Installation Instruction Number: 10

Installation Instructions
UniRail

Page 1 of 9
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
25/01/2010
Installation Instruction Number: 10

Contents

Page No.
Contents 2
Guidelines for Installation 3
Important Information 4
System Installation - Marking Out 5
System Installation - Fitting a Concealed Fix Bracket 5
System Installation - Fitting a Side Fix Bracket 5
System Installation - Fitting a Rail Joint 6
System Installation - Finishing the System 6
Wall Mount External Corner 7
Structural Fixing - Mechanical 8
Structural Fixing - Resin 9

These instructions are an aid to training. Only trained personnel should

attempt to install a UniRail system.

Page 2 of 9
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
25/01/2010
Installation Instruction Number: 10

Guidelines for Installation

Diagrams for reference only. Refer to system datasheets and designers guide for more information.

3000mm (118.11") 3000mm (118.11")

520mm (20.47") Max

3000mm (118.11") Max
2600mm (102.36") Typ

Typical Concealed Fix Typical Concealed Fix

Fall Arrest System Suspended Access
System
200mm (7.87") Max

200mm (7.87") Max

3000mm (118.11") 3000mm (118.11")

520mm (20.47") Max
3000mm (118.11") Max
2600mm (102.36") Typ

Typical Side Fix Typical Side Fix

Fall Arrest System Suspended Access
System
200mm (7.87") Max

200mm (7.87") Max

Page 3 of 9
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
25/01/2010
Installation Instruction Number: 10

Important Information
Detailed below are examples of typical components used in both a side fix and concealed fix UniRail system
along with the tools required for installation. It is advisable to read through these instructions before beginning
the installation.

The component list below shows the full range available. Prior to installation of the product please
Your order is system specific and may not feature all of these ensure that:
components.
Concealed Fix System Components 1) You have received training from Uniline
180-258-000 - M10 Tamper Proof Stop Assembly Safety Systems.
180-258-002 - Plunger Stop Assembly
180-258-001 - System Rail Stop Assembly
182-430-000 - Moulded Rail End 2) You have all of the appropriate personal
180-669-601 - UniRail Carriage Assembly safety equipment to complete the task
180-669-500 - Rail Joint Assembly
safely.
182-258-205 - UniRail 3m
182-258-003 - Concealed Fix End Anchor
182-258-201 - Concealed Fix Intermediate Anchor - Tapped Don’t use tools until
182-258-202 - Concealed Fix Intermediate Anchor
Side Fix System Components
instructed to do so
180-258-000 - M10 Tamper Proof Stop Assembly
180-258-002 - Plunger Stop Assembly
180-258-001 - System Rail Stop Assembly
182-430-000 - Moulded Rail End Tool List
180-669-601 - UniRail Carriage Assembly 1 x Drill + Drill Bits (Various)
180-669-500 - Rail Joint Assembly 1 x Tape Measure
182-258-205 - UniRail 3m 1 x 1/2” Torque Wrench
182-258-010 - Side Fix End Anchor 1 x 6mm Hex Socket Driver
182-258-207 - Side Fix Intermediate Anchor 1 x 19mm Socket
UniRail Corners 1 x Rubber Mallet
180-258-100 - UniRail Wall Mount 90° Ext Corner 1 x Chalk Line
182-258-600 - 90° x 200 Rad Corner 1 x Permanent Marker/Other
182-258-601 - 90° x 200 Rad Wall Mount External Corner 1 x Circular Saw
182-258-602 - 90° x 200 Rad Wall Mount Internal Corner
182-258-603 - 45° x 200 Rad Wall Mount Internal Corner 1 x Countersink
182-258-604 - 45° x 200 Rad Wall Mount External Corner 1 x File
182-258-605 - 45° x 200 Rad Corner 1 x 180-258-606 - Unirail Drilling Jig
1 x 182-040-600 - Step Drill
Other
Structural Anchors - Various (See Page 8-9)
For a full range of structural anchors, visit www.hilti.com Unirail External Corner Tools
Note: Uniline DO NOT stock the structural anchors or the 1 x 6mm Hex Socket Driver (Long)
corresponding fasteners.
Note: Step drills available from Uniline on request.

