Fabrications, Safety & Lighting solutions UK & Ireland Kingspan SafePro 2 Installers Guide Always read and follow the warings and instructions for use.
2 Kingspan SafePro 2 Installers Guide 1.0 Contents 1.0 Contents 2 2.0 General 3 2.1 Authorised Installers 3 2.2 Conformity 3 2.3 Work Restraint & Fall Arrest 3 2.4 Free Fall Space Calculator 5 3.0 Site Assessment 6 3.1 Reviewing the Task 6 3.2 Typical System Layout 7 3.3 Specifying Your Anchor 9 3.4 Roof Types & Anchors 11 3.4.1 KS1000 RW 11 3.4.2 KS500 & KS 1000 Zip 11 3.5 Sealing Details 13 3.6 Aggressive & Hazardous Environments 14 3.7 Rescue Planning 14 4.0 Roof Anchor Performance 15 4.1 Anchorage Strength 15 4.2 Forces on the End/Corner 15 4.3 Forces on a Intermediate 17 4.4 Thermal Bridging 18 5.0 Annual Maintenance 20 5.1 Testing the Roof Anchor 20 5.2 Testing the Swages 20 5.3 Cleaning the Anchor 20 6.0 Reference Documents 21 6.1 Abbreviations and Definitions 21 6.2 Standards Table 22 6.3 Markings Explained 23 7.0 Installation Instructions 24 7.1 Guidelines For Installation 24 7.2 Top Fix Installation 26 7.3 Toggle Installation 27 7.4 Component Installation 28 7.5 Baseplate Drilling 29 7.6 Hex Swaging 30
Installers Guide Kingspan SafePro 2 3 2.0 General 2.1 Authorised Installers Only competent installers certified by Kingspan are allowed to install and service the SafePro 2. 2.2 Conformity The SafePro 2 is a roof top anchorage system which is tested and where appropriate certified in accordance with the requirements of various national and international standards and codes of practice. Details can be found in standards table, Section 6.2. Components or parts are not to be altered, modified, dismantled or be replaced with items not supplied or manufactured by Kingspan, such action will invalidate any certification and could result in serious or fatal consequences. Parts or components not supplied by Kingspan may be of inferior specification and may cause incorrect operation of the system. 2.3 Work Restraint & Fall Arrest The SafePro 2 is a fall protection anchorage system. All anchorage systems must be designed for all arrest, although it is best to restrain the user to prevent a fall occuring, when possible. Work Restraint The advantages with work-restraint are that: Workers do not have to be subjected to the abrupt impact of an arrest as would be the case in a fall-arrest system, or risk falling into a hazard e.g. water or a hazardous substance The user can not be injured from swing-fall incidents There is no need for any rescue provision Personnel require less training.
4 Kingspan SafePro 2 Installers Guide 2.0 General In a work restraint system, to prevent the worker from entering an area where they could fall, there are two dimensions which need to be strictly controlled: The lanyard length A (Fig 1) The distance from the Anchor to the fall hazard B (Fig 1). A scale drawing should be made to ensure that the lanyard (including connectors) will always prevent the user from entering a fall arrest situation. If the position of the fall hazard relative to the Anchor varies this analysis should be performed at various points along the length of the system. A B A B Work Restraint Orientation (Fig 1) Fall Arrest Orientation (Fig 2) Fall Arrest Where a work restraint system cannot be employed, a fall-arrest system has to be used. The disadvantage is that a worker has to fall before the system can operate (Fig 2) and arrest the fall. This is achieved by applying a braking force to the worker for a few hundredths of a second. The SafePro 2 ensure that the braking force is always kept below a safe load, providing that the worker is wearing a full body harness and an energy-absorbing lanyard certified to the appropriate national standard. When designing the roof safety system, be aware of falls through fragile elements as well as falls from exposed edges. In a fall arrest situation appropriate rescue procedures must be in place to return the worker to safety as soon as possible. Refer to the Rescue planning section of this guide (Section 3.7). Important Note Whilst all horizontal lifeline systems must be designed for Fall Arrest in case of accidental misuse, it is recommended that system should be designed for Work Restraint. This design enables a user to access their work area whilst being prevented from being exposed to a fall hazard. This design will reduce risk and mitigate the consequences of a fall.
