m from the verge. Ensure the post is installed on the line of the lap joint between the first / second sheet and into the second sheet. Never install the post on to the first sheet next to the verge. Ridge ensure the post is installed below the line of the upper most purlin, sheet stitching screws and ridge cap. Never install the post on to the ridge cap. 4. For access purposes it is recommended that a stainless steel wire rope strop be installed from an adjacent intermediate or end anchorage post to provide an attachment point for safe access to and from the system. However it is permissible to install a post within easy reach of the access equipment, typically 0.5 to 0.75m from the edge of the roof. This post shall be used as a single point anchorage only providing safe access to and from the cable system. It shall not be used as an end or intermediate post for the fall arrest system. 5. Systems using constant force posts are designed for a maximum of 3 users. 6. Posts must be installed at intervals of between 6 and 10 metres to ensure correct performance. 7. The recommended minimum length of roof sheet is 4m. The minimum recommended roof area is 4m x 3m. For a roof area less than 4m x 3m it is recommended that the posts be installed as single point anchors at appropriate positions ensuring the minimum edge distance is maintained. 8. The constant force post has been tested for use with the deck profiles listed in (note 1 sheet 2) and is compatible with the marley range of elastermeric high performance bituminous membranes or similar. Refer to latchways for details of other approved bituminous membranes. Installation instructions 1. Locate the crowns of the steel deck, position posts and mark hole positions. Drill 4 x 25 mm holes through membrane, insulation and metal deck below using 25 mm hole saw 00797-00 and arbor extension 65010-03. Using 56mm counter bore tool 00795-00 drill four holes centrally over the first set of holes to a depth of 10mm. 2. In order to ensure a secure fix, toggle bolts supplied by latchways shall be used. Approved: T.Bissett Sheet 4 of 19
3. Align toggle guide so that the arrow is pointing in line with the direction of the deck. Insert all four toggle guides into the four 25mm holes (maintaining toggle orientation) and press firmly into membrane. 4. Fit the four toggle bolt assemblies to the single ply constant force base plate. 5. Line all four toggles into the toggle guides, lower the single ply constant force post onto the membrane. 6. Push all four toggle bolts into the four toggle guides until each toggle makes contact with the bottom of each toggle guide, each toggle will swing into the locked position (if toggle does not swing, shaking the bolt and the toggle will then engage). 7. Tighten all four toggle bolts using a 13mm socket. Secure by tightening the toggle bolt until the neoprene washer under the head of the bolt goes flat. 8. Push the four toggle caps over the head of the four bolts until the top surface of the toggle cap is level to the surface of the base plate. The bituminous membrane constant force post can be used with the range of marley high perfomance elastomeric membranes or similar. 9. Prime the base plate prior to bonding the bituminous membrane using the marley bitumen primer (code 646405 (5 litre) or 64625 (25) litre) or similar. Failure to do so will result in a poor bond an premature failure of the joint between the membrane and base plate. 10. Weather proofing of the constant force post to the roof membrane should be completed as follows. a) The first layer of the membrane is detailed in the diagram below. This layer shall overlap the edge of the base plate by a minimum of 150mm and terminate at the bottom of the raised profile in the base plate. Approved: T.Bissett Sheet 5 of 19
B) The second layer is detailed in the diagram below. This shall be placed over the post to form a weather tight detail between the first membrane layer and the raised profile in the base plate. It should terminate 35mm from the post, overlapping the first layer. c) the assembly of the first and second layers are detailed below. Approved: T.Bissett Sheet 6 of 19
