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LIFELINE INSTALLATION MANUAL

Index
Index ....................................................................................................................................... 1
............................................................................ 2
Anchor Point FS-LDV-2001 ....................................................................................................... 3
Intermediate Point FS-LDV-2002............................................................................................... 4
Curve 90 Degree Point FS-LDV-2007 ....................................................................................... 4
Absorber FS-LDV-2005 ............................................................................................................. 5
Crimp Connection FS-LDV-2006 ............................................................................................... 6
Crimp Tuner FS-LDV-2008 ........................................................................................................ 6
Join FS-LDV-010 ....................................................................................................................... 7
Stainless steel wire rope 7x7 FS-LDV-006 ................................................................................ 7
Glider FS-LDV-2011 .................................................................................................................. 8
Identification Sign FS-LDV-007 ................................................................................................. 9
Marking .................................................................................................................................... 10
Tools ........................................................................................................................................ 11
Module II – User manual ............................................................................................................. 12
Preliminary check .................................................................................................................... 12
Attach to the cable ................................................................................................................... 13
Glider FS-LDV-2011 ................................................................................................................ 13
Warning.................................................................................................................................... 14
Prohibited use .......................................................................................................................... 14
Instructions for storage and maintenance ............................................................................... 15
Operational life of the installation............................................................................................. 15
Module III – Planning / Calculation / Installation ......................................................................... 15
Minimum free fall distances ..................................................................................................... 16
Support structure / system installation ..................................................................................... 18
Personal Protection Equipment ............................................................................................... 19
Lifeline System......................................................................................................................... 20
Installation ................................................................................................................................ 21
Installation of anchor points, intermediate points and curves .................................................. 22
Connect the absorber to the anchor point ............................................................................... 23
Connect the crimp connection to the absorber ........................................................................ 24
Connect the crimp turner to the absorber ................................................................................ 24
Stainless steel wire rope .......................................................................................................... 25
Glider ....................................................................................................................................... 26
Documentation ......................................................................................................................... 26
Inspection................................................................................................................................. 28

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LIFELINE INSTALLATION MANUAL

Presentation / Description
The FALL SAFE® S-Line Horizontal Lifeline Systems is a permanent and flexible anchoring
system developed, tested and certified according to EN795:2012-C and CEN / TS16415:2013-C

The FALL SAFE® S-Line Horizontal Lifeline Systems should only be used for personal fall
protection equipment.

Features:

 No. of users simultaneously from 1 to 4;


 Distance between anchors in single-spam from 4m to 15m;
 Distances between anchorages in multi-spam from 2m to 15m;
 Tested on 90 ° curves;
 Energy absorber installed at both points;
 Possibility of installation on different types of supports: concrete, metal beams, metal
posts, corrugated roofing, sandwich panel, stapled sheet, deck;
 Installation on the ground with a maximum inclination of up to 15º;
 Possibility of using glider or carbine in single-span.

The flexible anchor device has been tested and certified by accredited ISO 17025 laboratory
QUINTIN CERTIFICATIONS:

QUINTIN CERTIFICATIONS
1031 route de Saint Ange
38640 Varces Allières et Risset
France

General instructions
Lifeline installation manual and user manual are provided in Portuguese and English language.
The retailler / installer is responsible for providing the manuals in the language of the country in
question.

The system must be installed by a competent person or body, duly trained and certified by FALL
SAFE® with the same valid certificate proving it.

The installation must be verified / validated using the calculation software provided by FALL
SAFE® or tests.

The maximum installation inclination of the system should be 15º including the angle of attack to
the intermediate points.

A prior study of the best layout must be carried out so that the user can access the system
safely.

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The system must be installed so that, in the event of a fall, the deflection of the cable does not
allow it to hit sharp edges or other surfaces that may damage it.

The maximum loads that can be transmitted in service from the anchoring device to the
structure and the loading directions relevant to the type of fixation and structure.

Anchor Point FS-LDV-2001

Material: Stainless steel AISI 304 and square tube AISII316

Dimensions: 200X40X90mm

Weight: 2251gr.