Page 4 of 9
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
25/01/2010
Installation Instruction Number: 10

System Installation
Marking Out

01

02

03

04
Refer to layout If installing a wall mount Mark the centre line Begin the installation at
before beginning the system, measure up/ of the system using a corner or other fixed
installation. down to the centre line a chalk line or similar point.
of the system. tool.
Once the fixed point/corner has been marked it is best to install this component.
See page 7 for Wall Mount Ext Corner fitting instructions.
Note: When marking out the end rail section, please allow a gap of 1mm for every linear
metre of rail at each end of the system between the system rail stop and the end bracket.
05

06

07

08
Follow the fixing Measure out from the Mark the centre Once the first section
guidelines on page corner or other fixed positions. of rail is marked out,
7-8 for installing the point the positions of the install this section and
structural anchors. next brackets. then continue to mark
out the next section.
Refer to the steps below and over leaf for installation instructions of specific components.

Fitting a Concealed Fix Bracket

09

10

11

12

Position over the socket
and add fixing.
Fitting a Side Fix Bracket
13
Tighten to 30Nm. Fit the other brackets Slide rail into concealed
in the 3m length, fix bracket.
following step 09 & 10.
(Note: Side fix brackets can be installed while the rail is in the brackets.)

14

15

16

Position over a socket/ Tighten to 30Nm/50Nm Fit the other brackets in Slide rail into side fix
stud and add fixing. M10/M12. a 3m length, following bracket.
steps 13 & 14.
Page 5 of 9
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
25/01/2010
Installation Instruction Number: 10
System Installation
Fitting a Rail Joint
17
Slide the rail into the
joint and insert the
screws into the rail on
one side of the joint.
Finishing the System
21
Cut the rail down to the
correct length.
25
Repeat for the second
hole.
29
Slide the carriage onto
the rail.
If you are required to shorten a rail that is NOT at the end of a system, follow steps 21-28 except step 26 as this hole is
not required in the middle of a system.
Page 6 of 9
18
Insert the spigot into
the end of the rail and
tap firmly with rubber
mallet.
(Skip steps 21-25 if the length of the rail is already correct.)
22
Using a file, make sure
the end of the rail is
free from sharp edges.
26
Using a 10mm drill bit,
drill to the centre of the
rail. Skip step 27 as
applicable.
30
Position the tamper
proof stop in the hole
drilled in step 26 and
tighten to 15Nm.
Form 66c v5 (DCN 213)
19
Slide the other rail into
position.
23
Position the drilling jig
on the end of the rail
and lock it down with
the screw.
27
Use a countersink tool (or
step drill - 182-040-600)
to countersink the two
holes nearest the end of
the rail. Fasteners should
sit sub-flush with the rail.
31
Slide the system rail
stop into position and
insert and tighten
screws to 30Nm.
Issue Number: 02
20
Tighten the screws in
the joint to 30Nm.
24
Using an 11mm drill
bit, drill all the way
through the rail.
28
Slide the rail into the
concealed fix brackets.
32
Using a rubber mallet,
gently tap the Moulded
Rail End into the end of
the rail. Repeat steps
21-32 for the other end
of the system.
Issue Date:
25/01/2010
Installation Instruction Number: 10

Wall Mount External Corner

This installation guide is based on a mechanical push in anchor fixing method with concealed fix anchors, however, it is
possible to use a resin socket, through fix and/or side fix anchors. For fixing advice, see page 8-9.
Installation of this assembly requires two people.

01

02

03

04
Assemble the Hold the assembled Mark out the slot detail Mark through the hole
components on the corner unit in position. on the wall. in the rail. If marking
corner as illustrated. brickwork, it may be
better to use a drill.
05

06

07

Disassemble the corner
component and hold
the spacer against the
structure to mark out the
second slot.
09
08
Drill holes in the structure Insert anchors. Set the anchors into
in the marked positions. position, following
Holes are suitable for the manufacturer’s
M10/M12 anchors (not instructions.
supplied) as applicable.