Installers Guide Kingspan SafePro 2 5 2.0 General 2.4 Free Fall Space Calculator Kingspan provides a calculation tool which helps the designer to assess the recommended free space required below the system to ensure that the system is safe to use. The calculation tool and information on how to use it is available from Kingspan separately from this guide. Below is a picture of the calculation sheet (Fig 3). Free Fall Space Calculator SafePro RoofSafe 2 Anchors SafePro RoofSafe 2 Cable Using the input boxes below, change the the values to to suit suit the the length length of your of your RoofSafe SafePro Anchor 2 Anchor and Cable and Cable system. system. Note: Calculations are based on on maximum span span widths widths (15(12 m) m) with with the the fall fall occuring occuring the in the midspan midspan of the of system. the system. Project Name Date Inputs Title Character Units Values Description Lanyard Length L m Total length of lanyard Edge Distance E m Distance from the edge of the roof to the system Number of Users U # Total number of users per span D-ring Height D m Height from roof surface to the user connection point System Length S m Total length of system (or section of system) Outputs Title Character Units Value Fall potential FP m Fall factor (fall potential / lanyard length) FF m Minimum distance required below platform level MD m Maximum end loads ML kn Issue No: 01 Issue Date: 05/03/2012 (Fig 3)
6 Kingspan SafePro 2 Installers Guide 3.0 Site Assessment 3.1 Reviewing the Task Only installers certified by Kingspan are allowed to install and service the SafePro 2 s. Site Survey At the start of each job a site survey should be carried out to assess the type and location of the system required. Accurate measurements should be taken to make sure that the system will fit the required area correctly. During a site survey the following information should be gathered: The purpose of the system / Task to be performed The maximum No. of people that will be using the system at any one time The specification and manufacturer of the roof to which the system will be fitted, including critical dimensions such as seam/crown centres and insulation thickness Scale drawings of the structure or building (in digital format if available) The exact path of the system Any special requirements from the architect or the customer such as; a specific type of bracket, or particular considerations for historical buildings The risks to the installers so that suitable risk controls during installation can be planned. When seeking technical support on a specific job, the Kingspan sales team will be able to help you more quickly if you have the above information available as a minimum. Method Statements Before work begins a method statement should be written by the installer, agreed with the client and signed by both the parties. This is a detailed step by step guide of how the work is to be carried out by the installer. The method statement protects both the client and the installer in the event of the work not being carried out in a safe manner, and can be used to ensure that the workers are adhering to safe and suitable working practices while carrying out the work. Verifying The Roof Structure The strength of the roof structure should be verified before the system is fitted to ensure that the fixings are strong enough to hold the anchor onto the roof. This can be done by calculation or through roofing approvals. Contact Kingspan for any specific roof testing that may be relevant to the roof profile. Where these methods can not be used to verify the strength of the structure and the fixings, a sample fixing should be installed, and pull tested. The fixings should withstand as a minimum the forces given in the SafePro 2 Anchor and Cable and Cable Forces Calculation Sheet.
Installers Guide Kingspan SafePro 2 7 3.0 Site Assessment B E E B C A D Max 15m m A E A E Key A - End/Corner Anchor as System end post B - End/Corner Anchor as Corner post C - Intermediate Anchor as Intermediate post D - End/Corner Anchor as Systemt-joint, with RA throw plate E - End/Corner Anchor as Variable post for roof hips Direction of Fall Hazard
8 Kingspan SafePro 2 Installers Guide 3.0 Site Assessment Gaining Access To The Anchor The entry point is defined as the point where the user can attach to the system. The exit point is defined as the point where the user can detach from the system. The entry point and the exit point can be at the same position. It is important to remember that the user is not fully protected from a fall until the safety lanyard and harness are attached and secured to the attachment eye or slider, via a carabiner. Consideration should always be given to the positioning of the Anchor in regards to the above. The entry point should always be in a safe area, i.e. free from fall hazards. Where this cannot be achieved, a secondary means of fall protection needs to be installed to give protection whilst bridging the gap between the access route and the Anchor. The same consideration needs to be made in respect to the exit point, should it be in a different position to the entry point. Swing Falls Swing falls can be fatal when working near a gable end. Fig 8 shows a worker using a rope and grab at maximum extension near a gable end. In this case the flank length exceeds the ridge height so if the user falls they have inadequate clearance to ground level. Another risk is the slicing effect of the edge of the roof on the rope or lanyard as the user falls. This situation must be avoided. Installation of edge protection to the end elevation and Installing the Anchor inboard of the roof eaves can help to alleviate this issue. (Fig 8) A Key A - Inaccessible zone B Key A - Swing fall zone B - Zone for potential swing fall B - Accessible area with anti swing fall posts E D C A B C - User D - Lanyard E - SafePro 2 Anchor and Cable System (Fig 9.1) (Fig 9.2) E D B F C A C - User D - Lanyard E - SafePro 2 Anchor and Cable System F - Single point anchor as anti swing fall post Fig 9.1 shows the potential swing fall and the inaccessible areas. Fig 9.2 shows how the swing fall potential can be limited when using a manually adjustable lanyard and an single point anchor as an anti swing fall post.