FS-LDV-2001 is a terminal point, which must be installed at each end of the lifeline. It consists
of two points of one anchor point for the lifeline connected to two energy absorbing cubes
named "Force-Cube". The Force-Cube also increase installation height of the lifeline, the
distance between the anchor point and the below structure is 170 mm. The distance between
Force-Cubes attachment points is 165mm.
To fix to the various support structures, threaded rod / screw / auto blocking nut M12 in
stainless steel must be used.

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Intermediate Point FS-LDV-2002

Material: Stainless steel sheet AISI 304 and square tube in AISI 316

Dimensions: 80X60X82,5 mm

Weight: 1145gr.

FS-LDV-2002 is an intermediate point, which must be installed at a minimum distance of 2m


and a maximum distance of 15m from each other, as well as from end points or curves. It
consists of one energy absorbing lifeline point and one energy absorbing cube named “Force-
Cube". The Force-Cube also increase installation height of the lifeline, the distance between the
lifeline point and the below structure is 170 mm, threaded rod / screw / auto blocking nut M12 in
stainless steel must be used.

Curve 90 Degree Point FS-LDV-2007

Material: Stainless steel sheet AISI 304 and square tube in AISI 316

Dimensions: 366X366X82,2mm

Weight: 2831gr.

FS-LDV-2007 is the curve 90 and is composed by two types of elements.

FS-LDV-2003 is an element similar to the intermediate point, but with a longer tube that is
installed on top of the energy absorbing cube named "Force-Cube”, FS-LDV-2004 is the loose
tube and serves to make the cable guide and check the angle. The part is fixed to the support at
2 points.

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LIFELINE INSTALLATION MANUAL

To fix the various support structures, threaded rod / screw / auto blocking nut M12 in stainless
steel must be used.

Absorber FS-LDV-2005

Material: Stainless steel AISI 304

Dimensions: 306,4X66X40mm

Weight: 1307gr.

FS-LDV-2005 is the energy absorber and must be installed close to the 2 end points of the
lifeline. It serves to dissipate energy at the end points of the lifeline in the event of a fall as well
as system expansion in environments with high temperature fluctuations.
The FS-LSV-2005 also serves as a pre-tensioner indicator for the stainless steel cable.
For a correct adjustment of the steel cable, the spring should compress 27,5 mm which equals
a pre-tension load of 800N (aprox. 80kg). Stainless steel M12 screws / auto blocking nut must
be used for fixing to the end point.

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LIFELINE INSTALLATION MANUAL

Crimp Connection FS-LDV-2006

Material: Stainless steel AISI 316

Dimensions: 147X25mm

Weight: 220gr.

FS-LDV-2006 is the union that allows the connection between the stainless steel cable and the
terminal point. The fixation to the end point is done through an M12 screw / auto blocking nut,
the fixation to the stainless steel cable is done by crimping the tube in 5 points. This crimping
must be carried out by pliers with a force of 35kN and special die of 10 mm.

FS-LDV-2006
ORDER FOR CRIMPING

Crimp Tuner FS-LDV-2008

Material: Stainless steel AISI 316

Dimensions: 330X25mm

Weight: 541gr.

FS-LDV-2008 is the union that allows the connection between the stainless steel cable and the
end point as well as the correct tensioning of the stainless steel cable. The fixation to the end
point is done through an M12 screw / auto blocking nut and the fixation to the stainless steel
cable is done by crimping the tube in 5 points. This crimping must be carried out by pliers with a
force of 35kN and special die of 10 mm.

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Join FS-LDV-010

Material: Stainless steel AISI 316

Dimensions: 200X Ø 15mm

Weight: 173gr.

FS-LDV-010 It is a tube used to join steel cables. The fixation to the stainless steel cable is
done by crimping the tube in 12 points. This crimping must be carried out by pliers with a force
of 35kN and special die of 10 mm.

