SAFEWAZE FS-EX5501-5 Safe Link Post Base Plate User Manual

: July 25, 2024
: SAFEWAZE

SAFEWAZE FS-EX5501-5 Safe Link Post Base Plate

Product Information

Specifications

Product: Safewaze Mobile SafeLink Horizontal Lifeline System
Manufacturer: Safewaze
Compliance: OSHA regulations for personal fall arrest systems
Address : 225 Wilshire Ave. SW, Concord, NC 28025
Contact:

Product Usage Instructions

WARNING:
This product is part of a complete personal fall arrest system. These instructions must be provided to the user of this equipment. Users must read and understand these instructions, or have the instructions explained to them, before using this equipment. Users must read and follow the manufacturer’s instructions for each component or part of the complete system. Manufacturer’s instructions must be followed for proper use and maintenance of this product. Alterations or misuse of this product or failure to follow these instructions may result in serious injury or death.

IMPORTANT:
If you have any questions on the use, care, or suitability of this equipment for your application, contact Safewaze.

Safelink System Introduction
This User Manual describes the Safewaze Mobile SafeLink Horizontal Lifeline System, which is an engineered personal fall arrest system designed to comply with all OSHA regulations. The system is crucial for workers at elevated work positions where fall hazards exist. This User Manual describes the Safewaze Mobile SafeLink Horizontal Lifeline System, an engineered personal fall arrest system. When erected, used and maintained as described in this manual, the SafeLink System complies with all OSHA regulations pertaining to personal fall arrest systems and can save the at-risk worker’s life in the event of a fall from an elevated work position. The SafeLink System is the result of a decade of development. It addresses the difficulties and limitations of working at leading edges at the top surface of buildings under construction, and other applications where workers are required to work horizontally and a fall hazard exists. At such locations, there are few usable anchorage points and those that exist may have severely limited strength.

THE INSTRUCTIONS FOR ERECTION, USE AND MAINTENANCE PRESENTED IN THIS MANUAL MUST BE FOLLOWED PRECISELY. MISUSE OR FAILURE TO FOLLOW WARNINGS AND INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

Subsequent sections of this manual describe and specify the components that comprise a properly installed SafeLink System. What may, on the surface, appear to be minor modifications to the SafeLink System can lead to unexpected, significant and potentially disastrous changes in the behavior of the SafeLink System. For example, using stronger or stiffer components than specified may cause the system to generate higher forces to the anchorage points, causing the anchorage points to be overloaded. Special field circumstances may require custom designs or components. However, any custom design must be analyzed and authorized by a “qualified person,” as identified by a safety engineer, before that custom SafeLink System may be erected. State-of-the-art fall protection technology and the Safewaze Mobile SafeLink Horizontal Lifeline System are still evolving. Safewaze is proud of its role as a leader in developing fall protection technology and is pleased to provide the most effective and practical system available for the safety of workers. As new equipment becomes available, as experience teaches new lessons, and as new approaches are conceived, Safewaze will periodically upgrade the SafeLink System and update this User Manual.

SAFELINK SYSTEM DESCRIPTION

The graphics above provide an overall view of the Safewaze Mobile SafeLink Horizontal Lifeline System being used during the deck forming operation. The typical SafeLink System uses an overhead horizontal lifeline connected to a Stoplink Brake supported by aluminum posts, cross-arm straps and other approved anchorages covered in this manual. The user wears a full-body harness, and is attached to the overhead horizontal lifeline with a Self- Retracting Lifeline (SRL). Self-locking connectors must be used for all attachments of the user to the horizontal lifeline. This User Manual specifies the components to be used and describes permissible variations to the SafeLink System.

It should be noted that the horizontal lifeline is positioned overhead, which provides certain advantages, including:

The horizontal lifeline should not constitute an obstruction to the worker;
If an employee should fall, it is less likely that the fall would pull another co-worker off of the elevated work surface;
The total fall distance is minimized by providing an overhead horizontal lifeline.

THE HORIZONTAL LIFELINE SHOULD NEVER BE POSITIONED BELOW THE ELEVATION OF THE DORSAL D-RING ON THE BACK OF THE FULL-BODY HARNESS.