Installers Guide Kingspan SafePro 2 9 3.0 Site Assessment 3M DBI-SALA RoofSafe 3.0 Site Assessment 3.3 Specifying Your Anchor 3.3 Specifying Your Anchor The SafePro 2 Anchor and Cable provides a secure anchor point for a worker at height, close to an exposed edge or other fall The RoofSafe Anchor and Cable provides a secure anchor point for a worker at height, close to an exposed edge or other hazards, when used in conjunction with associated PPE, such as fall hazards, when used in conjunction with associated PPE, such as a full body harness and a energy absorbing lanyard. a full body harness and a energy absorbing lanyard. The The RoofSafe SafePro Anchor 2 Anchor and and Cable Cable is is designed to to re-orientate and deploy an energy absorber in the event of a fall, thereby reducing the load and transferred deploy to energy the user absorber and the in the roofing event system. of a fall, The thereby Anchor can be used for both fall arrest and work restraint applications. reducing the load transferred to the user and the roofing system. There are two types of Anchors within the range. The SpiraTech Anchor and the Tip Over Anchor. Both anchors are modular in design The Anchor can be used for both fall arrest and work restraint allowing for speed of fitting and use. applications. Both There Anchors are two allow types the of user Anchors to walk within 360 the degrees range. around The SpiraTech the anchor without needing to reorientate the lanyard or connectors. The Anchor Anchor and allows the Tip full Over weather Anchor. sealing Both to anchors prevent are water modular ingress, and allows different roof membranes to be fitted and sealed around design the allowing anchor for speed weather of fitting proofing. and use. The Both modular Anchors design allow allows the user the to designer walk 360 to degrees chose and around purchase the the baseplate, module and top attachment separately. This anchor gives without flexibility needing for application to reorientate to any the roof lanyard type or or membrane. connectors. The Anchor allows full weather sealing to prevent water ingress, and allows different roof membranes to be fitted and sealed around the anchor for weather proofing. The modular design allows the designer to chose and purchase the baseplate, module and top attachment separately. This gives flexibility for application to any roof type or membrane. (Fig 10.1) Base Plate (Fig 10.1) Base Plate (Fig 10.2) SpiraTech Anchor or Tip Over Anchor (Fig 10.2) End/Corner Anchor or Intermediate Anchor (Fig 10.3) Attachment Eye (Fig 10.3) Attachment Eye (Fig 11.1) Assembled End/Corner Anchor Can be used as a single point anchor for up to two (Fig users. 11.1) Assembled SpiraTech Anchor Can Can be be used used as as a single a single point point anchor for for up up to two to two users. users. (Fig 11.2) Assembled Intermediate Anchor Can be used as a single point anchor for one user. (Fig 11.2) Assembled Tip Over Anchor Can Can be be used used as as a single a single point point anchor for for one one user. user. Ref: 5903918 REV B 9
10 Kingspan SafePro 2 Installers Guide 3.0 Site Assessment The base plate designs incorporate several fixing holes to allow the same plate to be fitted on dissimilar roof types. The base plates also accommodate common roof pitch centres, allowing the baseplates to be used in two orientations. (Fig 12.1) RA Baseplate 405mm x 405mm. Baseplate 405 KS1000 RW KS1000 LP KS1000 Zip KS1000 TD (Fig 12.2) RA Baseplate 350mm x 440mm. (Fig 12.3) RA Baseplate 550mm x 450mm. Baseplate 550 KS1000 Zip Pitches For Toggle Fixing The RA Baseplate 405 x 405 H (Baseplate405) incorporates hole centres for the toggle fixings. The holes are set at 333. To suit KS1000 TD
Installers Guide Kingspan SafePro 2 11 3.0 Site Assessment 3.4.1 KS1000 RW Pre-insulated / built up metal roof panels. Fixings: SafePro 2 7.7 Rvt 7. 7x28 (Fig 13.1) 3.4.2 KS500/1000 Zip Standing seam roof, Aluminium Steel or Stainless Steel. Posts can be fitted to a range of seam profiles and roof sheet materials, see details on page 13. (Fig 13.2)
12 Kingspan SafePro 2 Installers Guide 3.0 Site Assessment Standing Seam Roofing Systems When Specifying a SafePro 2 Anchor and Cable for a standing seam consideration should first be given to the Standing Seam profile and the type of clamps that will be required to secure the anchors to the roof. Kingspan provides a range of fixing clamps to fit to varying roof seam profiles. Details on individual clamp compatibility can be provided by Technical Services. KS500/1000 Zip Standing Seam SafePro 2 S5Z/Clampmini (Fig 14) The baseplate selection will be based on the roofing centres, see the page 10 for more detail. Important Note: It is recommended to avoid fitting clamps directly over halter clips as this will affect the performance of the clamp and the roof. Always refer to the roofing manufacturer for guidance.
Installers Guide Kingspan SafePro 2 13 3.0 Site Assessment 3.5 Sealing Details B A B A D PVC Membrane A - PVC bonded onto the weather shround up to the ridge B - RA weather shroud PVC C - Baseplate D - Toggle fixing sealed in under the membrane RA Module PVC End/Corner Intermediate C C D E Other Membranes A - Membrane sealed over the baseplate and up to the top of the can B - RA Weather Cap C - Baseplate D - Toggle fixing sealed in under the membrane E - RA Seal Ring RA Module All Mem End/Corner Intermediate B D C A Rivet Fix And Standing Seam A - RA Seal Ring B - RA Can C - Baseplate D - Fixings with Seals or Clamps which do not penetrate the roof RA Module Top Fix End/Corner Intermediater Information in this section is given as a guide only, always refer to the roofing manufacturers information for their specifications.
