INSTALLATION INSTRUCTIONS

RoofSafe™ Anchor & Cable

Installation Instruction Number: 21

Always read and follow the warnings and instructions for use
© Copyright Capital Safety Systems Ltd 2013

T H E U LT I M AT E I N FA L L PR OT E CT I O N
 RoofSafe™ Anchor & Cable
Contents

GUIDELINES FOR INSTALLATION 3

TOP FIX 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™ ANCHORS SYSTEM.

Issue Date: 18/04/2013 Issue No: 3 2

 RoofSafe™ Anchor & Cable
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 Prior to installation of the product please ensure that:
1) You have received training from Capital Safety.
General
2) You have all of the appropriate personal safety equipment to complete the task safely.
Heavy duty drill with a hammer action facility
32mm Auger drill bit or wood drill bit and extension bar for cutting DON’T USE TOOLS UNTIL INSTRUCTED TO DO SO
through the roof insulation material
Marker pen
Steel Ruler/Tape Measure
Pair of plastic pipe cutters The component list below shows typical RoofSafe™ Anchor components. Your order is system specific
Pen Torch and may not feature all of these components.
Knife
Torque wrench with a range of 0-50Nm (calibrated) ROOFSAFE™ ANCHOR & CABLE COMPONENTS
Hex driver to torque wrench adaptor
7241136 - RA Baseplate 405x405 H
13mm Socket for use with the torque wrench
7241137 - RA Baseplate 405x405 BL
Socket to drill adaptor
7241138 - RA Baseplate 350x440 H
Alcohol Solution/Wipes
7241139 - RA Baseplate 350x440 BL
RA 6mm Hex Drive Bit (9600044)**
RA Removal Spanner (9600043)** 7241140 - RA Baseplate 550x450 BL
7241141 - RA Module End / Corner Top Fix
Standing Seam Anchor
7241142 - RA Module Intermediate Top Fix
19mm Socket for use with the torque wrench
7241143 - RA Module End / Corner Bitumen
3/16” hex driver
7241144 - RA Module Intermediate Bitumen
Trapezoidal Anchor
7241145 - RA Module End / Corner PVC
8.2mm HSS Drill Bit
7241146 - RA Module Intermediate PVC
Toggle Fix
7241147 - RA Module End / Corner All Membrane
Powerbird Industrial Rivet Gun (7241102)**
Powerbird Jaws (7241105)** 7241148 - RA Module Intermediate All Membrane
Powerbird Nose Piece (7241106)** 7241161 - RA System Eye and Pin
RA Baseplate Drilling Jig (9600046)** 7241162 - RA 90º Corner
7241163 - RA 45º Corner
Concrete Anchor
12mm HSS Drill Bit The drill bit must be long enough to penetrate 7241164 - RA Variable Corner
the roof construction and concrete 7241165 - RA Intermediate Bracket
14mm HSS Drill Bit The drill bit must be long enough to penetrate 7241166 - RA Throw Plate Kit
the roof construction and any screed 7241167 - RA Single Point Eye EMEA
Blow pump 7241204 - RS Maxi Clamp Z x4
Flat File 7241205 - RS Mini Clamp Z x4
Hack saw 7241206 - RS Maxi Clamp E x4
Lump hammer 7241207 - RS Mini Clamp E x4
RA Concrete Setting Tool (7241112)**
7241208 - RS Maxi Clamp U x4
Eyebolt Testing Kit (7241125)**
7241209 - RS Mini Clamp U x4
Plywood board (18mm x 500mm x 500mm) for distributing
test load 7241180 - Concrete Anchors 150mm x 4
Depth Gauge Rod (knitting needle) long enough to reach deck 7241181 - Concrete Anchors 300mm x 4
through insulation 7241182 - RA Toggle Fixing 150mm x 4
** these tools are available for purchase 7241183 - RA Toggle Fixing 300mm x 4
from Capital Safety. 7240166 - Uni 8™ 8mm Hex Swage Tensioner 0.8kN
7240211 - 8mm 7 x 7 Stainless Steel Cable
7234011 - Uni 8™ 8mm Hex Swage Toggle
Issue Date: 18/04/2013 Issue No: 3 3
 RoofSafe™ Anchor & Cable
Top Fix Installation

STANDING SEAM INSTALLATION

01 02 03 04

Ensure the seam is correctly formed Attach the clamps and position Slide the inserts into position. The inserts should be flush with the
prior to installing the anchor. the anchor. main body of the clamp.