SAFELINK SYSTEM OVERVIEW AND CONNECTIONS

A complete Mobile SafeLink fall protection system consists of the following components: Anchorage, Body Support, and Connecting Devices. A list of component options is detailed on pages 7-9 of this manual. There are a number of different configurations that can make up a complete SafeLink System. Typically, the SafeLink System will be setup as a dual-point anchorage system, and the lifeline assembly portion of the system will be made up of the same components for most applications: The Come-A-Long, SafetyLink Strap, Cable, Fist-Grip Cable Clamps, Carabiners, Stoplink Brake, and Shoulder Eye-Bolts, as shown in Fig. A below. The most common anchorage option is outlined in Fig.

A below: A PVC sleeve is inserted into pre-poured concrete, into which aluminum posts are inserted, once the concrete has set. Figures B-G detail other anchorage configuration options. See pages 7-12 for detailed component descriptions and installation instructions.

Fig. A. Typical Configuration for SafeLink Horizontal Lifeline System
PVC Sleeve is inserted into pre-poured concrete, and aluminum posts are inserted into PVC sleeve, steel sleeve, or SafeLink Post Baseplates

USER INSTRUCTIONS AND LIMITATIONS

SYSTEM OBJECTIVE
The Safewaze Mobile SafeLink Horizontal Lifeline System is a pre-engineered temporary horizontal lifeline system, designed as part of a complete personal fall arrest system, to limit the total fall distance and arresting forces in the event of a fall.

IMPORTANT—USER MUST READ AND UNDERSTAND THESE INSTRUCTIONS.
Keep these User Instructions on site for reference.

INSTRUCTIONS FOR USE

Failure to follow all instructions and limitations on the use of the Mobile SafeLink Horizontal Lifeline System may result in serious personal injury or death.
Before using a personal fall arrest system, employees shall be trained in accordance with the requirements of OSHA 1910.66 in the safe use of the system and its components.
Personal fall arrest systems, including the Mobile SafeLink Horizontal Lifeline System, shall be inspected prior to each use for wear, damage, and other deterioration and defective components, which must be immediately removed from service, in accordance with the requirements of OSHA 1910.66 and 1926.502.
The complete fall protection system must be planned before using (including all components, and the calculation of fall clearance and swing fall).
Users must have a rescue plan, and the means at hand to implement it, that provides for the prompt rescue of employees in the event of a fall, or assures that employees are able to rescue themselves.
Store the SafeLink System in a cool, dry, clean environment, out of direct sunlight, when not in use.
In the event a fall occurs on the SafeLink System, the system must be removed from service

USE LIMITATIONS

The Safewaze Mobile SafeLink Horizontal Lifeline System is designed for up to four (4) users at one time, per system, with a capacity (including clothing, tools, etc..) up to 310 lbs (140.61 kg) per user.
The Mobile SafeLink System is designed to be used in temperatures between -40ºF and +130ºF (-40°C to +54°C).
Do not expose the Safewaze Mobile SafeLink Horizontal Lifeline System to chemicals or harsh solutions which may have a harmful effect. Contact Safewaze Technical Service with any questions.
Only ANSI certified full-body harnesses may beused with the Mobile SafeLink System. Additionally, Safewaze offers a line of fixed Dorsal D-ring harnesses that allow for a 4” reduction in fall clearances.
In accordance with the requirements of OSHA 29 CFR 1910.66 and 1926.502, the Safewaze Mobile SafeLink System must be installed and used under the supervision of a “qualified person” as defined by OSHA 1926.32(m).
Caution must be taken when using the Safewaze Mobile SafeLink Horizontal Lifeline near moving machinery, electrical hazards, sharp edges, or abrasive surfaces. Contact with these elements may cause equipment failure, personal injury, or death.
Minors, pregnant women and anyone with a history of back or neck problems should not use this equipment.
Do not use or install equipment without proper training from a “competent person” as defined by OSHA 29 CFR 1926.32(f).
Only Safewaze, or persons or entities authorized in writing by Safewaze, shall make repairs or alterations to the equipment.
For custom applications of the Safewaze Mobile SafeLink Horizontal Lifeline System not addressed in these User Instructions, please contact Safewaze Technical Service.

PRIOR TO USE
Prior to using the Mobile SafeLink Horizontal Lifeline System, a rescue plan must be in place if the user cannot rescue themselves. Users of the Mobile SafeLink Horizontal Lifeline System must read and understand these User Instructions, as well as the User Instructions for every component and/or subsystem of the personal fall arrest system.