14 Kingspan SafePro 2 Installers Guide 3.0 Site Assessment 3.6 Aggressive and Hazardous Environments Corrosive Environments The SafePro 2 Anchor and Cable has been tested in saline environments that exceed those specified in all National Standards. All components that are continuously exposed to the atmospheric conditions are made from Aluminium or Stainless Steel. Aluminium components are anodized to AA11 (11 microns thick) as a minimum and 316 stainless steel components are polished to remove any surface impurities. The SpiraTech coil and associated steel components are coated in a Zinc inorganic coating which has a minimum saline performance of 1000 Hrs. In an aggressive or saline environment a SafePro 2 Anchor and Cable System will require more frequent inspections and servicing to assure corrosion damage is not affecting the performance of the product. A appropriate inspection plan should be implemented based on the environmental conditions and agreed with the customer. 3.7 Rescue Planning Employers have a responsibility to make specific provisions for emergency planning. Work should be appropriately planned and previsions should be made for emergency situations. The need for rapid and appropriate response following a fall should not be ignored. In any situation where a fall could occur it is essential that appropriate rescue equipment is available for rapid deployment by trained personnel. Failure to have correctly trained personnel and equipment in place to respond to a fall scenario may result in serious injury or death. Kingspan has a range of rescue equipment appropriate for different scenarios and can advise on specification and use. Chemical Hazards Solutions containing acids, alkali, or other caustic chemicals, especially at elevated temperatures may cause damage to this equipment. Consult Kingspan if doubts exists concerning installing this equipment where chemical hazards are present. Electrical Hazards Do not install the SafePro 2 Anchor and Cable where either the anchor, cable or user can come into contact with electrical power lines. Always allow a safe working distance between the user and power lines. If you are uncertain about a particular application please contact your local energy infrastructure provider or health and safety advisory service for information on safe working practices.
BI-SALA RoofSafe of Anchor Performance horage Strength 4.0 3M DBI-SALA Roof Anchor RoofSafe Anchor Performance and Cable System 4.0 Roof Anchor Performance Installers Guide Kingspan SafePro 2 s been designed to withstand the loads generated when a person falls from height while attached to the anchor. oof Anchors are designed with internal supports which enable the post to maintain correct system tension as well annual testing 4.1 of the Anchorage strength of Strength the fixings (section 5.1). The internal supports break away at less than 3kN allowing sorbing element The to range take of the Roof full Anchors force of are the designed fall. with internal supports which enable the post to maintain correct system tension as well as allowing for annual testing of the strength of the fixings (section 5.1). The internal supports break away at less than 3kN allowing the or has been deployed energy absorbing the energy element absorbing to take elements the full force reduce of the the fall. load on the user and the roof to safe levels, so that remains safely Once attached the anchor to the has roof been structure, deployed and the the energy user absorbing is brought elements comfortably reduce to the a load post on fall the resting user and position. the roof to safe levels, so that Anchor and Cable the anchorage can then withstand remains safely a minimum attached static to the load roof of structure, twice the and peak the user arrest is brought load for comfortably 3 mins as required to a post fall resting position. The SafePro 2 Anchor and Cable can then withstand a minimum static load of twice the peak arrest load for 3 mins as required by EN795. es on the SpiraTech Anchor 15 4.2 Forces on the End/Corner Anchor SCALE HIGH STRESS LOW STRESS SCALE HIGH STRESS LOW STRESS (Fig 15.1) (Fig 15.2) (Fig 15.2) a horizontal load (Fig applied 15.1) to the anchor connector. The highest stress areas can be seen (Fig around 15.2) the narrowest section re it is designed is designed to break. to break. Fig 15.2 shows a horizontal load applied to the anchor connector. The highest stress areas can be seen around the narrowest section of the pin where it SCALE HIGH STRESS LOW STRESS SCALE HIGH STRESS LOW STRESS (Fig 16) Fig 16 shows the coil deployed, it can be seen that the stress is taken up by the middle section of the coil. (The rest of the assembly is not shown for clarity). he coil deployed, (Fig it can 16) be seen that the stress is taken up by the middle section of the coil. (The rest of the assembly or clarity). REV B 16
16 Kingspan SafePro 2 Installers Guide 4.0 Roof Anchor Performance The End/Corner Force management technology, absorbs much of the impact energy returning a low peak load as shown in the traces below Fig 17a / 17b. EN 795 - Dynamic 100 kg, 2.5 m EN 795 - Dynamic 100 kg, 2.5 m Peak 5.2 kn (Fig 17a) Equivalent of a single user fall on a End/Corner Anchor. Peak 6.1 kn (Fig 17b) Equivalent of a two user fall on a End/Corner Anchor. In a system the load is transmitted to the ends and the corners. Therefore ends and corners should be secured by means of a End/ Corner anchor rather than a Tip Over anchor. Tip Over anchors can be used as intermediate posts as they see less load. A system consisting of 2 End/Corner anchors (Fig 18) will return a peak load of approximately 4.6 kn (Fig 19). (Fig 18) Force (kn) Drop On Deployed System System (Fig 19) Time (secs) However if a second user was to fall on the system after the anchor had already been deployed the peak load would increase to approximately 5.7 kn (Fig 19). Equivalent of a single user fall on a SafePro 2 End/Corner posts.