11. The bituminous membrane can then be bonded to the flat flange of the constant force post base. This shall be fitted by the roofing contractor to provide a weather-tight seal (see figure 1). 12. The membrane used for detailing the base plate should be the same as the waterproofing system that is used for the main specification: typically a) for marley high perfomance elastomeric roofing the detail can be applied by mopping and back torching, or jugging hot bitumen using the appropriate marley torch-on detailing membrane or cap sheet may be used. b) for marley mach 1 single layer roof system the specified mach 1 detailing membrane must be used, which can be applied by hot air or gas torch. 13. To secure the end or intermediate cable support brackets use m12 x 40mm minimum grade a4/70 set screw. To secure the corner bracket use a m12 x 40mm minimum grade set screw. warning care must be taken when applying the detail, particularly when using gas torches which are less controllable than hot air guns. excessive heat will damage the seals of the fall arrest post. for the purposes of applying mach 1 detailing membrane, latchways recommend the use of a leister triac hot air welder. when using naked flame gas torches, a practical solution to avoid the naked flame coming into contact with the post seals is to use a short length of metal pipe to cover the post while applying the roofing detail. care must also be taken with the mach 1 system to ensure that the fixings used to anchor the base plate do not coincide with the mach 1 lap fixings or the fixing channels located within the marley surefix insulation boards. Approved: T.Bissett Sheet 7 of 19
Cast in situ or composite concrete roofing systems 1. For use on in-situ and composite concrete slabs only. Minimum grade c111a light weight c30 lytag concrete. Minimum compressive strength of 23n/mm2 and minimum density of 1930kg/m3 2. For use on concrete slabs with a minimum thickness of 80mm. 3. For use as an end, intermediate and corner anchorage on concrete deck roofing that is suitable to carry fall arrest loads. If in any doubt as to the suitability of the substrate to carry the required loads then consult a structural engineer for verification. 4. Base plate dimensions = 375 x 532 mm. 5. Constant force posts are to be installed on top of any insulation and or screed. 6. A plastic spacer must be used to protect the insulation while drilling the concrete. This spacer should be a u pvc plastic tube with an inside diameter of 25mm (supplied by latchways). This is inserted into the hole in the insulation. 7. For screed and insulation depths greater than 200mm contact latchways for assistance. 8. To be secured back to the concrete deck using 4 mechanical fix hsc-ir m8 stainless steel anchorages and suitably specified fixings. 9. No mechancial fixing shall be installed less than 90mm from the edge of the concrete slab. Also no fixing shall be installed any less than 90 mm from an expansion joint. 10. Each of the 4 hsc-ir m8 stainless steel mechanically fixed anchors must be installed to the manufacturers recommendations and be capable of carrying a minimum load of 10kN in both tension and shear. For example the (m8) safety anchors supplied, are suitable for use in un-cracked concrete. Please note self-undercutting products will require the use of an extended setting tool if installing through insulation. If a hole or anchor has to be abandoned, the minimum distance for the new hole is 90mm away. 11. Always use fixings of grade a4/70 minimum and where possible use internally threaded anchorages and bolts, however grade a4/70 stainless steel studding may be substituted and the base plate retained against the insulation using grade a4/70 minimum nyloc nuts or a suitable alternative locking off mechanism. 12. To ensure maximum fixing strength it is imperative that the strength of the concrete substrate you are installing into meets with the minimum requirements of the anchor manufacturer. If there is any uncertainty as regards the strength of the concrete substrate consult a structural engineer. It is also imperative that the anchor manufacturers minimum edge distance of 90mm is strictly observed. 13. It is recommended that a nylon insulating washer be fitted between the base plate and head of the fixing bolt or nut. 14. Systems using constant force posts are designed for a maximum of 3 users. 15. Posts must be installed at intervals of between 6 and 10 metres to ensure correct performance. 16. In the event of a fall, each post will absorb approximately 6000 joules of energy. 17. To secure the end and intermediate cable support bracket use m12 x 40mm minimum grade a4/70 set screw. 18. For concrete in situ and composite concrete slab contact latchways for further advice. 19. The latchways depth guage (part number 00783-00) must be used in steps 4 & 9; this is used to measure both the hole depth and the anchor depth. It is essential that this is used to ensure the anchor is set into Approved: T.Bissett Sheet 8 of 19
the concrete at the correct depth, which is fundamental to the safety of the system. The diagram below shows the latchways depth gauge measuring the hole in the concrete. Approved: T.Bissett Sheet 9 of 19