The entire Mobile SafeLink Horizontal Lifeline System and its subsystems must be inspected prior to each use.

Check the Stoplink Brake in the lifeline system to ensure that no more than 6 in (152.4 mm) of web extends outside the housing. All snap hooks and carabiners must be able to self-close, lock and meet all ANSI standards.
Check the operation of Self-Retracting Lifelines (SRLs) by pulling smoothly on the device, then pull sharply on the device to engage the locking mechanism.
All webbing must be inspected for tears, cuts, fraying, abrasion, discoloration, or other signs of wear and damage. Sewn terminations should be secure, complete, and not visibly damaged.
Cable must be inspected for kinks, broken strands, corrosion, abrasion, or other signs of wear and damage. Terminal ends should be secure with the thimble tight and not visibly damaged. System must be properly tensioned.
If the Come-A-Long is used, the SafetyLink Adjustable Safety Strap must be used and taut.
Damaged and other deteriorated and/or defective components must be immediately removed from service, in accordance with the requirements of OSHA 29 CFR 1910.66 and 1926.502.

ANCHORAGE REQUIREMENTS
All anchorages to which the Safewaze Mobile SafeLink Horizontal Lifeline System attaches must meet the requirements of OSHA 29 CFR, and 1910.66

In accordance with OSHA standards:
The Mobile SafeLink Horizontal Lifeline System has been designed as part of a complete personal fall arrest system, which maintains a safety factor of at least 2:1 and must be installed and used as outlined by the qualified person (Safewaze) according to the Mobile SafeLink Horizontal Lifeline System User Manual. The Mobile SafeLink Horizontal Lifeline System incorporates the Safewaze Stoplink Brake as an in-line energy absorber. Anchorages to which the system is attached must be rated to a minimum of 5,000 lbs. (2,268 kg.), unless otherwise specified. End anchor points MUST remain dedicated to the system. The anchor points cannot be used to consecutively connect multiple systems together.

ANCHORAGE CONNECTORS
Anchorage connectors are components that couple the personal fall arrest system to the anchorage. The end anchorage connectors are designed to resist and transfer at least two (2) times the maximum arrest load to the end anchorage.

CONNECTION REQUIREMENTS
All connecting subsystems must only be coupled to compatible connectors. OSHA 29 CFR 1926.502 prohibits snap hooks from being engaged to certain objects unless two (2) requirements are met: 1) it must be a locking type snap hook, and 2) it must be “designed for” making such a connection. “Designed for” means that the manufacturer of the snap hook specifically designed the snap hook to be used to connect to the equipment in question.

The following connections must be avoided, as they can lead to rollout when a locking snap hook is used:

Directly connecting a snap hook to the horizontal lifeline
Two (2) (or more) snap hooks connected to one (1) D-ring
Two (2) snap hooks connected to each other
A snap hook connected back on its integral lanyard
A snap hook connected to a web loop or web lanyard
Improper dimensions of the D-ring, rebar or other connection points in relation to the snap hook dimensions that would allow the snap hook keeper to be depressed by a turning motion of the snap hook

System Components
The SafeLink System comprises specific components that must be installed correctly. Any modifications to the system can lead to dangerous consequences, so it is essential to follow the manufacturer’s instructions precisely.

COMPATIBILITY LIMITATIONS
All components and subsystems used with the Mobile SafeLink Horizontal Lifeline System have been tested as part of a pre-engineered flexible horizontal lifeline system. Only ANSI compliant Full Body Harnesses, Anchorages, and SRLs can be used with the system.

SYSTEM COMPONENTS
A complete Mobile SafeLink fall protection system consists of the following components: Anchorage, Body Support, and Connecting Devices.

Anchorage
An anchorage, as defined by OSHA 1926.502(d) (15), shall be independent of any anchorage being used to support or suspend platforms and capable of supporting at least 5,000 lbs (2267.97 kg) per employee attached, or shall be designed, installed, and used as follows: as part of a complete personal fall arrest system which maintains a safety factor of at least two (2); and under the supervision of a “qualified person.”

Body Support
Body support is the component of a personal fall protection system that is worn on or around the body. Per OSHA 1926.502, effective January 1, 1998, body belts are not acceptable as part of a personal fall arrest system. Full-body harnesses must be used for all fall arrest systems. The fall clearance charts provided were established using measurements from Safewaze full-body harnesses.