Installers Guide Kingspan SafePro 2 17 4.0 Roof Anchor Performance 4.3 Forces Intermediate Anchor (Fig 20.1) (Fig 20.2) Fig 20.2 shows a horizontal load applied to the anchor connector. The highest stress areas can be seen around the top and bottom of the support strap where it is designed to break. (Fig 21) Fig 21 Shows the deformation of the wire form under a horizontal load, It can be seen that wire orientates the load and absorbs energy from the fall. (Fig 22) The Single Point Anchor absorbs much of the impact energy returning a peak load of approximately 7.1 kn as shown on the trace in Fig 22.
18 Kingspan SafePro 2 Installers Guide 4.0 Roof Anchor Performance 4.4 Thermal Bridging Loss of heat from a building is a concern on insulated built up roof types where the toggle fixings penetrate through the roof (Fig 23.1). This can create a thermal bridge through the central bolt. The SafePro 2 Anchor and Cable toggles minimise the affect by insulating the area around the toggle bolt (Fig 23.2). In common toggle fixings the area around the bolt is open allowing convection around the bolt as well as conduction through the bolt. Transfer of of heat Transfer of of heat (Fig 23.1) Uninsulated Toggle Fixing (Fig 23.2) Insulated Toggle Fixing Toggle Top Support tube Foam Insulation Bolt Toggle Pressing (Fig 24) SafePro 2 Anchor Toggle Fixing
Installers Guide Kingspan SafePro 2 19 4.0 Roof Anchor Performance Testing has been carried out to show the heat transfer through the toggle fixings (Fig 25/26). Uninsulated fixings show a temperature increase of 7 C (44.6 F) at the fixing which is also transferred to baseplate (Red areas Fig 25). The Insulated SafePro 2 Anchor and Cable toggle fixings show a temperature increase of just 4 C (39.2 F), isolated to the top of the fixings. (Fig 25) The temperature range on a post with typical uninsulated toggle fixings 7 C (44.6 F) increase and heating of baseplate. (Fig 26) The temperature range on a SafePro 2 Anchor post with insulated toggle fixings. 4 C (39.2 F) localised increase and limited heating of the baseplate. (Fig 27) The temperature range on a solid post fixed directly to the structure through the insulation. 15 C (59 F) increase in temperature around the post. Test conditions: All tests were brought up to temperature and then allowed to equalise with the surrounding environment to ensure comparable test readings. Temperature below the insulation 60 C (140 F), Air Temperature around the post 20 C (68 F).
20 Kingspan SafePro 2 Installers Guide 5.0 Annual Maintenance 5.1 Testing the Roof Anchor Anchors can be vertically pull tested up to 5kN. Pulling the anchor can be used as a way of testing the integrity of the fixings, where the post has been sealed in and they are not accessible. Components such as end or intermediate brackets and connection eyes should be removed before the test, and the load should be applied to the top thread. 5.2 Testing the Swages Swages as part of cable system should always be inspected to ensure that the cable is attached securely. Kingspan provide guidance on the swaging method and inspection of swages. Please refer to section 7.7. Electrical Hazards Do not install the SafePro 2 Anchor and Cable where either the anchor, cable or user can come into contact with electrical power lines. Always allow a safe working distance between the user and power lines. If you are uncertain about a particular application please contact your local energy infrastructure provider or health and safety advisory service for information on safe working practices. 5.3 Cleaning The Anchor All of the exposed materials in the anchor have been specified as naturally corrosion resistant, or have been coated with sacrificial coatings to prevent oxidisation of the base material. It is important to consider that in some environments the anchors may need to be cleaned to gain the best possible life expectancy from the materials. Poorly maintained SafePro 2 s can become unusable or become unsafe and in extreme cases may have to be replaced. Details on best practice for the maintaining the system can be found in the User Instruction Manual.
