RoofSafe™ Anchors: Designer's Guide

Brand: DBI SALA

Slogan: The Ultimate in Fall Protection

1.0 Foreword

This guide is essential reading for anyone involved in the installation or servicing of RoofSafe™ Anchors or RoofSafe™ Cable systems. The RoofSafe™ Anchor is designed to prevent or minimize the risk of injury from falls. Incorrect design, installation, or servicing, or failure to adhere to these instructions, can lead to serious consequences.

This guide details applications for each anchor type and common roof types, including recommended fixing methods. It explains the forces acting on the anchor and system, and how these forces are transferred to the roof structure. Information on anchor performance, conformity to standards, and testing conducted by Capital Safety is provided for reference to ensure correct product application.

Management must ensure that personnel tasked with installing or servicing RoofSafe™ Anchor products are trained to the standards expected by Capital Safety. This guide serves as a critical reference document for designing RoofSafe™ Anchor and RoofSafe™ Cable Systems.

2.0 General

2.1 Authorised Installers

Only competent installers certified by Capital Safety are authorized to install and service the RoofSafe™ Anchor or RoofSafe™ Cable System.

2.2 Conformity

The RoofSafe™ Anchor System is a rooftop anchorage system tested and certified according to national and international standards and codes of practice. Details are available in the standards table (Section 6.2). Altering, modifying, dismantling, or replacing components with non-Capital Safety supplied items will invalidate certification and may result in serious or fatal consequences. Non-Capital Safety components may have inferior specifications and lead to incorrect system operation.

2.3 Work Restraint & Fall Arrest

The RoofSafe™ Anchor is a complete fall protection system designed to address falls from height. While all anchors must be designed for fall arrest, restraining the user to prevent a fall is the preferred method.

Work Restraint Advantages:

Users are not subjected to the abrupt impact of a fall arrest.
Eliminates the risk of swing-fall incidents.
No rescue provision is required.
Requires less training for personnel.

For work restraint, two dimensions must be strictly controlled: the lanyard length (A) and the distance from the anchor to the fall hazard (B). A scale drawing should ensure the lanyard prevents the user from entering a fall arrest situation. This analysis should be performed at various points along the system if the fall hazard position varies.

Diagram Description (Fig 1 & Fig 2): Illustrates Work Restraint Orientation (A: Lanyard length, B: Distance to fall hazard) and Fall Arrest Orientation (A: Lanyard length, B: Distance to fall hazard), showing a worker attached to an anchor at height.

Fall Arrest: When work restraint is not feasible, a fall-arrest system is used. This system arrests a fall after it occurs by applying a braking force. RoofSafe™ Anchors and Cable systems ensure this force remains below safe levels, provided the user wears a full body harness and an energy-absorbing lanyard certified to the appropriate standard. Be aware of falls through fragile elements and from exposed edges. Appropriate rescue procedures must be in place for fall arrest situations.

IMPORTANT NOTE: While horizontal lifeline systems must be designed for Fall Arrest, designing for Work Restraint is recommended to allow users access to work areas while preventing exposure to fall hazards, thereby reducing risk and mitigating fall consequences.

2.4 Free Fall Space Calculator

Capital Safety offers a calculation tool to assess the recommended free space required below a system to ensure safe use. This tool and its usage information are available separately. The calculator is based on maximum span widths (12m) with falls occurring mid-span.

Diagram Description (Fig 3): Shows the 'Free Fall Space Calculator' interface with input fields for Lanyard Length (L), Edge Distance (E), Number of Users (U), D-Ring Height (D), and System Length (S), and output fields for Fall Potential (FP), Fall Factor (FF), Minimum Distance (MD), and Maximum End Loads (ML).

3.0 Site Assessment

3.1 Reviewing the Task

Only certified installers can install and service RoofSafe™ Anchors and Cable Systems.

Site Survey:

A site survey is crucial for assessing system type and location. Gather the following information:

Purpose of the system / Task to be performed.
Maximum number of users at any one time.
Roof specification, manufacturer, critical dimensions (seam/crown centres, insulation thickness).
Scale drawings of the structure (digital format preferred).
Exact path of the system.
Special requirements (e.g., specific brackets, historical buildings).
Installer risks for planning control measures.