Connecting Devices
A connecting method is the link between the body support and anchorage. Connecting methods will vary depending on the application. The SafeLink System can be used with ANY Class A, Class B, or Class 1 SRL.

A. Aluminum Post (FS-EX5501-5):
The 6061-T6511 Aluminum Posts are 7-1/2 ft (2.29 m) with a 3-1/2 in (88.9 mm) outside diameter and a 1/2 in (12.7 mm) wall thickness. Each post has two (2) sets of 9/16 in (14.29 mm) holes set 4 in (101.60 mm) apart and at 90º for the FS-EX2508 eye-bolts (not included).
B. Eye-Bolt and Nut (FS-EX2508):
The zinc-plated eye-bolts used to connect the horizontal lifeline cable to the aluminum post(s) are 1/2 in (12.7 mm) diameter by 4.5 in (114.3 mm) long drop- forged steel eye-bolts with shoulders.
C. Fist-Grip Cable Clamp (019-8050):
The fist-grip cable clamps attach to 5/16 in (7.94 mm) cable and provide a strength equal to no less than 80% of the cable itself.
D. PVC Sleeve (FS-EX2504):
The PVC sleeve is 12 in (304.80 mm) in length with a 4 in (101.6 mm) inside diameter, and constructed of Schedule 40 PVC. PVC sleeve must be cast at a min. depth of 11 in (279.4 mm), and no closer than 3-1/2 in (88.9 mm) to any concrete edge, into 2,000 PSI (13.79 MPa) or greater concrete.
E. Shackles (019-8037):
The shackles are forged and rated to have a safe working load of at least 750 lbs (340.19 kg). Screw pin or bolt-type shackles are permitted to connect components of the lifeline system together. “Safety type” shackles, which use a bolt and a cotter pin, are the only type permitted to connect an SRL to the Lifeline System.
F. 10,000-lb (4535.92 kg) Rated Anchorage (Concrete):
The 10,000 lb (4535.92 kg) rating is in any direction up to 90º when placed in concrete with a compressive strength of 3,000 PSI (20.7 MPa).
G. Reinforced Cross-Arm Strap (FS88811-HW-10):
Constructed with 1-3/4 in (44.45 mm) polyester webbing and a 3 in (76.2 mm) nylon abrasion padding, the 10 ft (3.05 m)Cross-Arm Strap is designed to choke around reinforced concrete structures to create an anchorage point.
H. Whizzler (FS-EX2514):
The Whizzler is an aluminum cap with D-ring that swivels 360º. The cap is placed over the FS-EX5501-5 Aluminum Post and is used for single-point anchorage applications only.
I. RebarLink (FS-EX2507):
The RebarLink bracket is designed with 6061-T6511 aluminum and clamps to twelve (12) # 9 or larger stirruped rebar. The RebarLink consist of two (2) separate brackets attached with threaded rebar and wing nuts. The front bracket with eye-bolt is centered at the appropriate height on the face of the stirruped rebar and attaches to the back bracket via insertion of the threaded rods. Wing nuts are then hand-tightened and a minimum of twelve (12) #9 rebar must be captured by the bracket.
J. EZLink Double Connector (FS-EX2502-DBL):
The EZLink is attached directly to the column rebar cage without the need for decking alterations. Unit clamps directly to six (6) # 9 rebar or larger. Aluminum post is placed into the attached sleeve.
K. FormLink (FS-EX2502):
Constructed with 6061- T6511 aluminum the FormLink can be used in three (3) different applications.

1. It can be clamped around rebar—a minimum of six (6) # 7 stirruped rebar or larger with two (2) 30 in (762 mm) threaded bars. The FormLink has a sleeve that accepts the 7-1/2 ft (2.29 m) long FS-EX5501-5 Aluminum Posts.
2. The FormLink can be clamped around a finished column. A 1-1/2 in (38.1 mm) block is used to support the sleeve with post during activation.
3. The FormLink can be mounted on a finished wall as indicated. The finished wall must be a minimum of 8 in (203.2 mm) thick with internal steel rebar reinforcement. Again, a 1-1/2 in (38.1 mm) block is used to support the sleeve during activation.

