installation instructions

Transcription

1 installation instructions RoofSafe Rail for Bulb Type Standing Seam & Folded Standing Seam Roofs Installation Instruction Number: 11 Always read and follow the warnings and instructions for use Copyright Capital Safety 2011

2 Contents Page No. Contents Guidance for Installation Important Information Installation on a Bulb Type / Folded standing seam roof Section 1 - Installation of a corner Section 2 - Installation of a straight rail, perpendicular to the crowns Section 3 - Installation of a straight rail, parallel to the crowns Finishing the System These instructions are an aid to training. Only trained personnel should attempt to install a RoofSafe Rail System. 2

3 Guidance for Installation Diagrams are for reference only. Refer to system datasheets and designers guide for more information. MAX 800mm (31.50") 255 mm (10.04") Y Z MAX 566 mm (22.28") at 45 97mm (3.82") 1000 mm (39.37") Typ 3000 mm (118.11") Typical Folded & Bulb Type Standing Layout (Fall arrest) X MAX 750 mm (29.53") W 3

4 mm (4.72" 1 20 ) Guidance for Installation Diagrams for reference only. Refer to system datasheets and designers guide for more information. Typical fixing details Parallel to the seams Detail W: Intermediate/End rivet and clamp configuration Detail X: Joint/corner/position closest to the end stop rivet and clamp configuration. MAX 500 (19.69") 120 mm (4.72") Typical fixing details Detail W Detail X Perpendicular to the seams Detail Y: Typical clamp configuration Detail Z: Typical clamp configuration at a corner 120 mm (4.72") Detail Y Detail Z 4

5 Guidance for Installation Diagrams for reference only. Refer to system datasheets and designers guide for more information. For suspended access applications, Capital Safety recommend a maximum spacing of 500mm (19.69 ) between fixing positions. The clamp/rivet patterns are the same as the fall arrest layout. If the roof is flexible, reduce the spacing to increase the stiffness of the system. System flex can be reduced further by positioning the system close to (but not on) the roof fixing mechanism e.g. halter clips. MAX 500mm (19.69") 255 mm (10.04") MAX 354 mm (13.93") at 45 97mm (3.82") 1000 mm (39.37") Typ MAX 500 mm (19.69") 3000 mm (118.11") Typical Suspended Access layout 5

6 Guidance for Installation There are 3 types of clamp which can be used to install Roofsafe Rail. The matrix below illustrates where each clamp must be used. The table also illustrates what hole size is needed to be drilled for the clamp bolts and the required torque setting. Clamp type/ Roof type Folded standing seam Folded standing seam Bulb type standing seam Bulb type standing seam Parallel to the crowns Perpendicular to the crowns Parallel to the crowns Perpendicular to the crowns S-5-E Maxi Clamp Hole required - 11mm (0.43 ) Torque to - 30Nm (11.1lbf) S-5-E Mini Clamp Hole required - 9mm (0.35 ) Torque to - 15Nm (11.1lbf) S-5-Z Mini Clamp Hole required - 11mm (0.43 ) Torque to - 30Nm (22.1lbf) S-5-E Maxi Clamp S-5-E Mini Clamp S-5-Z Mini 6

7 Important Information Detailed below are examples of typical components used in RoofSafe Rail installation, on a Bulb Type/ Folded Standing Seam roof. It is advisable to read through these instructions before beginning the installation. The components listed below shows the full range available. Your order is system specific and may not feature all these components. Components Moulded Rail End M10 Tamper Proof Stop Assembly Plunger Stop Assembly Unirail Carriage Assembly RS Rail Spreader Plate RS Rail 3m Asm System ID Tag RS Rail 90 Corner Asm RS Rail 45 Corner Asm S-5-Z Mini Clamp S-5-E Maxi Clamp S-5-E Mini Clamp Bulb Tite 7.7mm Rivets Bulb Tite 7.7mm Rivets- 500 UF Butyl Tape 5m Other RS Rail Ridge / Gutter Bridge Special 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 Tool List 1 x Drill + Drill Bits 6.5mm, 8mm, 9mm, 10mm & 11mm 1 x Permanent Marker/Pencil 1 x Tape Measure 1 x 10mm Punch 1 x 8 oz hammer 1 x Soft mallet 1 x 3/16 hex driver and wrench adaptor 1 x 20 oz hammer 1 x Circular Saw 1 x Torque Wrench 1 x 13mm Socket head 1 x 17mm Socket head 1 x 6mm Hex Socket driver 1 x File/ Deburring tool 1 x RS Corner Drilling Jig 1 x PowerBird Rivet Gun Or 1 x Gesipa Manual Rivet Gun + 1 x mm Rivet Pulling Head Other 1 x Wooden Block 7

