Installation Instruction Number: 11

Installation Instructions
RoofSafe Rail for
Bulb Type Standing Seam &
Folded Standing Seam Roofs

Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
01/11/2010
Installation Instruction Number: 11

Contents
Page No.
Contents 2
Guidance for Installation 3
Important Information 7
Installation on a Bulb Type / Folded standing seam roof 8
Section 1 - Installation of a corner 8
Section 2 - Installation of a straight rail, perpendicular to the seam 9
Section 3 - Installation of a straight rail, parallel to the seam 10
Finishing the System 12

These instructions are an aid to training. Only trained personnel should attempt
to install a RoofSafe Rail System.

Page 2 of 13
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
01/11/2010
Installation Instruction Number: 11

Guidance for Installation

Diagrams for reference only. Refer to system datasheets and designer’s guide for more information.

MAX 800mm (31.50")

Z
Y

97mm (3.82")
255 mm (10.04")

MAX 566 mm
(22.28") at 45
10
00
3000 mm (118.11")

m
m
(3
9.
37
")
Ty
p
Typical Folded & Bulb Type Standing Layout
(Fall arrest)

X
MAX 750 mm (29.53")

Page 3 of 13
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
01/11/2010
Installation Instruction Number: 11

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")
1 2 0 mm ( 4 . 7 2 ")

120 mm (4.72")

Detail W Detail X

Typical fixing details

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

Page 4 of 13
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
01/11/2010
Installation Instruction Number: 11

Guidance for Installation

Diagrams for reference only. Refer to system datasheets and designers guide for more information.
For suspended access applications, Uniline 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")

97mm (3.82")
255 mm (10.04")

MAX 354 mm
(13.93") at 45

10
00
3000 mm (118.11")

m
m
(3
9.
37
")
Ty
p
Typical Suspended Access layout
MAX 500 mm (19.69")

Page 5 of 12
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
01/11/2010
Installation Instruction Number: 11

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

Parallel to the crowns Perpendicular to the crowns
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

Page 6 of 13
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
01/11/2010
Installation Instruction Number: 11

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. Prior to installation of the product please
Your order is system specific and may not feature all these ensure that:
components.
1) You have received training from Uniline
Safety Systems.
Components
182-430-000 - Moulded Rail End
180-258-000 - M10 Tamper Proof Stop 2) You have all of the appropriate personal
180-258-002 - Plunger Stop Assembly safety equipment to complete the task
180-669-600 - Unirail Carriage Assembly safely.
192-260-600 - RS Rail Spreader Plate
190-250-500 - RS Rail 3m Asm Don’t use tools until
082-218-600 - System ID Tag
instructed to do so
190-250-101 - RS Rail 90° Corner Asm
190-250-102 - RS Rail 45° Corner Asm Tool List
1 x Drill + Drill Bits 6.5mm, 8mm, 9mm, 10mm &
170-258-501 - S-5-Z Mini Clamp 11mm
1 x Permanent Marker/Pencil
170-258-502 - S-5-E Maxi Clamp 1 x Tape Measure
170-258-503 - S-5-E Mini Clamp 1 x 10mm Punch
1 x 8 oz hammer
173-240-501 - Bulb Tite 7.7mm Rivets- 100 1 x Soft mallet
173-240-502 - Bulb Tite 7.7mm Rivets- 500 1 x 3/16” hex driver and wrench adaptor
1 x 20 oz hammer
Other 1 x Circular Saw
1 x Torque Wrench
190-250-200 - RS Rail Ridge / Gutter Bridge Special 1 x 13mm Socket head
1 x 17mm Socket head
1 x 6mm Hex Socket driver
1 x File/ Deburring tool
1 x 190-210-500 - RS Corner Drilling Jig

1 x 175-669-600 - PowerBird Rivet Gun

Or
1 x 175-669-604 - Gesipa Manual Rivet Gun
+
1 x 175-669-605 - 7.7mm Rivet Pulling Head

Other
Page 7 of 13 1 x Wooden Block

Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
01/11/2010
Installation Instruction Number: 11

System Installation-Standing Seam Roof System

Section 1- Installation of a corner
Form 066b v2 (DCN220)

Technical Datasheet No: 1098

01

02

03

04
Typical Bulb Type Standing Seam Roof System
(Fall Arrest)

P.P.E A
B
C
D
E
F
G
Moulded Rail End (182-430-000)
M10 Tamper Proof Stop (180-258-000)
Plunger Stop Assembly (180-258-002)*
UniRail Carriage Assembly (180-669-600)
RoofSafe Rail Spreader Plate (192-260-600)
RoofSafe Rail 3m Assembly (190-250-500)
RoofSafe Rail 90° Corner Assembly (190-250-101)
RoofSafe Rail 45° Corner Assembly (190-250-102)
H S-5-Z Mini Clamp (170-258-501)#
Bulb-Tite Dome Head 7.7mm Rivet – 100 off (173-240-501)#
I
Bulb-Tite Dome Head 7.7mm Rivet – 500 off (173-240-502)#
*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
Issue Date: 21/12/2010 Page 1 of 2 Issue No: 01