L. Bolt On SafeLink Post Baseplate (019-8034):
Post Baseplate for use with the FS-EX5501-5 SafeLink Aluminum Post. Can be mounted to concrete or steel.
- Concrete:
  (4) 1/2” diameter Anchor Rods with Epoxy (HILTI HIT-Z or similar) 6-1/2” length at a minimum of 4-1/2” embedment in 7 in. thick concrete, or (4) 1/2” diameter screw style Concrete Mechanical Anchors or 5/8’’ wedge style Concrete Bolts (021-4053 & 021- 4073, or similar) 5” length with a minimum of 4-1/4” embedment in 7 in. thick concrete. Cast into 3,000 PSI (20.69 MPa) or greater concrete.
M. Weld On SafeLink Post Baseplate (019-8035):
Post Baseplate for use with the FS-EX5501-5 SafeLink Aluminum Post. Designed for Weld On applications.
- Steel:
  (4) 1/2” diameter Grade 8 Bolts with locking hardware such as Nyloc Nuts and Flat washers. Steel (Welded Installation): Must be installed by an American Welding Society (AWS) certified welder in accordance with all applicable welding regulations
N. Come-A-Long (FS-EX2510):
The Come-A-Long is constructed of zinc plated steel with 12 ft (3.66 m) of 7/32 in (5.56 mm) Aircraft cable to adjust tension in the Mobile SafeLink Horizontal Lifeline System. The Come- A-Long must always be used in conjunction with the SafetyLink Adjustable Safety Strap.
O. SafeLink Snatch Block w/Shackle (FS-EX320):
The SafeLink Snatch Block w/Shackle is constructed of powder coated tensile steel with a minimum breaking load of 5,000 lbs. The SafeLink Snatch Block w/Shackle is utilized when tensioning the system with a customer provided cable puller.
P. SafetyLink (FS-EX2505):
The SafetyLink Adjustable Safety Strap is constructed of 1 in (25.4 mm) polyester webbing and is adjustable from 3 ft (0.91 m) to 6 ft (1.83 m). An ANSI standard approved snap hook on each end is used to connect it to the system.
Q. Turnbuckle (019-8036):
The Jaw and Jaw 5/8 in (15.88 mm) turnbuckle is constructed of forged galvanized steel and adjusts from 18 in (457.2 mm) to 28 in (711.2 mm).
R. 42 in. Stanchion (019-8038 / 019-8046):
Safewaze 42” Stanchions are designed for SafeLink Installation on I-beams from 4” to 18” (019-8038) and 4” to 24” (019-8046).
NOTE: Refer to Fall Clearance Table on Page 15 if SafeLink System is Installed utilizing 42 in. Stanchions.
S. Stoplink Brake V2 (019-8044):
TheStoplink Brake is an in-line energy absorber. The Stoplink brake includes a built-in tension indicator, which displays whether or not the Mobile SafeLink system has been properly tensioned.
T. Cable (FS-EX2500-GA):
The cable in the Mobile SafeLink Horizontal Lifeline System is 5/16 in (7.94 mm) 7 x 19 galvanized aircraft cable. A minimum of two (2) cable fist-grips are used to secure the ends of the cable. U. Snap hooks and Carabiners (FS1015): used with the Mobile SafeLink Horizontal Lifeline System, marked with the ANSI Z359.12-2009 standard, are self-locking with a minimal tensile breaking strength of 5,000 lbs (2267.96 kg) and a 3,600-lb (1632.93 kg) gate rating. Snap hooks and carabiners marked to the ANSI Z359.12-1999 standard incorporate self-locking snap hooks and carabiners with minimal tensile breaking strength of 5,000 lbs (2267.96 kg), and minimum gate rating of 220 lbs (99.79 kg) and a minimum side-load gate rating of 350 lbs (158.76 kg).
V. Retractable (SRL):
The SafeLink System is compatible with any Class A, Class B, or Class 1 Self Retracting Lifeline. SRL testing is conducted as prescribed by ANSI Z359.14- 2014 (Class A and B), and ANSI Z359.14-2021 (Class 1). Device performance and environmental factors may affect the performance of different classifications of SRLs. A Competent Person must determine if any adjustments in Fall Clearances are required based on all jobsite equipment, conditions, and potential hazards.
W. Steel Sleeve (023-8089):
An alternative to FS-EX2504 for seismic regions. The sleeve is 12’’ (304.8 mm) in length with a 4’’ (102 mm) outer diameter. The sleeve must be cast at a min. depth of 11’’ (279.4 mm), and no closer than 3-1/2’’ (88.9 mm) to any concrete edge, into 2,000 PSI (13.79 MPa) or greater concrete.