Installation instructions for cast in situ or composite concrete roofs The following information is a guide to the installation of mechanically fixed anchors, always consult the manufactures documentation for specific instructions relating to the anchor type that you are using. Please read the installation instructions thoroughly before commencing the installation of this product. Materials and equipment required supplier Hilti hsc-ir m8 x 40 a4 stainless steel anchor fixing latchways Plastic tubing (25mm inside diameter) latchways Hilti te-c-hb 22/40 drill bit hilti (part 62190) Hilti te-cx 16/47 drill bit hilti (part-370157) Hilti te-c-hsc-mw 16 specially extended setting tool Latchways (part-65616-00) Hilti hole cleaning pump hilti (part-60579) Hilti te 15-c drill with rotary, rotary hammer & hammer functions hilti (part-308363) Latchways depth gauge latchways (part-00783-00) Latchways counter bore tool (if using recessed base plate) latchways (part-00795-00) Hack saw or angle grinder Factors to consider Concrete deck thickness Screed thickness Insulation thickness Additional protection for the membrane in the working area Approved: T.Bissett Sheet 10 of 19
1. Using the CF post as a template Mark the 4 fixing holes required. Set drill to rotary position and drill through the membrane, insulation and/or screed using the 22/40 Hilti drill bit until the concrete slab is reached. Ensure that all holes are perpendicular to the concrete surface. The four fixing holes should be counter bored if using a recessed base plate. 2. Insert plastic tubing into hole, mark the tubing at the top of the Insulation then cut to size. (Cut a further 20mm off when using a recessed base plate). Repeat this process for each fixing hole. Using the tube as a guide and the drill set to hammer position drill a minimum 50mm / maximum 55mm deep hole in the concrete surface using the te-cx 16/47 Drill bit. 3. Remove debris from in and around the fixing holes including the concrete ledge using the hole-cleaning pump (see diagram 3A/3B). This is done to clear the hole for the mechanical anchor and to ensure the Latchways depth gauge seats correctly / level with the top of the concrete surface Important: both the hole and the ledge must be clear. Approved: T.Bissett Sheet 11 of 19
4. Insert the depth gauge into the hole. Ensure the outer tube of the depth gauge is sitting firmly on top of the concrete surface. (See diagram 4) 5. Push the handle of the depth gauge downwards so that the inner part of the gauge reaches the bottom of the concrete hole. Approved: T.Bissett Sheet 12 of 19
6. The hole depth line must be level or below the top of the outer tube. If depth line is above the top of the outer tube the hole must be cleaned / redrilled accordingly. Important: to ensure that the hilti fixing is embedded correctly into the concrete the hole depth is critical. 7. Using the plastic tubing as a guide drop the anchor fixing down the hole (treaded end uppermost). Pre check anchor depth by inserting depth gauge in the hole as per step 4. Push downwards on the handle of the gauge so that the inner part reaches the top of the anchor fixing. Take an initial reading from anchor calibrated scale. 8. Using the setting tool (part 65616-00) with the drill set to hammer position drive the outer shell of the anchor firmly home Approved: T.Bissett Sheet 13 of 19
9. Check the depth of the anchor fixing by re-inserting the depth gauge (as in step 7). Ensure that the anchor has been driven down a further 5mm from the initial reading. Important This process must be repeated for all 4 fixings. 10. Position the base plate over the 4 fixing holes, thread the M8 stainless steel bolts into the anchors to hand tightness. Measure the excess bolt length from the base plate to the underside of the washer, then minus a further 7mm from this dimension. Remove bolt. Screw an M8 nut onto the thread of each bolt beyond the excess bolt dimension. Cut the excess bolt length off using a hack saw or angle grinder. Remove the nut taking away any burrs and maintaining a quality thread. Fix the base plate down using the 4 cut to length bolts, tighten until the spring washer is flat. Finally fit cover caps to the bolt heads. 11.the constant force post is now ready to be weathered in accordance with the membrane manufacturers recommendations. Approved: T.Bissett Sheet 14 of 19