10

11

12
Conduct a pull test on Fasten the steel Using a torque Tighten the second
each anchor using the support spacers with wrench, 19mm socket screw.
Hydrajaws testing kit M12 screws and and socket extender,
to 6kN. washers. tighten the screws to
50Nm.
13

14

15

16

Slide the intermediate
anchors onto the rail
with the screws in
and position it on the
structure.
Tighten the screws
in the intermediate
anchors to 30Nm.
Insert the screws
through the rail into the
spacers and tighten to
30Nm.
Once the installation
of the corner is
completed, continue
installing the rest of the
system.

Page 7 of 9
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
25/01/2010
Installation Instruction Number: 10

Structural Fixing -
Mechanical
Uniline recommends the use of Hilti products with UniRail. Please check the structural material against the selected
anchor when specifing the task. Uniline do not keep any anchors in stock. Please order directly from Hilti.
Note: Ensure you have specified the correct socket/stud material. Uniline recommends all fasteners and anchors are
stainless steel for all exterior applications.

THESE INSTRUCTIONS ARE FOR REFERENCE ONLY, PLEASE REFER TO HILTI FOR DETAILED INSTRUCTIONS FOR USE

Hilti HSC-I Safety Anchor

01

02

Drill hole with drill bit to
appropriate depth (See Hilti
instructions for use).
04
03
Blow out dust and Insert the anchor. Use the Hilti setting tool to
fragments. set the anchor (See Hilti
instructions for use).

06
06
05

Make sure the anchor is flush against the Conduct a pull test Fit the component and apply
surface. on each anchor tightening torque.
using the Hydrajaws
testing kit to 6kN.

Hilti HST Stud Anchor (Side Fix Anchors Only)

01

02

05
03

04

Drill hole with drill bit Blow out dust and Install the anchor by Conduct a pull test Fit component and
to appropriate depth fragments firmly tapping the on each anchor apply tightening
(See Hilti instructions anchor into the hole. using the Hydrajaws torque.
for use). testing kit to 6kN.

For more detailed information, see instruction for use given with the package of the product.

Page 8 of 9
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
25/01/2010
Installation Instruction Number: 10

Structural Fixing - Resin

01

02

03

04
Drill hole with drill bit to Blow out dust and Using a round steel Repeat step 2.
appropriate depth (See fragments. brush, remove dust and
Hilti instructions for use.). fragments from the hole.
05

06

07

08
Load foil pack into the Insert Static Mixer. Load cartridge into the Waste a small amount
cartridge. resin gun. of resin.
09

10

Note: Anchor rods to be used with

side fix only. Internally threaded sleeves
required for concealed fix systems.
Insert resin into the Once finished, release
drilled hole. the cartridge.

Hilti HIT-HY 150 - Concrete

14
11

12

13

Wait for the resin to Leave to cure for Conduct a pull test Fit component and
gel and then insert the the recommended using the Hydrajaws apply tightening torque
anchor. period of time (see Hilti testing kit to 6kN. to nut.
instructions for use).

Hilti HIT-HY 70 - Hollow Brick, Block, Natural Stone

11

12

14
13

Wait for the resin to gel Leave to cure for Conduct a pull test Fit component and
and then insert anchor the recommended using the Hydrajaws apply tightening torque
making sure it is flush period of time (see Hilti testing kit to 6kN. to bolt.
against the surface. instructions for use).

Page 9 of 9
Issue Date:
Form 66c v5 (DCN 213) Issue Number: 02
25/01/2010
 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
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because lives depend on it

www.unilinesafety.com

local distributor/systems integrator

Uniline Safety Systems Limited

UK USA AUSTRALIA SPAIN

5a Merse Road 17200 Chenal Parkway P.O. Box 1226 C/Albarracin 6-3D
North Moons Moat Suite #352 Surfers Paradise 11300 La Linea
Redditch, Worcestershire Little Rock, AR 72223 Queensland 4217 Cadiz
B98 9HL USA Australia España
t: +44 (0) 1527 548 000 t: +01 (501) 517 6056 t: +61 (7) 5539 0164 t: +34 (856) 125 173
f: +44 (0) 1527 591 000 f: +01 (501) 325 3477 f: +61 (7) 5570 4208 m: +34 (627) 902 606