Providing this information to Capital Safety's sales team will expedite technical support.

Method Statements:

A detailed, agreed-upon method statement must be written and signed by the installer and client before work commences. This protects both parties by ensuring safe working practices.

Verifying the Roof Structure:

The roof structure's strength must be verified before fitting to ensure fixings are adequate. This can be done via calculation or roofing approvals. Contact Capital Safety for specific roof testing relevant to the profile. If these methods are insufficient, a sample fixing should be installed and pull-tested to withstand minimum forces specified in the RoofSafe™ Anchor Forces Calculation Sheet.

3.2 Typical System Layout

Diagram Description (Fig 8): Illustrates a typical RoofSafe™ Anchor system layout on a roof, showing anchor placements (A-E) and the direction of fall hazard. Maximum span is indicated as 12m. KEY: A - SpiraTech™ Anchor as System end post, B - SpiraTech™ Anchor as Corner post, C - Tip Over Anchor as Intermediate post, D - SpiraTech™ Anchor as System t-joint with RA throw plate, E - SpiraTech™ Anchor as Variable post for roof hips.

3.3 Specifying Your Anchor

RoofSafe™ Anchors provide secure anchor points for workers at height, near exposed edges or fall hazards, when used with appropriate PPE (full body harness, energy-absorbing lanyard). The anchor is designed to re-orientate and deploy an energy absorber during a fall, reducing load on the user and roof. Anchors can be used for both fall arrest and work restraint. The SpiraTech™ and Tip Over Anchors are modular for quick fitting and use, allowing 360-degree movement without reorienting the lanyard. They offer full weather sealing and compatibility with various roof membranes.

The modular design allows selection of baseplate, module, and top attachment separately for flexibility across roof types.

Diagram Description (Fig 10.1, 10.2, 10.3): Shows the anchor components: Base Plate, SpiraTech™ or Tip Over Module, and Attachment Eye.

Diagram Description (Fig 11.1, 11.2): Shows assembled anchors: Assembled SpiraTech™ Anchor (for up to two users) and Assembled Tip Over Anchor (for one user).

Base Plates and Pitch Matrix

Base plates are designed with multiple fixing holes for compatibility with various roof types and pitches. Two blank base plate sizes are available for roofs without typical centres.

Diagram Description (Fig 12.1, 12.2, 12.3): Illustrates RA Baseplate sizes: 405mm x 405mm, 350mm x 440mm, and 550mm x 450mm, noting availability with holes or blank.

PITCH MATRIX
Roof Type	Pitches (mm) - Trapezoidal												Pitches (mm) - Standing Seam
Roof Type	200	250	275	300	304	333	334	347	350	367	400	500	200	300	400
RA Base Plate 405x405 Holes (7241136)	X	X	X	X	X	X	X	X	X	X	X	X	X	X	X
RA Base Plate 405x405 Blank (7241137)	X	X	X	X	X	X	X	X	X	X	X	X	X	X	X
RA Base Plate 350x440 Holes (7241138)	X	X	X	X									X	X	X
RA Base Plate 350x440 Blank (7241139)	X	X	X	X	X	X	X	X	X	X	X	X	X	X	X
RA Base Plate 550x450 Blank (7241140)	X	X	X	X	X	X	X	X	X	X	X	X	X	X	X

NOTE: This table assumes baseplates fit the centre of the trapezoidal roof sheet crown. Always check with the roof manufacturer for guidance.

Pitches for Toggle Fixing:

The RA Baseplate 405x405 H (7241136) has hole centres at 333mm and 200mm pitches, designed for suitability across many roof deck styles and pitches. Blank baseplates can be drilled for custom hole types if standard options are unsuitable. Contact Capital Safety for queries.

3.4 Roof Types and Anchors

Images in this section are for indicative purposes only.

3.4.1 Wood Deck, (Built Up)

For built-up roof types with rigid insulation and a wooden deck (minimum 18mm thickness).

Fixings: RoofSafe™ Anchor Toggle Fix 150mm x 4 (7241182), RoofSafe™ Anchor Toggle Fix 300mm x 4 (7241183).

Diagram Description (Fig 13.1): Illustrates anchor fixing on a wood deck with insulation.

