Instructions for Beam Anchors Warning! THE USER OF THIS EQUIPMENT, AND THE USER’S EMPLOYER MUST READ AND COMPLY WITH THESE INSTRUCTIONS. FURTHERMORE, THE USER AND THE USER’S EMPOLYER MUST READ AND COMPLY WITH ALL INSTRUCTIONS, LABELS WARNINGS AND MARKINGS INCLUDED WITH EACH COMPONENT OF THE FALL ARREST SYSTEM OF WHICH THIS PRODUCT IS A PART. FAILURE TO UNDERSTAND AND COMPLY WITH THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH. IF THESE INSTRUCTIONS ARE UNCLEAR TO YOU, PLEASE CONSULT A COMPETENT PERSON. SHOULD THESE INSTRUCTIONS BECOME LOST OR DAMAGED, OR SHOULD ANY LABELS, INSTRUCTIONS OR MARKINGS BECOME ILLEGIBLE, PLEASE CONTACT FALLTECH FOR REPLACEMENTS. SHOULD YOU NEED FURTHER ASSISTANCE WITH UNDERSTANDING THE PROPER EMPLOYMENT OF THIS PRODUCT, PLEASE CONTACT FALLTECH FOR ASSISTANCE: Alexander Andrew, Inc. (dba FallTech) 1306 South Alameda Street Compton, CA 90221, USA 1-800-719-4619 1-323-752-0066 www.falltech.com 1 Table of Contents Section 1: Warnings and Advisories Section 2: Fall Protection Basics – ABCD’s 2.1: Anchorage 2.2: Body wear 2.3: Connectors/Connecting devices 2.4: Deceleration devices 2.5: Fall Arrest 2.6: Fall Restraint 2.7: Work Positioning 2.8: Free-fall 2.9: Clear-fall 2.10: Swing-fall Section 3: Use and Limitations 3.1: General Guidelines 3.2: Approved applications 3.3: Restricted Applications 3.4: Specialty Applications 3.5: Installation and Use – Ratcheting/Sliding Beam Anchors 3.6: Installation and Use – Detent-Pin Beam Anchors 3.7: Installation and Use – Fixed-Position Beam Anchors 3.8: Installation and Use – Vertical Beam Anchors 3.9: Installation and Use – Beam Trolley Section 4: Product Selection Section 5: Anchorage Considerations Section 6: Employer and User Training 6.1: Special notes for the employer 6.2: User training Section 7: Fall Protection Plan 7.1: The fall protection plan 7.2: Suspension trauma 7.3: Rescue plan Section 8: Product Inspection 8.1: Issuing 8.2: Daily/Incidental use 8.3: Mandatory semi-annual inspection Section 9: Maintenance and Storage Section 10: Specifications 10.1: Mandatory disclosures 10.2: Performance specifications 10.3: Labels and markings 10.4: Standards and references 2 Product Listing This instruction manual pertains to the use and operation of the products listed below. Should you have any questions about the product that you have purchased, please contact FallTech for additional details. Ratcheting/Sliding Beam Anchors: Flange Max. Flange Model # Description Width Thickness 7411 Single-Ratcheting Beam Anchor, Stainless Steel 4” – 12” 1” 7490 Dual-Ratcheting Beam Anchor 3-1/2” – 13” 1-1/4” 7530 Dual-Ratcheting Beam Anchor 4” – 14” 1-1/4” 7531 Single-Ratcheting Beam Anchor 4” – 14” 1-1/4” Detent-Pin Beam Anchors: Flange Max. Flange Model # Description Width Thickness 7485 Detent-Pin Beam Anchor, Small 3-1/2” – 12” 1-1/8” 7486 Detent-Pin Beam Anchor, Large 3-1/2” – 18” 1-1/8” Fixed-Position Beam Anchors: Flange Max. Flange Model # Description Width Thickness 7487 Stationary Beam Anchor, Small 4” – 12” 1-1/8” 7488 Stationary Beam Anchor, Large 4” – 18” 1-1/8” 7533 Hex Bar Beam Anchor, Small 3-1/2” – 12” 1” 7534 Hex Bar Beam Anchor, Large 3-1/2” – 18” 1” 7471 J-Hook Beam Anchor 6” – 16” 1-1/2” Vertical Beam Anchors: Flange Max. Flange Model # Description Width Thickness 7489 Vertical Beam Anchor 2-1/2” – 12” 1-1/2” 7535 Hex Bar Vertical Beam Anchor 4-1/2” – 12” 2” 7536 Hex Bar Vertical Beam Anchor 10” – 24” 2” Beam Trolley: Flange Max. Flange Model # Description Width Thickness 7710 Overhead Beam Trolley 6” – 12” 1-1/2” 3 Section 1: Warnings and Advisories This product is to be used as a part of a personal fall arrest system, and should be used only with compatible components. Please see Advisory #3 in this section for further details. Failure to use compatible components can result in a failure of the system to perform as intended, which may result in serious injury or death. Throughout the OSHA regulations for safety and health, there are references to Competent Persons and Qualified Persons. ANSI Z359.0-2007 goes on to further define the roles and qualifications of these individuals; as well as Authorized Persons, and their importance in the workplace. These terms are also used in these instructions. Below is a brief description of the part these individuals play in the employment of fall protection equipment: Authorized Person - a person who is exposed to fall hazards during the course of their work. This individual requires formal training in the use of personal fall protection equipment and systems. The term Authorized Person may be used interchangeably with User and End-User. Competent