INSTALLATION—ANCHORAGE CONNECTORS

DO NOT USE A PVC/STEEL SLEEVE THAT DOES NOT MEET ALL OF THESE REQUIREMENTS.

Installation of PVC/Steel Sleeve for Aluminum Post
Cast PVC or Steel Sleeve into freshly poured concrete of 2,000 PSI (13.8 MPa), or greater. Use duct tape to seal the ends of the sleeve, preventing fresh concrete from filling the sleeve. The sleeve must not be cast into concrete within 3-1/2 in (88.9 mm) of any concrete edge. When stirrups exist in the column within 2-1/2 in (63.5 mm) of the top surface, the minimum column size must be no less than 12 in (304.8 mm) in either direction. When no stirrups exist, the minimum column size must be no less than 17 in (431.8 mm). Sleeves should be plumb and must be cast to a minimum depth of 11 in (279.4 mm). Ensure the sleeves do not floatupwards in the concrete before it sets. To help keep sleeves from floating, punch a small air hole through the duct tape on the bottom of the sleeve, and use a vertical 2×4 in the sleeve, nailed to the top of the form. This method will also help ensure the sleeve stays plumb. A sleeve should normally be placed at the center of the column section. This will minimize the tendency to split the column. When sleeves are placed at the center of the column section, and when columnties exist in the concrete within 2-1/2 in (63.5 mm) of the top surface (thereby crossing the potential fracture surface), the minimum column size permitted is 12 in (304.8 mm) measured perpendicular to the direction of the span of the lifeline system. When there are no such ties, the minimum column dimension measured perpendicular to the span of the lifeline system is 17 in (431.8 mm). Sleeves should never be placed closer than 3-1/2 in (88.9 mm) to any edge of the column cross-section. When possible, request that a column tie be located approximately 2 in (50.88 mm) below the top surface of the column pour (Only one tie shown in Fig.1 for clarity). The aluminum post is 7 ft-6 in (2.29 m) long. With a 12 in (304.8 mm) embedded sleeve to support the post, the height of the horizontal lifeline is approximately 6 ft-6 in (1.98 m) above the poured height of the column. At this height, the average employee should pass easily under the cable and conveniently reach it to attach a self-retracting device. It is easier and safer to assemble as much of the SafeLink System as possible before raising the assembly to the elevated location. Generally, the horizontal lifeline can be attached to the posts before inserting the posts into the column tops. Final tension of the horizontal lifeline, however, must always be completed with the posts set into the sleeves.

Reinforced Cross-Arm Strap
To secure the Cross-Arm Strap, wrap the strap around the concrete column at a height of at least 6 ft-6 in (1.98 m) above the walking / working surface using a choker hitch. This is done by passing one end of the strap through the other end and cinching. Attach the Stoplink Brake by use of a carabiner. Secure the other end of the lifeline to column by tensioning the line as required. 10,000 lb (4535.92 kg) Removable Concrete Anchor The Removable Concrete Anchor is a reusable concrete anchor designed to be used with horizontal lifelines. This device is made for use with concrete columns or walls with a compressive strength of 3,000 PSI (20.7 MPa). The 10,000-lb (4535.92 kg) rating is in any direction up to 90º when placed in concrete. Install the anchor in accordance with user instructions. Attach Stoplink Brake by use of carabiner to Concrete Anchor eyelet.

RebarLink
The RebarLink Bracket is to be installed 6-1/2 ft (1.98 m) above the working surface. With the eye-bolt facing outward, place the bracket face perpendicular to the front of the rebar, centered on the cage. Slide the supplied cinching rebar bolts through both plates and tighten together with supplied wing nuts so that the Rebar Link is tightened onto the rebar cage (See Fig. 2).

NOTE: When using the RebarLink, Aluminum Posts are not used.

FormLink
The FormLink Bracket must be attached to the base of a rebar cage. Receiver sleeve must face the direction of tension in the system. To attach the FormLink Bracket to the base of the rebar cage, place the front and back bracket at the top of the concrete base. Slide the threaded bars through the holes on the front bracket into the slots of the back bracket. The front and back panels of the FormLink Bracket must capture a minimum of twelve (12) #9 or larger rebar, two (2) with the front panel and two (2) with the back panel, with the threaded bars. Hand-tighten all four (4) wing nuts, then add an additional 1/2 in (12.7 mm) turn to secure.

