Installation Instructions ROOFSAFE ANCHOR & CABLE THE ULTIMATE IN FALL PROTECTION MANUAL
Contents Guidelines for Installation 3 Top Bolt 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 anchor system. 2
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 1.25" (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 0.51" (13mm) Socket for use with the Torque Wrench Socket to Drill Adaptor Alcohol Solution/Wipes RA 0.23" (6mm) Hex Drive Bit (96004)** RA Removal Spanner (960)** Standing Seam Anchor 0.74" (19mm) Socket for use with the torque wrench 3/16" (4.7mm) hex driver Trapezoidal Anchor 0.32" (8.2mm) HSS Drill Bit Toggle Bolt Powerbird Industrial Rivet Gun (72411)** Powerbird Jaws (72411)** Powerbird Nose Piece (72411)** RA Baseplate Drilling Jig (960)** Concrete Anchor 0.47" (12mm) HSS Drill Bit The drill bit must be long enough to penetrate the roof construction and concrete 0.55" (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 (7241112)** Eyebolt Testing Kit (7241125)** Plywood board 0.70" x 19.6" x 19.6" (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 7241136 - RA Baseplate 4 x 4 H 7241137 - RA Baseplate 4 x 4 BL 7241138 - RA Baseplate 350 x 440 H 7241139 - RA Baseplate 350 x 440 BL 7241140 - RA Baseplate 550 x 450 BL 7241149 - RA Module End / Corner Standing Seam 7241150 - RA Module Intermediate Standing Seam 7241151 - RA Module End / Corner Bitumen 7241152 - RA Module Intermediate Bitumen 7241154 - RA Module End / Corner PVC 7241154 - RA Module Intermediate PVC 7241155 - RA Module End / Corner All Membrane 7241156 - RA Module Intermediate All Membrane 7241161 - RA System Eye and Pin 7241162 - RA 90º Corner 7241163 - RA 45º Corner 7241164 - RA Variable Corner 7241165 - RA Intermediate Bracket 7241166 - RA Throw Plate Kit 7241167 - RA Single Point Eye Americas 72412 - RS Maxi Clamp Z x 4 72412 - RS Mini Clamp Z x 4 72412 - RS Maxi Clamp E x 4 72412 - RS Mini Clamp E x 4 72412 - RS Maxi Clamp U x 4 7241209 - RS Mini Clamp U x 4 7241180 - Concrete Anchors 5.9" (150mm) x 4 7241181 - Concrete Anchors 11.8" (300mm) x 4 7241182 - RA Toggle Fixing 5.90" (150mm) x 4 7241183 - RA Toggle Fixing 11.8" (300mm) x 4 72466 - Uni 8 0.31" (8mm) Hex Swage Tensioner 0.8kN 72411-0.31" (8mm) 7 x 7 Stainless Steel Cable 72341 - Uni 8 0.31" (8mm) Hex Swage Toggle 3
Top Bolt 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 22.12 ft lb (30Nm). Torque set screws to 11. ft lb (15Nm). Fit the top module into the baseplate and torque to 29.50 ft lb (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 0.32" (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 29.50 ft lb (40Nm). Anchor installation is complete and ready for the system components to be secured. 4
Toggle Installation Mark out the bolt positions of the anchor on the roof membrane. Be sure toggles will bolt into the crowns on metal deck. While the baseplate is in position, mark positions through the toggle inserts. Using a 1.125" (29mm) 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. 09 10 11 12 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. While holding the toggle insert, use a hand drill (18v recommended) and 13mm hex driver to drive the toggle into place. 13 14 15 16 This will lock the toggle as shown. Using a torque wrench, torque the toggles to 11. ft lb (15Nm). Fit the RoofSafe Anchor module into the baseplate and torque to 29.50 ft lb (40Nm). The anchor is now installed and ready for the application of waterproofing detail and system components. 5
Concrete Installation Mark out the bolt positions of the anchor on the roof membrane. Using the 1.14" (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 0.47" (12mm) drill bit, drill a hole in the concrete 1.96" - 2.16" (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 0.55" (14mm) masonry drill bit, until you reach the concrete. Then revert to the 0.47" (12mm) drill bit. 09 10 11 12 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). 6
Concrete Installation 13 14 15 16 Insert into the hole in the concrete. Place the setting tool (7241112) over the threaded rod and on to the shoulder of the bolt. The setting tool should be resting on top of the fixing socket. Hit with a hammer to set the bolt 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. 17 18 19 20 Slide the toggle foam spacer over the threaded rod. Test each bolt to a load of 1,124 lbs (5kN) using pull tester. See pull test instructions for more details. Place the baseplate in position. Place the toggle inserts over the threaded rods. 21 22 23 24 Add the nut and tighten to 11. ft lb (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 29.50 ft lb (40Nm). The anchor installation is now complete and ready for waterproofing detail and system component. 7
Component Installation 90 /45 Corner Remove M12 nut and washer. Intermediate Bracket Position the corner component and align. Refasten nut and washer. Torque to 22.12 ft lb (30Nm) and replace nut cap. Remove M12 nut and washer. Position the Intermediate component and align. Refasten nut and washer. Torque to 22.12 ft lb (30Nm) and replace nut cap. Variable Corner Remove M12 nut and washer. RoofSafe System Eye & Pin Position the Variable component and align. Refasten nut and washer. Torque to 22.12 ft lb (30Nm) and replace nut cap. Remove M12 nut and washer. Position the System Eye component and align. Refasten nut and washer. Torque to 22.12 ft lb (30Nm) and replace nut cap. Single Point Eye - EMEA Remove M12 nut and washer. Position the Single Point Eye component and align. Refasten nut and washer. Torque to 22.12 ft lb (30Nm) and replace nut cap. 8
Baseplate Drilling Clean the surface 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 roof sheet using an 0.32" (8.2mm)s drill bit. Rivet down the first hole to the roof. 09 10 11 12 Drill and rivet the opposite corner. Drill and rivet through the remaining holes. Fit the top module into the baseplate and torque to 29.50 ft lb (40Nm). The anchor is now installed and ready for the top component. 9
Hex Swaging Only 0.31" (8mm) 7 x 7 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 7241122 0.39" (10mm) bite dies. For any other hex swaging system/machine the installer needs to verify that the minimum strength of the hex swage is 8,543 lbs (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 (3" (78mm) 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 3" (78mm). Using the hex swager, make the first bite immediately after the solid section (A) (see below). Each bite is approximately 0.39" (10mm) wide. Following the table dimensions below, ensure the 6th bite finishes short of the chamfer section (B) (see below). Using a caliper, check the swage bite dimensions against the specified tolerance on the part. Cable Hex Swaging Table Swage Dies Swage Bites Bite Gap Dimension Across Flats 7 x 7 cable 7241122 6 discontinuous 0." - 0." (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) 3.14" (80mm) Dimension across flats Bite Gap 10
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