3.4.2 Metal Deck, (Built Up / Composite)

For built-up or composite panel roofs with rigid insulation and a trapezoidal metal deck.

Fixings: RoofSafe™ Anchor Toggle Fix 150mm x 4 (7241182), RoofSafe™ Anchor Toggle Fix 300mm x 4 (7241183).

Diagram Description (Fig 13.2): Illustrates anchor fixing on a metal deck with insulation.

3.4.3 Solid Concrete, (Built Up)

For warm solid concrete roofs with rigid insulation.

Fixings: RoofSafe™ Anchor Concrete Fix 150mm x 4 (7241180), RoofSafe™ Anchor Concrete Fix 300mm x 4 (7241181).

Diagram Description (Fig 13.3): Illustrates anchor fixing on solid concrete with insulation.

3.4.4 Hollow Concrete, (Built Up)

For warm hollow concrete roofs with rigid insulation.

Fixings: RoofSafe™ Anchor Concrete Fix 150mm x 4 (7241180), RoofSafe™ Anchor Concrete Fix 300mm x 4 (7241181).

Diagram Description (Fig 13.4): Illustrates anchor fixing on hollow concrete with insulation.

3.4.5 Trapezoidal Insulated Panel

For pre-insulated or built-up metal roof panels.

Fixings: RoofSafe™ 7.7 Rivet (7234005).

Diagram Description (Fig 13.5): Illustrates anchor fixing on a trapezoidal insulated panel.

3.4.6 Standing Seam

For standing seam roofs (Aluminium, Steel, or Stainless Steel). Posts can be fitted to various seam profiles and roof sheet materials; see page 14 for details.

Diagram Description (Fig 13.6): Illustrates anchor fixing on a standing seam roof.

Standing Seam Roofing Systems

When specifying for standing seam roofs, consider the seam profile and required clamp type. Capital Safety offers various fixing clamps for different seam profiles. Contact Technical Services for clamp compatibility details.

Diagram Description (Fig 14): Shows examples of standing seam roof fixing clamps: Bulb Type Standing Seam (RoofSafe™ Maxi Clamp Z, 7234028), Folded Seam (RoofSafe™ Maxi Clamp E, 7234008), and Folded Seam (RoofSafe™ Maxi Clamp U, 7234029).

IMPORTANT NOTE: Avoid fitting clamps directly over halter clips, as this affects clamp and roof performance. Always consult the roofing manufacturer for guidance.

3.5 Sealing Details

Information in this section is a guide; always refer to roofing manufacturer specifications.

Diagram Description: Illustrates sealing details for various roof membranes and fixing types:

PVC Membrane: A: PVC bonded to weather shroud, B: RA weather shroud PVC, C: Baseplate, D: Toggle fixing sealed under membrane. (RA Module PVC SpiraTech™ / Tip Over)
Bitumen Membrane: A: Bitumen sealed to weather shroud, B: RA weather shroud, C: Baseplate, D: Toggle fixing sealed under bitumen. (RA Module BIT SpiraTech™ / Tip Over)
Other Membranes: A: Membrane sealed over baseplate and up to top of can, B: RA Weather Cap, C: Baseplate, D: Toggle fixing sealed under membrane, E: RA Seal Ring. (RA Module All Mem SpiraTech™ / Tip Over)
Rivet Fix and Standing Seam: A: RA Seal Ring, B: RA Can, C: Baseplate, D: Fixings with seals or clamps that do not penetrate the roof. (RA Module Top Fix SpiraTech™ / Tip Over)

3.6 Aggressive and Hazardous Environments

Corrosive Environments:

RoofSafe™ Anchors are tested in saline environments exceeding national standards. Components exposed to atmosphere are Aluminium or Stainless Steel. Aluminium parts are anodized to AA11 minimum, and 316 stainless steel parts are polished. SpiraTech™ coil and associated steel components have a Zinc inorganic coating with a minimum saline performance of 1000 hours. Aggressive environments require more frequent inspections and servicing. An appropriate inspection plan should be implemented based on environmental conditions.

Chemical Hazards:

Chemicals like acids, alkali, or caustic chemicals, especially at elevated temperatures, can damage the equipment. Consult Capital Safety if chemical hazards are present.