Person – a trained and experienced person who is designated to supervise, implement and monitor an employer’s managed fall protection program. This individual is capable of identifying and addressing fall hazards and is authorized to make decisions and take corrective action in the workplace. Qualified Person – a person possessing a degree or professional certificate and having extensive training, knowledge and experience with fall protection and who is capable of designing and specifying fall protection equipment and systems to address fall hazards. Please read these instructions and be sure that you understand them prior to utilizing this equipment. Also be sure to read the instructions included with other components which are being utilized in your Personal Fall Arrest System (Harnesses, connectors, anchorage connectors, etc.). Failure to understand and comply with manufacturer’s instructions may result in serious injury or death. IF YOU DO NOT UNDERSTAND ANY PART OF THESE INSTRUCTIONS, PLEASE HAVE THEM EXPLAINED TO YOU BY A COMPETENT PERSON. This product is to be used as part of a complete fall arrest system in accordance with industry-recognized best-practices and your employer’s fall protection plan, as required by the Occupational 4 Safety and Health Administration. Be aware of your employer’s fall protection plan and rescue plan. Be aware of the specific fall hazards on your jobsite and work deliberately to avoid these hazards in the course of your work. Also be aware of hazards and obstructions in your fall path, and work with your employer to eliminate these hazards where possible. Failure to be aware of and to address these hazards may result in serious injury or death. Do’s and Don’ts  Do use this device only with compatible components of a comprehensive fall arrest system.  Do use this device only in a system which limits free fall distance to 6 ft or less.  Do use extreme caution when rigging this device.  Do rig this device to avoid the hazards of “swing fall” (see Section 2.9)  Do use this device only when your clearance distance is a minimum of 2 ft AFTER you have calculated the total fall distance (see section 2.10 for details on clear fall distances).  Do make compatible connections (see Advisory #3 at the end of this Section).  Do call FallTech if the device is damaged, does not pass inspection (see Section 8), or has arrested a fall.  Don’t use this component to hoist materials or equipment.  Don’t use this device if it exhibits signs of corrosion or damage from exposure to chemicals, excessive heat, flames and electrical charge or shows signs of any physical damage or deformation.  Don’t use this equipment if there are signs of excessive wear, deterioration, deformation of corrosion.  Don’t use this equipment if you are working near high voltage power lines or other energized electrical equipment.  Don’t use near moving machinery which may entangle any component of the system.  Don’t use oil to lubricate moving parts. If lubrication is needed, first be sure to clean all moving parts thoroughly; then use only 100% silicone lubricant.  Don’t use this device if it will expose some element of your Personal Fall Arrest system (PFAS) to sharp or jagged edges.  Don’t use this device if you are pregnant, a minor, or have a reduced tolerance to fall forces by reason of age, physical medical condition, or other pre-existing disorders. 5  Don’t use this device if you weigh less than 75 lbs.  Don’t use this device if your total combined weight (body, clothes, tools, etc) exceeds 425 lbs.  Don’t attempt to modify, repair or alter this device in any way.  Don’t use this equipment if it has been used to arrest a fall. If it has been used to arrest a fall, this device must immediately be removed from service and replaced. Advisory #1: Further Reading If you have access to the internet, please go to www.osha.gov. This website is an exceptional resource, and has a great deal of information which is easy to access. Use the search field to find information on fall arrest, including standards, news, interpretations and other valuable tools. The more you know about how this product works and how it is supposed to be used, the safer you will be during the course of your work. Advisory #2: Proper product selection Product selection is an important element of fall protection. Fall Arrest products are like any other tools that you may use in the course of your work – there is a proper tool for every application. You may find that while this product is suitable for some applications, it may not be suitable for others. Please be sure to pay close attention to sections 2, 