Timber deck roofing systems 1. For use as an end, corner or intermediate anchor as either part of a class c system, a class a2 anchor in a class c system or as a single point anchorage. The base plate is suitable for fixing to a new build warm timber deck. Joists Timber deck construction is based on table a17 of the building regulations 1991/approved document a. Minimum joist size 150mm x 50mm grade sc3/sc16 with a maximum clear span of 3.19m Maximum joist spacing to be 600mm centres The size and spacing used will support the dead loads stated in the table and imposed loads of 0.75kn/m², or a concentrated load of 0.9kn. All joists to be fixed back to wall plate using galvanized steel joist hangers. Noggins to be fitted at the ply board side and/or end butt joints. Decking 18mm external grade ply to bs en 636 part 3 or bs 5268 part 2:2002. Sheet size 2.4 x1.2 m (8 x 4 ) or 18mm oriented strand board grade 3 to bs en 300. End and side butt joints to be fixed as per typical timber roof specification. Intermediate fixings to be fixed to suit joist spacings (400,450 or 600 centres) Approved: T.Bissett Sheet 15 of 19
Fixings (prior to vapour control layer being applied) All holes on joist hangers to be used and secured back to timber joists using 40mm long galvanized steel twisted clouts. Any decking sheet within the zoned area (see fig 2) must be fastened using 50mm no. 10 zinc plated screws set to a maximum torque value of 6nm. All end, side and intermediate fixings to be at 300mm centres maximum. Screws must not be over torqued. Torque setting of screws To ensure that the woodscrews are correctly installed it is recommended that a torque setting test be carried out prior to installation. Set the power drill to a maximum torque of 6nm. Install woodscrew into ply deck and joist. Use the rs torque driver (158-8472) to confirm the torque setting. Adjust the setting on the power drill accordingly and re-test if required. Once the correct setting has been consistantly achieved the installation of the deck may commence. It is recommended that regular torque checks be made throughout the entire installation. 2. Overall base plate dimensions = 375 x 532 mm. 3. It is recommended that the posts be installed at a distance of 1.8m or more from any edge. Approved: T.Bissett Sheet 16 of 19
4. For access purposes it is recommended that a stainless steel wire rope strop be installed from an adjacent intermediate or end anchorage post to provide an attachment point for safe access to and from the system. however it is permissible to install a post within easy reach of the access equipment, typically 0.5 to 0.75m from the edge of the roof. This post shall be used as a single point anchorage only providing safe access to and from the cable system. It shall not be used as an end or intermediate post for the fall arrest system. 5. Systems using constant force posts are designed for a maximum of 3 users. 6. Posts must be installed at intervals of between 6 and 10 metres to ensure correct performance. 7. The recommended minimum roof width is 3.6m. For a roof width less than 3.6m please contact latchways. Approved: T.Bissett Sheet 17 of 19
Tool list 25mm hole saw latchways part no. 00797-00 Drive arbor std for 25mm hole saw latchways part no. 65010-02 Arbor extension for 25mm hole saw latchways part no. 65010-03 13mm socket and driver attachment for power drill Insulation counter bore latchways part no. 00795-00 Installation instructions for timber deck roofing systems 1. Identify the positions of the roof joists. Check from underside for noggin positions to ensure that any noggins are not drilled through. 2. Place the constant force post centrally over a joist (see figure 3) and mark the hole positions through the baseplate as required. 3. Drill 4 x 25 mm dia holes through membrane, insulation and timber deck below using 25mm dia timber hole saw and arbor extension 65010-03. Using 56mm counter bore tool 00795-00 drill four holes centrally over the first set of holes to a depth of 10mm. 4. In order to ensure a secure fix, toggle bolts supplied by latchways shall be used. 5. Align toggle guide so that the arrow on top of the toggle is running in the same direction as the joists (see figure 4). Insert all four toggle guides into the four 25mm holes (maintaining toggle orientation) and press firmly into membrane. Approved: T.Bissett Sheet 18 of 19
6. Fit the four toggle bolt assemblies to the single ply constant force base plate. 7. Line all four toggles into the toggle guides, lower the single ply constant force post onto the membrane. 8. Push all four toggle bolts into the four toggle guides until each toggle makes contact with the bottom of each toggle guide, each toggle will swing into the locked position (if toggle does not swing, shaking the bolt and the toggle will then engage). 9. Tighten all four toggle bolts using a 13mm socket. Secure by tightening the toggle bolt until the neoprene washer under the head of the bolt goes flat. 10. Push the four toggle caps over the head of the four bolts until the top surface of the toggle cap is level to the surface of the base plate. 11. The constant force post is now ready to be weathered in accordance with the membrane manufacturers recommendations. Approved: T.Bissett Sheet 19 of 19