Stainless steel wire rope 7x7 FS-LDV-006

Material: Stainless steel AISI 304

Dimension: Ø 8mm

FS-LDV-006 It is a steel cable with a diameter of 8mm and construction of 7x7 and presents a
breaking strength of 37kN. The cable must be tensioned with a value of 80daN (maximum).

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Glider FS-LDV-2011

FS-LDV-2011 the continuous displacement glider allows the user to travel the entire length of
the lifeline without disconnecting from it. It allows you to easily pass through the intermediate
points and curves. Due to the movable tab, it is possible to insert the glider anywhere on the
lifeline. The carabiner in addition to connecting to the user blocks the opening and the glider
cannot be removed from the stainless steel cable without the user's intention.

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Identification Sign FS-LDV-007

A sign must be placed next to the access of each line with the indication of the manufacturer /
model, standards, maximum number of users, free fall distance, date of installation and
inspection.

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Marking

A – SERIAL NUMBER B – MODEL C – EUROPEAN STANDARDS D – DATE OF MANUFACTURE E – BRAND NAME

F – NUMBER OF USERS G –TENSION MARKING

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Tools

The following tools are needed for the installation and maintenance of the FALL SAFE® S-Line
Horizontal Lifeline Systems.

 2 pcs Spanner 19mm


 1 pcs Stainless steel tube crimping plier
 1 pcs Grinding wheel machine

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Preliminary check

Before using the FALL SAFE® S-Line Horizontal Lifeline Systems, please note the following
checks:

 The user of the lifeline must be in good physical condition, and not prone vertigo or
giddiness.

 The user must have received appropriate training to:


 Use the fall protection equipment;
 Working with the FALL SAFE® S-Line Horizontal Lifeline Systems;
 Use of the rescue equipment in the event of fall.

 A minimum of two people is required to work together on the lifeline, so that each can
assist the other in the event of an incident.

 A rescue plan must be in place to evacuate the person who fell within 15 minutes. The
rescue material must be easily accessible and be located in the vicinity from the lifeline.

 FALL SAFE® S-Line Horizontal Lifeline Systems was certified for 4 peoples in use
simultaneously, not allowing more than 4 people on the cable at the same time.

 Each user must be equipped with :


 A suitable harness with two anchoring points, one at the back and one at the
chest , in conformity with the EN 361 standard;
 The chest anchor point is the preferred point for anchoring the harness, the
dorsal anchoring point being used for rescue operations.
 A lanyard with energy absorber in conformity with EN 354, EN355 standard.

 Two karabiners screw lock in zinc plated steel, according to EN 362 and having the
following characteristics, length 110 mm, width 59 mm, opening 18 mm, breaking
strength 25 kN.

 Each person must be attached to a fall arrest subsystem that must limit fall forces to
6kN. Only use approved subsystem as lanyard with energy absorber (EN354/355)
and/or fall arrest block (EN360).

 On arrival in the work area, or whenever the user attaches to the cable, he is required to
check:
 That the manufacturer’s label is in place, and that it mentions the maximum
number of users who can connect to the lifeline simultaneously;
 That the glider, the harness and the lanyard are in good, working condition;
 That there is no obstruction under the walk way that could reduce the clearance
specified on the manufacturer’s label
 The system must be immediately put out of service if the user notes one or
more anomalies to the points indicated above.

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Checking the Fall Indicator:

 Check that the absorber has the correct tension (compressed spring at the 80
daN mark) as well as that the spring is not damaged or with any deformation. If
so, you should inform a competent person of the situation.
 Check that all "Force-Cube” is free of any deformation.
"Force-Cubs" must maintain their original cube shape, if not; you should inform
a competent person of the situation.
 If the user notices any anomalies, he must inform a competent person of the
situation before using the line.
 If the system has already been subjected to a fall, it must be taken out of
service immediately until it is inspected by a person qualified by the
manufacturer

 Check the legibility of the product markings.

Attach to the cable

The user attaches to the cable in an area where there is no risk of falling, in principle in the
vicinity of one of the two end anchors. The user must use a mobile anchor point (hereinafter
referred to glider) and the associated connector.