8 Typical Bulb Type Standing Seam Roof System (Fall Arrest) A Moulded Rail End ( ) M10 Tamper Proof Stop ( ) B Plunger Stop Assembly ( )* C UniRail Carriage Assembly ( ) D RoofSafe Rail Spreader Plate ( ) E RoofSafe Rail 3m Assembly ( ) F RoofSafe Rail 90 Corner Assembly ( ) G RoofSafe Rail 45 Corner Assembly ( ) H S-5-Z Mini Clamp ( ) # Bulb-Tite Dome Head 7.7mm Rivet 100 off ( ) # I Bulb-Tite Dome Head 7.7mm Rivet 500 off ( ) # *This item is different from the one illustrated # This item is detailed on the second page of this datasheet For more detailed component information refer to the individual datasheets System Specification - ISO 9001:2000 Conformity EN795 Class D 21/12/2010 Page 1 of 2 Issue No: 01 System Installation Standing Seam Roof System Section 1- Installation of a corner 01 Form 066b v2 (DCN220) Technical Datasheet No: Ensure that you have the adequate fall protection equipment. Refer to system layout, and measure system location accordingly. If the system does not contain a corner move on to sections 2 or 3. If the system contains a corner, rail ridge or gutter bridge, place the rail drilling jig at the end of adjoining rail and tighten screw. Drill a 6.5mm hole into the centre cavity De-burr the hole. Ensure that the hole is free from swarf. Repeat steps for other side of rail. Repeat steps for the other joining rail. Assemble the corner and the rail. Ensure that holes are aligned. Insert a spring pin. Using a 10mm punch and a larger hammer finish inserting spring pin. Ensure that the pin is flush with hole edge on both sides. Repeat steps for other side of the corner. To install rail perpendicular to the seams see section 2. To install rail parallel to the seams see section 3. 8

9 Typical Bulb Type Standing Seam Roof System (Fall Arrest) A Moulded Rail End ( ) M10 Tamper Proof Stop ( ) B Plunger Stop Assembly ( )* C UniRail Carriage Assembly ( ) D RoofSafe Rail Spreader Plate ( ) E RoofSafe Rail 3m Assembly ( ) F RoofSafe Rail 90 Corner Assembly ( ) G RoofSafe Rail 45 Corner Assembly ( ) H S-5-Z Mini Clamp ( ) # Bulb-Tite Dome Head 7.7mm Rivet 100 off ( ) # I Bulb-Tite Dome Head 7.7mm Rivet 500 off ( ) # *This item is different from the one illustrated # This item is detailed on the second page of this datasheet For more detailed component information refer to the individual datasheets System Specification - ISO 9001:2000 Conformity EN795 Class D 21/12/2010 Page 1 of 2 Issue No: 01 System Installation Standing Seam Roof System Section 2- Installing a straight system perpendicular to the seams. 01 Form 066b v2 (DCN220) Technical Datasheet No: Ensure that you have the adequate fall protection equipment. Refer to system layout, and measure system location accordingly. Ensure the seam is correctly formed prior to installation. Mark position and intended fixing points of rail. For max distances refer to page Using a centre punch, mark position of the hole in rail centre channel. Refer to page 4 Before drilling place a wooden block beneath the rail. Drill a hole for the clamps refer to page 6. Repeat steps for other side of the rail. Repeat step for all other fixing points. Position the clamp and slide insert into position. For S-5-E clamps move to step 11 Ensure insert is flush with clamp. Hand tighten grub screw (s) For S-5-E clamps ensure that the clamp is positioned the correct way around. Repeat steps for all clamps. Place the rail into position and insert bolts. Repeat step 13 for all other bolts and check the position of rail and clamps. Torque all the bolts to the required torque. Refer to page 6. Torque the grub (s) screws to 15Nm (11.1lbf) using a calibrated torque wrench with a 3/16 hex driver. 9