Installers Guide Kingspan SafePro 2 21 6.0 Reference Documents 6.1 Abbreviations and Definitions The following is a list of terms and their meanings as used in this publication (Further standards are listed in section 7.2 of this guide): BS EN 795 The European Standard for protection against falls from a height concerning anchor device requirements and testing BS EN 354 The European Standard for protection against falls from a height concerning lanyards BS EN 355 The European Standard for protection against falls from a height concerning energy absorbers BS EN 361 The European Standard for protection against falls from a height concerning full body harnesses BS EN 362 The European Standard for protection against falls from a height concerning connectors BS EN 363 The European Standard for protection against falls from a height concerning fall arrest systems BS EN 365 The European Standard for protection against falls from a height concerning instructions for use and markings BS 7883 Code of Practice for the application and use of anchor devices conforming to BS EN 795 89/686/EEC EC Directive relating to Personal Protective Equipment design and test SI 3139 Statutory Instrument 3139 The Personal Protective Equipment (EC Directive) Regulations 1992 - the transposition of 89/686/ EEC into UK National Law ACR[M]002:2009 - (Part2) Testing of Roof Anchors on Roof Systems.
22 Kingspan SafePro 2 Installers Guide 6.0 Reference Documents 6.2 Standards Table European Standards Standards Description Synopsis Test Data Available * / Documents EN 795:2012 Personal Fall Protection equipment - Anchor devices. Type A: comprises of anchor device with one or more stationary anchor points, while in use, and with the need for a structural anchor(s) or fixing element(s) to fix to the structure. Type C: Comprises anchor devices employing a flexible anchor line which deviates from the horizontal by not more than 15 degrees. Declaration of Conformity. Test report. CEN/TS 16415: 2013 Personal fall protection equipment - Anchor devices - Recommendations for anchor devices for use by more than one person simultaneously. Type A: comprises of anchor device with one or more stationary anchor points, while in use, and with the needs for a structural anchor(s) or fixing element(s) to fix to the structure. Type C: Comprises anchor devices employing a flexible anchor line which deviates from the horizontal by not more than 15 degrees. Declaration of Conformity. Test report. ACR Advisory Committee for Roof work ACR[M]002:2009 - (Part2) Testing of Roof Anchors on Roof Systems Best practice guide based on sound technical knowledge and many years collective experience of roof work. The documentation produced provides a bench mark for testing and overall performance of horizontal safety lines being installed on different roof types. Declaration of Conformity. Test Reports for primary roof types and for some specific manufacturers. US Standards Standards Description Synopsis Test Data Available * / Documents OSHA 1926.502M (d) (15) (i) Australian / New Zealand Standards AS/NZS 1891.2.2001 Fall protection systems criteria and practices. Standards Description Industrial fall-arrest systems and devices Part 2: Horizontal lifeline and rail systems AS/NZS. (a) General. This appendix serves as a non-mandatory guideline to assist employers comply with the requirements in 1926.502(d). Paragraphs (b), (c), (d) and (e) of this Appendix describe test procedures which may be used to determine compliance with the requirements in 1926.502 (d)(16). As noted in Appendix D of this subpart, the test methods listed here in Appendix C can also be used to assist employers comply with the requirements in 1926.502(e) (3) and (4) for positioning device systems. Synopsis Declaration of Conformity. Test report. Test Data Available * / Documents This Standard specifies design and performance requirements Declaration for systems and associated component hardware for of Conformity. horizontal lifelines and rails used for fall-arrest purposes. The Test report. Standard covers systems using either rigid rails or flexible lines. * If copies of the test certificates are required please contact Kingspan and quote certificate number.