3, and 4, for greater detail on this point. Advisory #3: Connector Compatibility Making compatible connections may mean the difference between life and death. Connectors (snap hooks, rebar hooks and carabiners), must be of the locking type and require two distinct actions to open the gate. Your connectors must be sized and shaped so that the rings or structural members to which they are attached will not pose a risk of forcing the gate open, and must fully captivate the connector so that it cannot become disengaged, slide or shift during use or in the event of a fall. Certain connections are forbidden and should never be attempted with this product or any other unless there is a specific allowance in the manufacturer’s instructions. Forbidden connections include, but are not limited to: 6  Two or more connectors to one d-ring are a forbidden connection.  A connection that rests on or loads the gate is a forbidden connection.  A connection that does not allow the gate to close and lock is a forbidden connection.  Two or more connectors attached to one another are a forbidden connection.  Connecting directly to webbing, rope, cable (wire rope) is a forbidden connection.  Connecting directly to a horizontal lifeline is a forbidden connection.  Tie-back with your FallTech SAL is a forbidden connection except for model # 7241, 7241Y, 8241 and 8241Y in the WrapTech series.  Connecting to any ring or structure that does not fully captivate and completely restrict the movement your connector is a forbidden connection. Section 2: ABCD’s Every Personal Fall Arrest System consists of four basic elements – Anchorage, Body-wear, Connectors/Connecting Devices and Deceleration Devices. Each of these four elements is discussed in greater detail below. If, after reading though this section, you do not fully understand these items and how they work together to form a compatible fall arrest system, please be sure to have this explained to you by a Competent Person. It is absolutely critical that you be familiar with the proper wear and/or use of each component of your Personal Fall Arrest System (PFAS). Failure to read, understand and adhere to instructional materials and warnings provided with each of these components could lead to a catastrophic failure of your PFAS, resulting in serious injury or death. 2.1: Anchorage The selection of an anchor point and anchorage connector is critical to the successful function of any Personal Fall Arrest System (PFAS). OSHA 1926.502 (d) (15) states that: “Anchorages used for attachment of personal fall arrest equipment shall be independent of any anchorage being used to support or suspend platforms and capable of supporting at least 5,000 pounds (22.2 kN) per employee attached, or shall be designed, installed, and used as follows: 7 as part of a complete personal fall arrest system which maintains a safety factor of at least two; and under the supervision of a qualified person.” Ensure that the structure to which you are attaching your anchorage connector is capable of meeting the above requirements and that your anchorage connector is installed in accordance with the manufacturer’s instructions. Also be sure to check that the anchorage connector is compatible with your connecting device (lanyard, SRL, vertical lifeline)and that it securely retains the connecting device without inhibiting its function. If you are unable to determine whether your connecting device and your anchorage are compatible, please immediately consult with a competent person or your immediate supervisor. For more details on anchorages, please see section 5 of this instruction manual. 2.2: Body-wear Body wear for any application where this Beam Anchor is to be used will be defined as a full body harness specifically manufactured for fall arrest. If being used for restraint applications where the user is restricted from reaching a fall hazard, a body belt may be used as an alternative. Be sure to read and follow the manufacturer’s instructions included with your full body harness or restraint belt at the time of purchase. 2.3: Connectors/Connecting Devices Connectors and Connecting Devices are terms that are sometimes used interchangeably. It is important to note the differences between these two terms in order to help distinguish the parts that these components play in the rigging of your PFAS. In both cases, these products/components are required to have a minimum static strength of 5,000 lbs. For additional details on requirements for connectors and connecting devices, see OSHA 1926.502 at www.osha.gov as referenced in section 1, advisory #1. A connector is any metallic, mechanical element such as a carabiner, snap hook or rebar hook that physically links one or more elements of a your PFAS together in a manner such that they will remain engaged to one another unless they are intentionally disengaged. A connecting device is an element that connects your full body harness to the anchorage in an effort to ensure that you remain attached or tethered to the structure upon which you are working. In other words, 8 the connecting device is that element which secures you to your anchorage. 