In FALL SAFE® S-Line Horizontal Lifeline Systems you must always use the glider FS-LDV-
2011 and a connector. In the single-span the user has the possibility of using glider karabiner
with Ref No.: FS802 in single-span.

FALL SAFE® S-Line Horizontal Lifeline Systems may be used in conjunction with a fall arrest
block, FS954 and FS956 from the FALL SAFE® range.

Glider FS-LDV-2011

To connect the glider, the user tilts the glider, opens the locking device and fits the glider over
the cable.

Once locking device is closed again under the action of the spring, the user is connected to the
glider with a karabiner delivered with the glider. An energy absorber lanyard connects the glider
to the harness.

To disconnect from the line, the user must first detach the karabiner of the glider and then open
the locking device. In the event that the user moves on both sides of the lifeline, for example in
the case of a line installed along a pitch roof, he will have to undo the glider and re-orientate it
before reconnecting to the cable whenever he needs to move from one side of the cable to the
other.

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Warning

 It is essential for safety that the device is always correctly positioned and that the work
is carried out so as to minimize the risk of fall and fall height.

 The weight of the user, including his equipment must not exceed 120 kg.

 The user will ensure that he is kept safe before detaching the glider.

 The FALL SAFE® S-Line Horizontal Lifeline Systems should not be used as a work
positioning system.

 Any repairs to the equipment can only be carried out by FALL SAFE® or by a
competent person authorized by FALL SAFE®.

 The FALL SAFE® S-Line Horizontal Lifeline Systems should be withdrawn from use
immediately if:

 Any doubt arise about its condition for safe use or;
 It have been used to arrest a fall and not used again until confirmed in writing by a
competent person that it is acceptable to do.

Prohibited use

Only one user working at height, but without the support of a second person able to provide
assistance if needed.

• More than four persons attached to the lifeline simultaneously.

• An obstacle under the walk way which reduces the clearance specified on the manufacturer’s
label

• Deposits of ice on the cable and the anchors.

• Temperatures lower than -30 °C

• It is strictly prohibited to use the lifeline outside the limits specified in this document or outside
any other situation for which it is designed.

• The length of the lanyard absorber is limited to 2 meters, except where there is a written
statement to the contrary from the manufacturer for a specific project.

• It is forbidden to use any another karabiner to attach the lanyard to the glider that provided by
FALL SAFE®. The function of safety of the glider could be affected if the karabiner used is not
the karabiner supplied by FALL SAFE®.

• It is forbidden to combined the FALL SAFE® S-Line Horizontal Lifeline Systems with
retractable fall arrest devices (EN 360) or guided fall arrest devices including a flexible anchor
cable (EN 353-2), which have not been tested together, at risk of falling.

• The FALL SAFE® S-Line Horizontal Lifeline Systems should only be used for personal fall
protection equipment and not for lifting equipment.

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Instructions for storage and maintenance

The glider must be stored in a place away from moisture.

• The FALL SAFE® S-Line Horizontal Lifeline Systems must be inspected by a qualified person
at least once a year, as well as after every fall.

• The safety of the users depends on the maintenance of the effectiveness and the resistance of
the equipment.

• Reconditioning of the line after a fall requires a re-tensioning of the cable using FALL SAFE®
tools, as well as the repositioning of the guide cables on their support brackets. This work must
be carried out by a qualified person who has received an adequate training by FALL SAFE®,
and is in the possession of the Installer manual.

• The lubrication of the cable is recommended once a year in order to facilitate the moement of
the glider. This recommendation is applicable only in an environment or installation where the
lifeline can accept oil lubrication.

• Any addition or alteration to the equipment is prohibited without written consent from FALL
SAFE®.

• If the equipment may be in contact with chemical, please contact FALL SAFE® and tell us the
exact name of the chemical concerned.

• The correct tightening of bolts and nuts should be checked.

Operational life of the installation

All the components of the lifeline are manufactured from of stainless steel according to the AISI
316 / 304, which have a great resistance to the atmospheric degradation.