6.0 Reference E RoofSafe Anchor Intermediate Documents Guide 6.3 Markings Explained Anchor Sticker* 1 - Standards to Typical which the Layout Anchor conforms for a Bitumen 3 Roof System 2 - Read Instruction for use 3 - Product Type 4 - Web Address 5 - Brand Logo * North American labels may differ. * North American labels may differ. System Tag A B 1 - Standards to which system conforms 2 - Read Instruction for use 3 - Web Address 35mm (1.378) 4 -Brand LogoLABEL GRAPHICS K 5 - Product Family 6 - System information to be filled in by installer RoofSafe Anchor System Eye & Pin Unieye 8 mm Hex Swage Tensioner C 8 mm 7 7 SS Cable Per M D F 8 mm UniGrab & Carabiner 90 Degree Corner 45 Degree Corner** 8 mm Variable Bracket** Note: Fasteners for fixing to the structure are not supplied. *This component is different from the one illustrated Installers Guide Kingspan SafePro 2 NOTES: 1 1 EN795: 2012 Type C CEN TS 16415:2013 Type C 7 - isafe tag (where used) OSHA 1926.502 2 1. MATERIAL: GLOSS CLEAR VINYL 125 MICRON CLEAR TEXURED HEAT STABILISED AS/NZS POLYESTER, 1891.2 2 321SK AD 7241184 Rev. E 3 www.kingspanpanels.com 3M.com/FallProtection 2. FINISH: COLOUR, 3M RED, PANTONE 2748 BLUE, BLACK, WHITE, GREY. UNDERSIDE 3 SCREEN PRINT. MA 3. THICKNESS INCLUDES BACKING. 4. DELIVERED KISS CUT ON SHEET. EN795: 2012 Type A / C CEN TS 16415: 2013 Type A / C AS/NZS 1891.2 1 5. PART NUMBER TO BE PRINTED OUTSIDE OF KISS CUT SHEET - AS PREVIOUSLY Ø.157 [4mm] PRODUCED. Ø.197 [5mm] TYP. 6. ARTWORK TO BE APPROVED BY 3M FALL PROTECTION. 6 4 2 109mm (4.291) A MAX 7. USE THE CURRENT REVISION OF FILE 9507965.ai FOR LABEL GEOMETRY AND ARTWORK. ALL.276 [7mm] LABEL GE BE ±.2mm (±.008) A E C D 8. MANUFACTURER SHALL PROVIDE DOCUMENTATION B DUE UPON ARRIVAL OF EACH SHIPMENT 2.008 [51mm] J CERTIFYIN 6 6 7 2 41 161 7240166 7240211 7234020 7241412 7241408 7 2 41 41 1 7241413 SafePro 2 Anchor 5 SafePro 2 Anchor 5 8.858 [225mm] R2S G 8 mm Hex Swage Toggle H RoofSafe Anchor Baseplate 40 I 5 4 www.kingspanpanels.com 3M.com/FallProtection 2 PLACES 7 7 23 RoofSafe Anchor Module End Corner Bitumen J RoofSafe Anchor Module Intermediate Bitumen K RoofSafe Anchor Tag EMEA L A * North American region only ** this component is different from the.874 [22.2mm] R5 (R.197 A) THE PARTS ARE RoHS 3.543 AND REACH COMPLIANT. LABEL DIMENSIONS [90mm] 3.937 [100mm] SpiraTech Anchor 8.465 [215mm] Tip Over Anchor.217 [5.5mm].197 [5mm] NOTES: Form No: 5903917 Rev: D 1. MATERIAL:.031 ±.004 [0.8mm ± 0.1mm] ALUMINUM 5005 2. FINISH: ANODIZED, SCREEN PRINTED BLACK, BLUE Pantone 2748, LOW TEMPERATURE BAKED. USE THE CURRENT REVISION OF FILE 7241184.ai FOR LABE ALL LABEL GEOMETRY TOLERANCE SHALL BE ±.010. L GEOMETRY AND ARTWORK.
24 Kingspan SafePro 2 Installers Guide 7.0 Installation Instructions 7.1 Guidelines for 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 0-50 Nm (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 (9600044)** RA Removal Spanner (9600043)** KS500/1000 Zip Anchor 19mm Socket for use with the torque wrench 3 /16 hex driver KS1000 RW Anchor 8.2mm HSS Drill Bit Toggle Fix Powerbird Industrial Rivet Gun (7241102)** Powerbird Jaws (7241105)** Powerbird Nose Piece (7241106)** RA Baseplate Drilling Jig (7241210)**
Installers Guide Kingspan SafePro 2 25 7.0 Installation Instructions Prior to installation of the product please ensure that: 1) You have received training from 3M Fall Protection. 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 3M DBI-SALA SafePro 2 Anchor components. Your order is system specific and may not feature all of these components. SafePro 2 Anchor & Cable Components Baseplate405 - RA Baseplate 405 x 405 H Baseplate350 - RA Baseplate 350 x 440 H Baseplate550 - RA Baseplate 550 x 450 BL EC/TopFix- RA Module End / Corner Top Fix Int/TopFix - RA Module Intermediate Top Fix EC/PVC - RA Module End / Corner PVC Int/PVC - RA Module Intermediate PVC EC/Mem - RA Module End / Corner All Membrane Int/Mem - RA Module Intermediate All Membrane SystemEye/Pin - RA System Eye and Pin Corner90-90 Degree Corner Corner45-45 Degree Corner VariGuide - Variable Bracket Guide8mm - Intermediate Bracket ThrowPlate - RA Throw Plate Kit Single/Eye - RA Single Point Eye EMEA S5Z/Clamp - RS Maxi Clamp Z x 4 S5Z/Clampmini - RS Mini Clamp Z x 4 S5u/Clamp - RS Maxi Clamp U x 4 Toggle150 - RA Toggle Fixing 150mm x 4 Toggle300 - RA Toggle Fixing 300mm x 4 Toggle230- RA Toggle Fixing 230mm x 4 Tensioner8mm - 8mm Hex Swage Tensioner 0.8 kn Cable8mm - 8mm 7 x 7 Stainless Steel Cable Toggle8mm - 8mm Hex Swage Toggle * North American region only
26 Kingspan SafePro 2 Installers Guide 7.0 Installation Instructions 7.2 Top Fix Installation KS500/1000 Zip Installation 01 02 03 04 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. 05 06 07 08 Torque the bolts to 30 Nm (22 ft-lbf). Torque set screws to 15 Nm (11 ft-lbf). Fit the top module into the baseplate and torque to 40 Nm (30 ft-lbf). Anchor installation is complete and ready for the system components to be secured. KS1000 RW 01 02 03 04 Torque the bolts to 30 Nm (22 ft-lbf). Torque set screws to 15 Nm (11 ft-lbf). Fit the top module into the baseplate and torque to 40 Nm (30 ft-lbf). Anchor installation is complete and ready for the system components to be secured. 05 06 07 08 Drill and rivet the opposite corner. Drill and rivet through the remaining holes. Fit the top module into the baseplate and torque to 40 Nm (30 ft-lbf). Anchor installation is complete and ready for the system components to be secured.