INSTALLATION—ALUMINUM POSTS

Insert Aluminum Post
Each Aluminum Post has two (2) sets of 9/16 in (14.29 mm) holes set 4 in (101.6 mm) apart and at 90º for the eye-bolts. Install eye-bolts into the Aluminum Post. Insert aluminum post into PVC Sleeve, or applicable receiver sleeve on the anchorage connector. Concrete must have a cured compressed strength of 2,000 PSI (13.8 MPa) for system use. Aluminum post must be inserted into PVC sleeve.

INSTALLATION-STOPLINK BRAKE W/TENSION INDICATOR

Stoplink BRAKE Connect the Stoplink Brake
to the anchorage connector at one end of the system using the supplied carabiner. The end of the system with the Stoplink Brake is the live end of the system. The dead end of the system is the end with the Come-A-Long tensioning device.

ATTACH COME-A-LONG or TURNBUCKLE
Install the adjustable end of either the Come-A-Long or Turnbuckle directly to the anchorage connector.

ATTACH CABLE
Attach the live end of the cable to the cable eye on the Stoplink Brake using an approved carabiner. Pass the cable through the carabiner attached to the Stoplink Brake and form an eye using two fist-grip cable clamps. Use a torque wrench to tighten fist-grip evenly, alternating from one nut to the other until reaching 30 ft lbs (4.15 kg-force) of torque. Take the other end of the cable and pass it through the eye of the Come-A-Long or Turnbuckle. Again, form an eye using two fist-grip cable clamps.Once complete, count the number of threads from the end of the nut on the fist-grip clamps. Installers should always tighten clamps to a numbered thread count; this will eliminate the need for torque wrenches. Spot-check periodically to ensure compliance. Per OSHA 1926.251, 5 in (127 mm) of rope is turned back and the first clip is applied one base width from the dead end of the rope. The second clip is applied as near the eye loop as possible.

TENSION THE SYSTEM
Initial tension in the horizontal lifeline can be created using either the Come-A-Long or a Turnbuckle.

Tensioning with the Come-A-Long:
With the Come-A-Long connected as per the steps in the previous section, engage the drive lever by pushing the black plastic-covered spring (on the handle) rearward and pivoting the handle back and forth. To release tension, disengage the drive lever by pushing the spring forward. Pivot the handle forward until the stop lever is contacted. Continue to apply pressure against the stop lever until it releases and allow the handle to pivotbackward. Repeat this procedure to release the load a notch at a time.

Tensioning with a Turnbuckle:
With the turnbuckle connected per ‘Attach Cable’ section, the tension can be adjusted by rotating the frame, which causes both eye bolts to be screwed in or out simultaneously. Reading the Built-In Load Indicator The load indicator protruding from the top of the Stoplink brake Tension Indicator will show 3 labels to indicate the amount of tension in the system: green, yellow and red. For spans less than 60 ft, stop tensioning once the green label is showing. For spans more than 60 ft, stop tensioning once both the green and yellow labels are visible.

DO NOT TENSION BEYOND YELLOW LEVEL IF THE RED INDICATOR IS VISIBLE, REDUCE TENSION ON SYSTEM.

SafetyLink Adjustable Safety Strap
With an approved carabiner, attach the SafetyLink Adjustable Safety Strap directly to the anchorage connector eye-bolt that is connected to the Come- A-Long. Attach the other end of the SafetyLink Adjustable Safety Strap directly to the cable lifeline, adjust it so that it is taut.

Note: The SafetyLink Adjustable Safety Strap is only required when the Come-A-Long is left in line with the system.

Installation Configuration Examples

INSTALLATION SINGLE-POINT ANCHORAGE APPLICATIONS

Single-Point Anchorage:
The Whizzler (FS-EX2514) is a device that fits over top of the FS-EX5501-5 Aluminum Post providing a connection for Single Point Anchorage. The Whizzler and Post are suitable for use with any Safewaze Aluminum Post Base. The Whizzler allows workers 360° of work activity.