• The operational life is a function of the building structure and of its capacity to maintain its
physical properties in the course of time.

• The operational life of the FALL SAFE® S-Line Horizontal Lifeline Systems is limited to 20
years.

The layout of the systems should take into account several factors such as access, location of
the installation and characteristics (e.g. inclination of the roof).

The entire surface of a roof should be considered a risk area. Areas less than 2m from
skylights, or roof limits are an area with particular risk.

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Particular attention should be paid to the layout design of the following risks:;

 Cable deflection and minimum safety distance;


 Pendulum effect;
 Sharp edges and obstacles to free fall;

Systems with a perimeter layout should be privileged due to the low dangerous area.

Minimum free fall distances

The distance available below the user's feet, in the event of a fall, determines the type of
protection required through personal protective equipment as well as the parameters of the
lifeline system, either through the length of the system, distance between anchor points or up to
the number of users allowed simultaneously.

The ideal configuration system will be designed using the calculation software.

The distance / height of the fall should be less than the distance / height available so that the
person falling does not hit an obstacle during the fall.

The height of the fall should be identified as follows:

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- The lenght of the lanyard “Li”.

- The length of the energy absorber when activated “Le”.

- The deflection of the stainless steel wire rope “d”.

- Distance from the harness anchor point to the user's feet e.g.1.5 m.

- The result of the equation below:

Ll + Le + d + 1,5 m < clearance

Ll < 2 m

Le < 0,8 m

d: according to FALL SAFE® software calculations.

The installer will write on the warning plate the maximum deflection of the wire rope in case of a
fall. FALL SAFE® provides a software for the calculation of the deflection.

To reduce cable deflection (Ɵ) and / or forces admitted at the end points, one or more
parameters must be reduced:

 L - Total line length


 S - Distances between anchor points
 Number of users simultaneously

The maximum deflection value in FALL SAFE® S-Line Horizontal Lifeline Systems is 1,74m.
lection of cable (m)

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Support structure / system installation

The certified installer should check the strength in the structure in relation to the forces
transmitted to the terminal and intermediate points. FALL SAFE®, developed a calculation
software that allows the forces in the components to be calculated according to the data
entered.

The forces calculated by the software must be less than the permitted forces. If a force greater
than the permitted force is found, it will be necessary to change one or more calculation
parameters.

Component description Allowable force Breaking strength

kN kN

Anchor Point FS-LDV-2001 20 50

Intermediate Point FS-LDV-2002 9 24

Stainless Stell wire rope 7x7 18.5 37

Glider 6 24

Table 1

In addition to the basic support in concrete or metal beam, FALL SAFE® has been developing
several types of fixings:

 Corrugated roofing sheet / sandwich panel roof


 Deck
 Stapled galvanized sheet

For each type of support is made an extension to the system installation manual.

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Personal Protection Equipment

The FALL SAFE® S-Line Horizontal Lifeline Systems should be used in conjunction with height
safety PPE in accordance with EN354, EN355, EN361 and EN362.

EN355
EN362
EN354 EN361

FS519-LN – LANYARD WITH FS802 FS242 LITE-HARNESS


ENERGY ABSORBER

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Lifeline System

System composed of:

 2 anchor points with absorber at each end.


 Crimp connection on one side
 Crimp turner on one side
 Intermediate points/curve between 2m to 15m each other (when applied)