2.4: Deceleration Devices A deceleration device is the element of a Personal Fall Arrest System (PFAS) which is activated during a fall event and reduces the forces exerted on the user’s body and on the anchorage during the arrest of the fall. In the case of Shock-Absorbing Lanyards and Self-Retracting Lifelines, these products are both a connecting device and a deceleration device as they will keep you attached to your anchorage and will reduce the forces on your body in the event of a fall. 2.5: Fall Arrest Fall Arrest is an area of Fall Protection which focuses on stopping a fall once it has occurred. Personal Fall Arrest Systems typically consist of an anchorage, a full body harness and a self-retracting lifeline, shock- absorbing lanyard or other deceleration device designed to bring a falling user to a stop in the shortest possible distance while limiting the force imparted to the user’s body. 2.6: Fall Restraint Fall Restraint is an area of Fall Protection devoted to restraining the user of the system in a manner which restricts his or her access to the fall hazard in a manner such that they cannot be subjected to a fall. A typical Fall Restraint System consists of an anchorage, a full body harness or a restraint belt and a restraint lanyard. A Shock-Absorbing Lanyard or a Self-Retracting Lifeline should never be utilized in a restraint application as it they not capable of restricting a user’s access to fall hazards. 2.7: Work Positioning Work Positioning is an area of Fall Protection devoted to allowing a user to work on a vertical surface by means of a positioning assembly, and restricting the user’s exposure to a fall of no more than two feet. Typical positioning assemblies consist of a large rebar hook and a length of chain, rope, wire rope or webbing with a double locking snap hook on either end. These snap hooks are attached to d-rings on the hips or on the waist of the user’s full body harness, with the rebar hook attached to the structure upon which the user is working. An SAL or an SRL should never be used for work positioning, nor should they ever be attached to a side or hip d-ring on a full body harness. However, while rigged for work positioning, the user should always have an SAL or SRL 9 attached to the back d-ring of their full body harness and tied-off to the structure on which they are positioning as a back up device. 2.8: Free-Fall Free-Fall is the distance that a worker will fall before the connecting device or deceleration device elements of the PFAS will begin to engage during a fall event. OSHA allows a maximum Free-Fall Distance of 6’ (6 feet) when rigging a Personal Fall Arrest System (PFAS). In some cases, exceptions may be allowed when there is no practical way to limit the Free-Fall Distance to 6’, such as a job-site where no overhead anchor-point is available. Tying off in a manner that would create a Free-Fall greater than 6’ should always be a last resort. If you are rigging a system that allows more than 6’ of Free-Fall, make sure your Connecting Device/Deceleration Device is rated for this application. 2.9: Clear-Fall Clear-Fall or Clear-Fall Distance is the distance that is required to safely arrest the fall of a user. When working at heights and using a PFAS, it is important to consider the distance between the walking/working level and the next lower level to ensure that the components selected are capable of arresting the user’s fall before they hit the next lower level. The required Clear-Fall Distance can easily be calculated by adding together the Free-Fall Distance, the Deceleration Distance, the height of the user plus a safety factor of 2 feet. The formula for calculating Clear-Fall Distance is shown below: Free-Fall Distance + Deceleration Distance + Height of Worker + Safety Factor = Clear-Fall Distance The matrix below can be used as a guide for calculating Clear-Fall Distance on your job-site: Example Values Actual Values Free-Fall Distance 6’ (OSHA allows up to 6’) Deceleration Distance 3.5’ (Typically 3.5’ or less) Height of Worker 6’ Safety Factor 2’ (Minimum of 2’) Total 17.5’ (Sum of all values) 10