Electrical Hazards:

Do not install anchors where contact with electrical power lines is possible. Maintain a safe working distance from power lines. Consult local energy providers or safety services for guidance on specific applications.

3.7 Rescue Planning

Employers must make provisions for emergency planning, including rapid response to falls. Appropriate rescue equipment must be readily available and operated by trained personnel. Failure to do so can result in serious injury or death. Capital Safety offers rescue equipment and training for various scenarios.

4.0 Roof Anchor Performance

4.1 Anchorage Strength

Anchors are designed to withstand fall loads. Internal supports maintain system tension and allow annual testing. The supports break away at less than 3kN, allowing the energy-absorbing element to manage the fall force. Energy absorbers reduce loads to safe levels, keeping the anchorage attached to the structure. Anchors can withstand a minimum static load of twice the peak arrest load for 3 minutes, as per EN795.

4.2 Forces on the SpiraTech™ Anchor

Diagram Description (Fig 15.1, 15.2): Shows a horizontal load applied to the anchor connector, highlighting stress areas around the pin designed to break.

Diagram Description (Fig 16): Shows the deployed coil, illustrating stress distribution in the middle section.

SpiraTech™ Force management technology absorbs impact energy, resulting in low peak loads, as shown in traces (Fig 17a/17b). These traces depict dynamic load scenarios (EN 795 - 100kg, 2.5m; ACR - 200kg, 1.5m).

Loads are transmitted to system ends and corners; these should use SpiraTech™ anchors. Tip Over anchors are suitable for intermediate posts. A system with two SpiraTech™ anchors (Fig 18) yields a peak load of approximately 4.6kN (Fig 19). A second fall after deployment can increase the peak load to approximately 5.7kN.

4.3 Forces Tip Over Anchor

Diagram Description (Fig 20.1, 20.2): Shows a horizontal load applied to the Tip Over anchor connector, highlighting stress areas on the support strap designed to break.

Diagram Description (Fig 21): Illustrates the deformation of the wire form under a horizontal load, showing how it orients and absorbs fall energy.

The Single Point Anchor absorbs impact energy, returning a peak load of approximately 7.1kN (Fig 22).

4.4 Thermal Bridging

On insulated roofs, toggle fixings penetrating the roof (Fig 23.1) can create thermal bridges through the central bolt. RoofSafe™ anchor toggles minimize this effect by insulating the area around the bolt (Fig 23.2). Standard toggle fixings leave the area around the bolt open, allowing convection and conduction.

Diagram Description (Fig 23.1): Illustrates heat transfer through an uninsulated toggle fixing.

Diagram Description (Fig 23.2): Illustrates heat transfer through an insulated toggle fixing.

Diagram Description (Fig 24): Shows the components of a RoofSafe™ Anchor Toggle Fixing.

Testing shows uninsulated fixings cause a 7°C temperature increase at the fixing and heat the baseplate. Insulated RoofSafe™ Anchor fixings show only a 4°C localized increase at the top of the fixings.

Diagram Description (Fig 25): Thermal image showing a 7°C increase on a post with uninsulated toggle fixings and baseplate heating.

Diagram Description (Fig 26): Thermal image showing a 4°C localized increase on a RoofSafe™ Anchor post with insulated toggle fixings and limited baseplate heating.

Diagram Description (Fig 27): Thermal image showing a 15°C increase around a solid post fixed directly through insulation.

Test Conditions: Tests involved bringing components to temperature, then allowing them to equalize with the environment for comparable readings. Temperatures below insulation: 60°C; Air temperature around post: 20°C.

5.0 Annual Maintenance

5.1 Testing the Roof Anchor

Anchors can be pull tested vertically up to 5kN to verify fixing integrity, especially when posts are sealed and inaccessible. Remove components like brackets and connection eyes before testing; apply load to the top thread. Refer to technical work instructions for pull testing details.

5.2 Testing the Swages

Inspect swages on cable systems to ensure secure cable attachment. Capital Safety provides guidance on swaging methods and inspection in the RoofSafe™ Anchor installation instructions.