10 Typical Bulb Type Standing Seam Roof System (Fall Arrest) A Moulded Rail End ( ) M10 Tamper Proof Stop ( ) B Plunger Stop Assembly ( )* C UniRail Carriage Assembly ( ) D RoofSafe Rail Spreader Plate ( ) E RoofSafe Rail 3m Assembly ( ) F RoofSafe Rail 90 Corner Assembly ( ) G RoofSafe Rail 45 Corner Assembly ( ) H S-5-Z Mini Clamp ( ) # Bulb-Tite Dome Head 7.7mm Rivet 100 off ( ) # I Bulb-Tite Dome Head 7.7mm Rivet 500 off ( ) # *This item is different from the one illustrated # This item is detailed on the second page of this datasheet For more detailed component information refer to the individual datasheets System Specification - ISO 9001:2000 Conformity EN795 Class D 21/12/2010 Page 1 of 2 Issue No: 01 System Installation Standing Seam Roof System Section 3- Installing a straight system, parallel to the crowns Note 01 Note 02 Note End / corner configuration spreader plate and RoofSafe edge are flush. Refer to page 4 Join configuration. The rail join is centred on the spreader plate. Refer to page 4 Intermediate spreader plate configuration. Less rivets required. Refer to page 4. Ensure that you have the adequate fall protection equipment. Form 066b v2 (DCN220) Technical Datasheet No: Refer to system layout, and measure system location accordingly. Ensure the seam is correctly formed prior to installation. Cut spreader plates to size. Cut enough so that it is flush with all clamp edges. Mark position of rail and intended fixing points. For max distances refer to page 3. If the rail has to be joined, the last spreader plate should be positioned so that the rail edge is aligned with the spreader plate centre line. Using a centre punch mark position of hole in the spreader plate centre channel. Drill a hole for the clamps, refer to page 6. Repeat step for the other corners of the spreader plate. Repeat steps for other spreader plates. Position the clamp and slide insert into position. For S-5-E clamps move to step 13 Ensure insert is flush with clamp. Hand tighten grub screw (s) For S-5-E clamps ensure that the clamp is positioned the correct way around. 10

11 System Installation Standing Seam Roof System Section 3- Installing a straight system parallel to the crowns Repeat steps for other clamps. Place spreader plate in position and insert bolts. Torque all the bolts to the required torque. Refer to page 6. Repeat steps for all other bolts. Repeat steps to secure all other spreader plates Torque the grub screws to 15Nm (11.1lbf) using a calibrated torque wrench with a 3/16 hex driver. Before drilling place a wooden block beneath the spreader plate to protect the roof sheet. Drill an 8mm hole to align with the centre rail channel and spreader plate centre channel. Secure with a 7.7mm (0.303 ) bulb tite rivet. Drill and rivet the opposite end of the rail to the spreader plate as in steps Drill and rivet all other fixing points. maintaining the correct pattern. Refer to page 4. Repeat steps to secure rail. Continue to fit spreader plates as applicable. See steps Insert Aluminium spigot into rail end and tap in place with rubber mallet. Join rails together Repeat steps to secure 2nd rail. 11

12 Installation Date / Installatiedatum / Fecha de instalación / Montagedatum / Date d'installation / Data da instalação / Data installazione / Installationsdatum Installed By / Geïnstalleerd door / Instalado Por / Montiert durch / Installateur / Instalado por / Installato da / Installerad av Contact Number / Contactnr. / Tel. de contacto / Kontakttelefon / Téléphone / Nº de Contacto / Numero contatto / Kontaktnummer Min Ground Clearance (m) / Min. vrije valruimte (m) / Distancia minima hasta el suelo (m) / Mindestabstand zum Boden (m) / Hauteur libre minimale (m) / Altura mínima livre (mt) / Distanza libera minima da terra (m) / Min. höjd ovanför marken Max Users Per Span / Max. aantal gebruikers per overspanning / Máximo de usuarios por vano / Höchstzahl der Benutzer pro Spannweite / Nombre maximal d utilisateurs par portée / Nº máximo de utilizadores por vão / N. utenti max. per sezione / Max. användare per skena Max Users Per System / Max. aantal gebruikers per systeem / Máximo de usuarios por sistema / Maximale Benutzer pro System / Nombre maximal d utilisateurs par système / Nº máximo de utilizadores por linha / N. utenti max. per sistema / Max. användare per system Next Service Date / Datum volgende keuring / Próxima fecha de revisión / Termin der nächsten Wartung / Prochaine date d entretien / Data da próxima Inspecção / Data prossima manutenzione / Nästa servicedatum EN795:1996 Class D OSHA COMPLIANT System Serial No / Serienummer / Número de serie del sistema / Seriennummer des Systems / AS/NZS & Numéro de série / Nº de série do sistema / N. di serie sistema / Systemets serienr. Use Energy Absorbing Lanyards / Gebruik energie-absorberende verbindingslijnen / Utilice acolladores de absorción de energía / Verwenden Sie falldämpfende Sicherheits-/Anschlagseile / Utilisez des longes à absorption d énergie / Usar cordas com amortecedor de energia / Utilizzare funi ad assorbimento d energia / Använd energiupptagande taljerep Finishing the System Mark 1m (39 ) from the end of system and drill a 10mm hole to the to centre cavity, then deburr hole. Slide the carriage onto the rail. Slide the tamper proof stop onto rail and align with the 10mm hole. Torque to 15Nm (11.1lbf). For system with a plunger stop, pull head of stop upwards and slide stop onto rail When over the hole release the head. Ensure that the stop has engaged by giving it a sharp tug. 06 Remove any excess butyl tape. Sweep away any swarf and dust. 07 Using a rubber mallet, gently tap the moulded rail end into the end of the rail. 08 rail rail Install system tag and ensure that it has been filled in. 12

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