05 06 07 08

Torque the bolts to 30Nm. Torque set screws to 15Nm. Fit the top module into the baseplate Anchor installation is complete and
and torque to 40Nm. ready for the system components to
be secured.

TRAPEZOIDAL INSTALLATION

01 02 03 04

Stick the scapa tape over the holes Clean the fixing area with alcohol Drill through the first hole in the base Rivet down the first hole to the roof.
which align with the roof crowns. solution/ wipes and place post plate using an 8.2mm drill bit.
in position.

05 06 07 08

Drill and rivet the opposite corner. Drill and rivet through the Fit the top module into the baseplate Anchor installation is complete and
remaining holes. and torque to 40Nm. ready for the system components to
be secured.

Issue Date: 18/04/2013 Issue No: 3 4

 RoofSafe™ Anchor & Cable
Toggle Installation

01 02 03 04

Mark out the fixing positions of the Whilst the baseplate is in Using a 29mm (1.14”) diameter Clear away the debris.
anchor on the roof membrane. Be position, mark positions through bi-metal hole saw, drill through the
sure toggles will fix into the crowns the toggle inserts. insulation and through the metal or
on metal deck. plywood deck.

05 06 07 08

Measure the depth of the hole to the Mark alignment tube and toggle foam Insert alignment tubes into the holes. Slide the toggle into the hole as shown.
top of the metal or plywood deck. insulation with the measurement from
step 5 and cut.

09 10 11 12

Once it has dropped through, Pull upwards to lock the toggle Repeat steps 8 to 10 for the Whilst holding the toggle insert, use
the toggle should fall. in place. remaining toggles. 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, Fit the RoofSafe™ Anchor module into The anchor is now installed and ready
torque the toggles to 15Nm. the baseplate and torque to 40Nm. for the application of waterproofing
detail and system components.

Issue Date: 18/04/2013 Issue No: 3 5

 RoofSafe™ Anchor & Cable
Concrete Installation
01
Mark out the fixing positions of the
anchor on the roof membrane.
05
Mark alignment tube and toggle foam
insulation and cut to length.
09
Using a blow pump, clean all of the
dust and debris from the hole.
Issue Date: 18/04/2013
02
Using the 29mm Auger or wood drill
bit, drill through the roof membrane
and the insulation material.
06
Insert alignment tubes into holes
10
Screw the threaded rod into the fixing
socket so that two full threads are
protruding out of the bottom end.
Issue No: 3
03
Clear away the debris.
07
Set the drill to ‘hammer’ action and
using a 12mm drill bit, drill a hole in
the concrete 50-55mm maximum
depth from the surface of the concrete
roof structure.
11
Measure the depth of the insulation
with the steel ruler, plus the depth of
any screed.
04
Measure the depth of the hole.
08
Note: If screed is present above the
concrete roof structure, drill through it
with the 14mm masonry drill bit, until
you reach the concrete. Then revert to
the 12mm drill bit.
12
Mark the threaded rod with the
measurement taken in step 11, away
from the shoulder of the fixing socket
(see above).
6
 RoofSafe™ Anchor & Cable
Concrete Installation
13
Insert into the hole in the concrete.
17
Slide the toggle foam spacer over the
threaded rod.
21
Add the nut and tighten
to 15Nm.
Issue Date: 18/04/2013
14
Place the setting tool (7241112)
over the threaded rod and on to the
shoulder of the fixing. The setting
tool should be resting on top of the
fixing socket.
18
Test each fixing to a load of 5kN using
pull tester. See pull test instructions for
more details.
22
Cut off the excess threaded rod.
Issue No: 3
15
Hit with a hammer to set the fixing until
the mark made in step 12 is level with
the roof membrane.
19
Place the baseplate in position.
23
File down any burrs to prevent
penetration of the roof membrane.
16
Screw the threaded rod down
until it touches the bottom of
the concrete hole.
20
Place the toggle inserts over the
threaded rods.
24
Fit the RoofSafe™ Anchor module into
the baseplate and torque to 40Nm.
The anchor installation is now complete
and ready for waterproofing detail and
system component.
7
 RoofSafe™ Anchor & Cable
Component Installation
90°/45° CORNER