Multi-Span with curve

FS-LDV-2011 Glider

FS-LDV-2001 Anchor point

FS-LDV-2002 Intermediate point

FS-LDV-2005 Absorber

FS-LDV-2006 Crimp connection

FS-LDV-2008 Crimp turner

FS-LDV-2007 Curve

FS-LDV-010 Join

FS-LDV-2007

FS-LDV-006 FS-LDV-2002
FS-LDV-2006
FS-LDV-2011
FS-LDV-2005
FS-LDV-2008
FS-LDV-2001 FS-LDV-2005

FS-LDV-2001

FS-LDV-2004

FS-LDV-2003 FS-LDV-2003

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Single-Span

FS-LDV-2011 Glider

FS-LDV-2001 Anchor Point

FS-LDV-2002 Intermediate Point

FS-LDV-2005 Absorber

FS-LDV-2006 Crimp connection

FS-LDV-2008 Crimp turner

FS-LDV-2007 Curve

FS-LDV-2001
FS-LDV-2005
FS-LDV-2006

FS-LDV-010
FS-LDV-2011

FS-LDV-2008
FS-LDV-006 FS-LDV-2005

FS-LDV-2001

Installation

The system must be installed by a competent person or body, duly trained and certified by FALL
SAFE®, having a valid certificate to prove it.

The manufacturer and distributor decline any responsibility in the event of incorrect use,
improper application or modifications / repairs by persons not authorized by FALL SAFE®.

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Installation of anchor points, intermediate points and curves

The competent person must ensure that the surfaces where the end points, intermediate points
and curves will be fixed support the forces transmitted by the lifeline plus a safety margin. The
calculation software developed by FALL SAFE® displays the forces according to the data
entered

It is recommended to always use auto blocking nut, screws and M12 stainless steel “parabolt”
and when applying maximum performance with chemical injection. When choosing how to
mount the anchor points, it is necessary to carefully evaluate the quality and condition of the
support compatibility with other components and the influence of external factors on the service
life (for example, proximity to the sea), climatic conditions and external temperature (-40° / +
80°C)

Mounting of the anchor and intermediate point and correct direction of Force-
Cube.

1 2

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Mounting of the curve 90 degree and correct direction of Force-Cube.

Connect the absorber to the anchor point

4 5

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Connect the crimp connection to the absorber

6 7

Connect the crimp turner to the absorber

8 9

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Stainless steel wire rope

 Pass the stainless steel wire rope at all intermediate points and curves to the crimp
connection and crimp.
 Adjust cable lenght and cut to the size.
 Finally, fix the stainless steel wire rope to the crimp turner and crimp. Tension until the
absorber spring reaches the mark.

10 11

12 13 14

15 16 17

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Glider

 To insert or remove the glider of the lifeline should be taken the Karabiner and press the
lever.
 The user must always connect to the Karabiner provided by FALL SAFE®, together
with the glider.

Documentation

The installation documentation provides certification that the installation was carried out
correctly. It also serves as a basis for periodic inspections, with essential information as the
fixings may not be visible or accessible.

After installation, the documentation must be shared with the customer and stay in the building
where the installation was carried out.

The installation documentation must contain at least the following information:

 The address and location of the installation;


 The name and address of the company that performed the installation;
 The name of the person responsible for the installation;
 Product identification (anchor manufacturer, type, model / item);
 The fixing device (manufacturer, product and eligible transverse tensile forces);
 The schematic plan of the installation, for example, the roof, and information relevant to
the user, such as the position of the anchor points (for example, relevant in the case of
snow). This schematic plan must be fixed in the building visible to everyone (for
example when accessing the roof (see figure A.1)

Installation certificates provided by the responsible installer must be signed by the installer and
contain at least the following information:

 It was installed according to the manufacturer's installation instructions;


 It was carried out according to the plan;
 It was fixed in a specific structure;
 It was fixed as specified (for example, number of screws, correct materials, correct
position / location);
 It was commissioned according to the manufacturer's information;
 It was supplied with photographic information / documentation, especially of the fixings
where it is no longer visible after the installation is completed.

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It is recommended that, when installed more than one anchoring point, they are marked with
numbers and photographed for registration in the inspections and incorporated in the schematic
plan of the installation.

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Inspection

Periodic inspection

Lifeline system must be inspected by a competent person accredited by FALL SAFE®, at least
once every 12 months or whenever a fall or damage occurs.

The following parameters must be followed:

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All tightening and connections should be checked and threaded blockers should be
placed whenever possible.

Diagram according to Annexe « A » of EN 795:2012 standard.

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