Installers Guide Kingspan SafePro 2 27 7.0 Installation Instructions 7.3 Toggle Installation KS1000 TD 01 02 03 04 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. 05 06 07 08 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. Whilst 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 15 Nm (11 ft-lbf). Fit the SafePro 2 Anchor module into the baseplate and torque to 40 Nm (30 lft-lbf). The anchor is now installed and ready for the application of waterproofing detail and system components.
28 Kingspan SafePro 2 Installers Guide 7.0 Installation Instructions 7.4 Component Installation 90 / 45 Corner 01 02 03 04 Remove M12 nut and washer. Position the corner component and align. Refasten nut and washer. Torque to 30 Nm (22 ft-lbf) and replace nut cap. 7.4 Component Installation Intermediate Bracket 01 02 03 04 Remove M12 nut and washer. Position the Intermediate component and align. Refasten nut and washer. Torque to 30 Nm (22 ft-lbf) and replace nut cap. 7.4 Component Installation Variable Corner 01 02 03 04 Remove M12 nut and washer. Position the Variable component and align. Refasten nut and washer. Torque to 30 Nm (22 ft-lbf) and replace nut cap. 7.4 Component Installation SafePro 2 System Eye & Pin 01 02 03 04 Remove M12 nut and washer. Position the System Eye component and align. Refasten nut and washer. Torque to 30 Nm (22 ft-lbf) and replace nut cap. 7.4 Component Installation Single Point Eye - EMEA 01 02 03 04 Remove M12 nut and washer. Position the Single Point Eye component and align. Refasten nut and washer. Torque to 30 Nm (22 ft-lbf) and replace nut cap.
Installers Guide Kingspan SafePro 2 29 7.0 Installation Instructions 7.5 Baseplate Drilling 01 02 03 04 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. 05 06 07 08 Mark all hole positions. Centre punch the first hole. Drill through the baseplate and roofsheet using an 8.2mm (0.323) 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 40 Nm (30 ft-lbf). The anchor is now installed and ready for the top component.
30 Kingspan SafePro 2 Installers Guide 7.0 Installation Instructions 7.6 Hex Swaging Only 8mm 7 x 7 construction stainless steel wire cable supplied by Kingspan may be used for SafePro 2 Anchor & Cable applications. The hex swage data is based on the results from an Izumi EP410 model hex swager with 7241122 10mm bite dies. For any other hex swaging system / machine the installer needs to verify that the minimum strength of the hex swage is 38 kn. Kingspan offers a testing service, please contact us for more information. Measure & Cut Cable 01 02 03 04 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 (3.2 ) 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. Measure & Cut Cable 05 06 07 08 If required, uninstall the swage and insert the cable into the tube and mark with tape / marker. Check it inserts to full depth (80mm (3.2 ). Using the hex swager, make the first bite immediately after the solid section (A) (see below). Each bite is approximately 10mm (0.39 ) 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) Part number, batch number and swage bite dimensions are etched on the side of the swage part. Key: Etching - (xxxxxx xxxxxx) Cable Hex Swaging Table Swage Dies Swage Bites Bite Gap Dimension Across Flats 7 x 7 cable 7241122 6 discontinuous 1mm - 1.5mm See etched markings on part xxxxxx xxxxxx xxxxxx xxxxxx Dimension across flats Bite Gap
Installers Guide Kingspan SafePro 2 31 Notes
United Kingdom Kingspan Limited Sherburn, Malton, North Yorkshire, YO17 8PQ T: +44 (0) 1944 712444 F: +44 (0) 1944 710830 www.kingspanpanels.co.uk Ireland Kingspan Limited Carrickmacross Road, Kingscourt, Co Cavan, Ireland T: +353 (0) 42 96 98500 F: +353 (0) 42 96 98572 www.kingspanpanels.ie For the product offering in other markets please contact your local sales representative or visit www.kingspanpanels.com Care has been taken to ensure that the contents of this publication are accurate, but Kingspan Limited and its subsidiary companies do not accept responsibility for errors or for information that is found to be misleading. Suggestions for, or description of, the end use or application of products or methods of working are for information only and Kingspan Limited and its subsidiaries accept no liability in respect thereof. 04/2018