01 02 03 04

Remove M12 nut and washer. Position the corner component Refasten nut and washer. Torque to 30Nm and replace nut cap.
and align.

INTERMEDIATE BRACKET

01 02 03 04

Remove M12 nut and washer. Position the Intermediate component Refasten nut and washer. Torque to 30Nm and replace nut cap.
and align.

VARIABLE CORNER

01 02 03 04

Remove M12 nut and washer. Position the Variable component Refasten nut and washer. Torque to 30Nm and replace nut cap.
and align.

ROOFSAFE™ SYSTEM EYE & PIN

01 02 03 04

Remove M12 nut and washer. Position the System Eye component Refasten nut and washer. Torque to 30Nm and replace nut cap.
and align.

SINGLE POINT EYE - EMEA

01 02 03 04

Remove M12 nut and washer. Position the Single Point Eye Refasten nut and washer. Torque to 30Nm and replace nut cap.
component and align.

Issue Date: 18/04/2013 Issue No: 3 8

 RoofSafe™ Anchor & Cable
Baseplate Drilling

01 02 03 04

Clean the fixing area with alcohol Position the sealing tape on the seams. Place the baseplate on the roof. Position the baseplate drilling jig on the
solution/ wipes. plate as shown.

05 06 07 08

Mark all hole positions. Center punch the first hole. Drill through the baseplate and Rivet down the first hole to the roof.
roofsheet using an 8.2mm drill bit.

09 10 11 12

Drill and rivet the opposite corner. Drill and rivet through Fit the top module into the baseplate The anchor is now installed and ready
the remaining holes. and torque to 40Nm. for the top component.

Issue Date: 18/04/2013 Issue No: 3 9

 RoofSafe™ Anchor & Cable
Hex Swaging

Only 8mm 7x7 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 10mm bite dies. For any other hex swaging system/machine the installer needs to verify that the minimum strength of the hex swage is
38kN. Capital Safety offers a testing service, please contact us for more information.

MEASURE & CUT CABLE

01 02 03 04

Remove the split pin from the tensioner Unscrew the stud by hand to fully Mark the tube at the depth of the hole Pull the cable tight and mark the cable
and attach it to the Energy Absorber or expose the threads. (80mm from the end of the tube). where it lines up with the mark on the
system eye. tube and then cut using appropriate
steel wire cable cutters.

SWAGING

05 06 07 08

If required, uninstall the swage and Using the hex swager, make the Following the table dimensions below, Using a vernia, check the swage
insert the cable into the tube and mark first bite immediately after the solid ensure the 6th bite finishes short of the bite dimensions against the specified
with tape/marker. Check it inserts to section (A) (see below). Each bite is chamfer section (B) (see below). tolerance on the part.
full depth (80mm). approximately 10mm wide. (Dimensions are in mm)

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

Part number, batch number and swage

bite dimensions are etched on the side of
the swage part.

A B
Key:

Etching - (xxxxxx xxxxxx) 80mm

xxxxxx xxxxxx
xxxxxx xxxxxx

Dimension across flats

Bite Gap

Issue Date: 18/04/2013 Issue No: 3 10

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