5.3 Cleaning the Anchor

Anchor materials are specified as naturally corrosion-resistant or coated for protection. In some environments, cleaning may be necessary for optimal lifespan. Poorly maintained systems can become unsafe or unusable. Best practices for maintenance are detailed in the User Instruction Manual.

6.0 Reference Documents

6.1 Abbreviations and Definitions

This section lists terms and their meanings used in the publication. Further standards are detailed in Section 7.2.

BS EN 795: European Standard for anchor device requirements and testing for fall protection.
BS EN 354: European Standard for lanyards for fall protection.
BS EN 355: European Standard for energy absorbers for fall protection.
BS EN 361: European Standard for full body harnesses for fall protection.
BS EN 362: European Standard for connectors for fall protection.
BS EN 363: European Standard for fall arrest systems.
BS EN 365: European Standard for instructions for use and markings for fall protection.
BS 7883: Code of Practice for 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: UK Statutory Instrument transposing 89/686/EEC into UK law.
ACR[M]002:2009 - (Part2): Testing of Roof Anchors on Roof Systems.

6.2 Standards Table

Standards Compliance
Standard Category	Standard Name	Standards Description / Synopsis	Test Data Available / Documents
European Standards	EN 795:1996	Protection against falls from a height - anchor devices - requirements and testing. Class A1: Structural anchor designs for vertical, horizontal, inclined surfaces. Class A2: Structural anchors for inclined roofs. Class C: Horizontal flexible lines (deviation ≤ 15°).	Declaration of Conformity, Test Reports for primary roof types
	ACR Advisory Committee for Roof work	ACR[M]002:2009 - (Part2) Testing of Roof Anchors on Roof Systems. Best practice guide based on technical knowledge and experience, providing benchmarks for testing and performance of horizontal safety lines.	Declaration of Conformity, Test Reports for primary roof types and specific manufacturers
	US Standards	OSHA 1926.502(d)(15)(i)	Fall protection systems criteria and practices. Appendix serves as a non-mandatory guideline for employers to comply with 1926.502(d) requirements. Test procedures described in Appendix C can assist compliance with 1926.502(e)(3) and (4).	Declaration of Conformity, Test Reports
Australian/ New Zealand Standards	AS/NZS 1891.2:2001	Industrial fall-arrest systems and devices Part 2: Horizontal lifeline and rail systems. Specifies design and performance requirements for systems and components for fall-arrest, covering rigid rails or flexible lines.	Declaration of Conformity, Test Reports

* If copies of test certificates are required, please contact Capital Safety and quote the certificate number.

6.3 Markings Explained

Anchor Sticker:

Standards to which the Anchor conforms.
Read Instruction for use.
Product Type.
Web Address.
Brand Logo.
Product Technology.

Diagram Description: Illustrates the Anchor Sticker with numbered elements and the DBI SALA logo.

System Tag:

Standards to which system conforms.
Read Instruction for use.
Web Address.
Brand Logo.
Product Family.
System information to be filled in by installer.
i-safe tag (where used).

Diagram Description: Illustrates the System Tag with numbered elements, including fields for installation date, installer, contact number, clearance, user limits, service dates, serial number, and lanyard usage instructions. Includes DBI SALA logo and web address.

Contact Information

Capital Safety is a global leader in fall protection equipment, systems, and anchors, with a presence in Europe, Middle East, Africa, and the USA.

France: Le Broc Center, Z.I. 1re Avenue – BP15, 06511 Carros Le Broc Cedex, FRANCE. T: +33 (0)4 97 10 00 10, F: +33 (0)4 93 08 79 70.

United Kingdom: 5a Merse Road, North Moons Moat, Redditch, Worcestershire B98 9HL UK. T: +44 (0) 1527 548 000, F: +44 (0) 1527 591 000.

Dubai: ME Branch Office, PO Box 17789, JAFZA, Dubai – U.A.E.

Germany: T: +49 (0)2 76 18 33 82 29.

Spain / Portugal: T: +33 (0)4 97 10 21 06.

Italy: T: +33 (0)4 97 10 21 08.

Scandinavia: T: +33 (0)4 97 10 21 01.

USA: 3833 SALA Way, Red Wing, MN 55066-5005 USA.

Email: information@capitalsafety.com

Website: www.capitalsafety.com