Ensure that you have
the adequate fall
protection equipment.
05
Refer to system layout, If the system contains Drill a 6.5mm hole into
and measure system a corner, rail ridge or the centre cavity.
location accordingly. gutter bridge, place
the rail drilling jig at the
If the system does not end of adjoining rail and
contain a corner move tighten screw.
on to sections 2 or 3.

06

07

08
De-burr the hole. Repeat steps 03-05 Repeat steps 03-06 for Assemble the corner
Ensure that the hole is for other side of rail. the other joining rail. and the rail. Ensure that
free from swarf. holes are aligned.
09

10

11

12
Insert a spring pin. Using a 10mm punch Ensure that the pin is Repeat steps 09-11 for
and a larger hammer flush with hole edge on other side of the corner.
finish inserting spring both sides.
pin.
13

14

15

16

To install rail To install rail parallel to

perpendicular to the the seams see section
seams see section 2. 3.

Page 8 of 13
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
01/11/2010
Installation Instruction Number: 11
System Installation-Standing Seam Roof System
Section 2- Installing a straight system perpendicular to the seams.
01
P.P.E
Ensure that you have
the adequate fall
protection equipment.
05
Using a centre punch,
mark position of the
hole in rail centre
channel. Refer to page
4 6.
09
Position the clamp and
slide insert into position.
For S-5-E clamps move
to step 11
13
Place the rail into
position and insert
bolts.
Page 9 of 10
Form 066b v2 (DCN220)
Technical Datasheet No: 1098
02
03
04
Typical Bulb Type Standing Seam Roof System
(Fall Arrest)
A
B
C
D
E
F
Moulded Rail End (182-430-000)
M10 Tamper Proof Stop (180-258-000)
Plunger Stop Assembly (180-258-002)*
UniRail Carriage Assembly (180-669-600)
RoofSafe Rail Spreader Plate (192-260-600)
RoofSafe Rail 3m Assembly (190-250-500)
RoofSafe Rail 90° Corner Assembly (190-250-101)
G RoofSafe Rail 45° Corner Assembly (190-250-102)
H S-5-Z Mini Clamp (170-258-501)#
Bulb-Tite Dome Head 7.7mm Rivet – 100 off (173-240-501)#
I
Bulb-Tite Dome Head 7.7mm Rivet – 500 off (173-240-502)#
*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
Issue Date: 21/12/2010 Page 1 of 2 Issue No: 01
Refer to system layout, Ensure the seam is Mark position and
and measure system correctly formed prior intended fixing points of
location accordingly. to installation. rail. For max distances
refer to page 3.
06
07
08
Before drilling place a Repeat steps 05-06 for Repeat step 05-06 for
wooden block beneath other side of the rail. all other fixing points.
the rail. Drill a hole for
the clamps refer to page
10
11
12
Ensure insert is flush with For S-5-E clamps Repeat steps 09-11
clamp. Hand tighten grub ensure that the clamp for all clamps.
screw (s) is positioned the
correct way around.
14
15
16
Repeat step 13 for all Torque all the bolts to Torque the grub (s)
other bolts and check the required torque. screws to 15Nm
the position of rail and Refer to page 6. (11.1lbf) using a
clamps. calibrated torque
wrench with a 3/16”
hex driver.
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
01/11/2010
Installation Instruction Number: 11

System Installation- Standing Seam Roof System

Section 3- Installing a straight system, parallel to the crowns.

Note 02
Note 01

Note 03

01
P.P.E
End / corner Join configuration. The Intermediate spreader Ensure that you have
configuration spreader rail join is centred on plate configuration. the adequate fall
plate and RoofSafe the spreader plate. Less rivets required. protection equipment.
edge are flush. Refer to Refer to page 4 Refer to page 4.
page 4

Form 066b v2 (DCN220)

Technical Datasheet No: 1098

02

03

04

05
Typical Bulb Type Standing Seam Roof System
(Fall Arrest)

A Moulded Rail End (182-430-000)

M10 Tamper Proof Stop (180-258-000)
B
Plunger Stop Assembly (180-258-002)*
C UniRail Carriage Assembly (180-669-600)
D RoofSafe Rail Spreader Plate (192-260-600)
E RoofSafe Rail 3m Assembly (190-250-500)
F RoofSafe Rail 90° Corner Assembly (190-250-101)
G RoofSafe Rail 45° Corner Assembly (190-250-102)
H S-5-Z Mini Clamp (170-258-501)#
Bulb-Tite Dome Head 7.7mm Rivet – 100 off (173-240-501)#
I
Bulb-Tite Dome Head 7.7mm Rivet – 500 off (173-240-502)#
*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
Issue Date: 21/12/2010 Page 1 of 2 Issue No: 01

Refer to system layout, Ensure the seam is Cut spreader plates to Mark position of rail
and measure system correctly formed prior size. Cut enough so and intended fixing
location accordingly. to installation. that it is flush with all points. For max
clamp edges. distances refer to page
3.
06

07

08

09
If the rail has to be joined, Using a centre punch Drill a hole for the Repeat step 07-08 for
the last spreader plate mark position of hole clamps, refer to page 6. the other corners of the
should be positioned in the spreader plate spreader plate.
so that the rail edge is centre channel.
aligned with the spreader
plate centre line.
10

11

12

13

Repeat steps 07-09 Position the clamp Ensure insert is flush For S-5-E clamps
for other spreader and slide insert into with clamp. Hand ensure that the clamp
plates. position. For S-5-E tighten grub screw (s) is positioned the
clamps move to step correct way around.
13

Page 10 of 13
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
01/11/2010
Installation Instruction Number: 11
System Installation- Standing Seam Roof System
Section 3- Installing a straight system parallel to the crowns.
14
15
Repeat steps 11-13 for Place spreader plate
other clamps. in position and insert
bolts.
18
19
Repeat steps 11-17 Torque the grub
to secure all other screws to 15Nm
spreader plates (11.1lbf) using a
calibrated torque
wrench with a 3/16”
hex driver.
22
23
Secure with a 7.7mm Drill and rivet the
(0.303”) bulb tite rivet. opposite end of the rail
to the spreader plate
as in steps 19-21.
27
28
Continue to fit Insert Aluminium spigot
spreader plates as into rail end and tap
applicable. See steps in place with rubber
05-19. mallet.
Page 11 of 13
Form 66c v5 (DCN 213)
16
Torque all the bolts to
the required torque.
Refer to page 6.
20
Before drilling place a
wooden block beneath
the spreader plate to
protect the roof sheet.
24
Drill and rivet all
other fixing points.
maintaining the correct
pattern. Refer to page
4.
29
Join rails together
Issue Number: 02
17
Repeat steps 15-16 for
all other bolts.
21
Drill an 8mm hole to
align with the centre rail
channel and spreader
plate centre channel.
25
Repeat steps 19-23 to
secure rail.
30
Repeat steps 20-23 to
secure 2nd rail.
Issue Date:
01/11/2010
Installation Instruction Number: 11

Finishing the System

01

02

03

04
Mark 1m (39”) from the Slide the carriage onto Slide the tamper proof Torque to 15Nm
end of system and drill the rail. stop onto rail and align (11.1lbf).
a 10mm hole to the with the 10mm hole.
to centre cavity, then
deburr hole.
05

06

07

08
For system with a When over the hole Remove any excess Using a rubber mallet,
plunger stop, pull head release the head. butyl tape. Sweep gently tap the moulded
of stop upwards and Ensure that the stop away any swarf and rail end into the end of
slide stop onto rail. has engaged by giving dust. the rail.
it a sharp tug.
09

10

11

12
Install system tag and ?? ?? ??
ensure that it has been
filled in.
13

14

15

16

?? ?? ?? ??

Page 12 of 13
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
01/11/2010
 Uniline Safety Systems is a leading international manufacturer of fall protection products
and systems. Through a combination of expert knowledge and practical experience,
we can help our customers reduce risk and increase safety when working at height.

Uniline’s comprehensive range of products offers fully compliant, practical solutions for structures of all types, in
all industries. Our ethos of delivering quality, service, training and support for our customers has earned Uniline a
deserved reputation for excellence around the world.

Operating through specialist safety companies in over 25 countries, Uniline provides local support and installation
services to meet the specific safety objectives of all our customers.

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roof access during maintenance
and inspection tasks, then look
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can provide a solution for all types
of rescue situations whilst keeping
safety the top priority.

because lives depend on it

www.unilinesafety.com

local distributor/systems integrator

Uniline Safety Systems Limited

UK USA AUSTRALIA
5a Merse Road 17200 Chenal Parkway Factory 1
North Moons Moat Suite #352 4 Reichert Drive, Molendinar
Redditch, Worcestershire Little Rock, AR 72223 Queensland 4214
B98 9HL USA Australia
t: +44 (0) 1527 548 000 t: +01 (501) 517 6056 t: +61 (7) 5563 1900
f: +44 (0) 1527 591 000 f: +01 (501) 325 3477 f: +61 (7) 5571 7093