Follow these steps when using the Whizzler:

Place the Whizzler over top of post
Attach the Stoplink Brake (if required) to swivel on the Whizzler using an ANSI Z359.12 compliant carabiner
Attach SRL to the Stoplink Brake using the carabiner supplied with the SRL

A. Use of the Whizzler and Post as a single-point anchorage does not allow for installation at the edge or corner of the deck (See Figure SA 1). Use as a single-point anchorage requires installation to be 12 in minimum distance from any corner or edge of the decking.
B. Figure SA 2 illustrates an appropriate application when the stanchion is set back from the edge. Table 1 gives the safe working height which varies with distances “D” and “B” as indicated in Figure SA 2. An “Interior” application is one that has stringers extending out from the leading edge at a spacing along the leading edge not to exceed 6 ft (1.83 m). (Figure SA 2 shows an “Exterior” application with no stringers.)
C. The distances indicated in Table 1 assume the SafeLink System is at least 78 in (1.98 m) above work surfaces. Lower installation heights require greater safe working heights.
D. Use care to ensure the Lifeline of the SRL does not wrap around the aluminum post or other obstruction. Web SRLs are authorized for use with the Whizzler and Post. If using a Web SRL, ensure there is no possibility lifeline can make contact with any edge.

Whizzler Applications and the Stoplink Brake:
While the Whizzler and Post can be used with any of our Aluminum Post Bases, there are specific instances where the StopLink Brake must be installed and used with the Whizzler and Post. If the Whizzler and Post are installed with the FS-EX2504 (Precast Sleeve), 023-8089 (Steel Sleeve), 019- 8034/8035 (SafeLink Post Baseplate), or the 022-8076/77 (Safe- Link I-Beam Post Baseplate), use of the StopLink Brake is not required (See Figure SA 3 and Fig. 4). However, if installed with the FS-EX2502 (FormLink) or FS-EX2502-DBL (EZLink DBL Connector), use of the 019-8004 (StopLink Brake) is required (See Figure SA 4 and Fig. 5).

NOTE: S afewaze recommends use of Cable SRLs with the Whizzler. If a web SRL is used, it must be ensured that the web lifeline cannot make contact with any edge.

NOTE: Always work as close to the anchor point as possible to minimize swing fall hazards.

Table 1. SAFE WORKING HEIGHTS. Based on D=Distance of anchorage point from edge of plywood and B=Measuring maximum drift of worker along edge for interior and exterior edges

NOTE: An “interior edge” is defined as one which is NOT at the perimeter of the structure, and which has stringers projecting out from the edge at a maximum spacing of 6 ft (1.83 m).

NOTE: Any Class A, Class B, or Class 1 SRL can be used with the SafeLink System.

WARNING: Installation of any Fall Protection System must be inspected and approved by a Qualified Person or Qualified Engineer! The Qualified Person or Qualified Engineer must also supervise and monitor use of the system.

SUBDUED EDGE GAUGE

Safewaze is a firm believer in 100% compliance when it comes to job site safety. We also understand that on occasion, products used in the field may not meet the rigid requirements of today’s voluntary standards but remain safe for use in specific applications. In order to provide clarification in the field as to what edges are are considered “subdued” Safewaze includes the Subdued Edge Gauge. This tool allows users to determine if a contact edge falls within the parameters of allowable use with a standard cable SRL when connected to the SafeLink System.

Anchor or attach the Self Retracting Lifeline at least 3’ (.91 m) above the working surface or edge. (See Fig.7) WARNING: While there are instances where a cable SRL attached to the SafeLink System can be used in a Subdued Edge environment, this DOES NOT make them Leading Edge capable units. If you are unable to comply with the instructions provided for this system or if your working edge exceeds the allowable parameters, please adjust your system by using one of our other Leading Edge compliant devices.
Remove the Sub-Edge Gauge from the StopLink Brake via the small ring connector and rotate the Gauge out of the protective pocket. (See Fig. 8) NOTE: The Sub-Edge Gauge comes pre-intalled onto the StopLink Brake. However, the Gauge can be attached to the user’s SRL if more conducive to work operations. The Gauge will not interfere with the operation or function of the SRL.
The Sub-Edge Gauge, SRL, and SafeLink System are intended for use as part of a complete personal fall protection system. Use in any other application including, but not limited to, material handling, recreational or sprots related activities, or other activities not described in the User Instructions, is not approved by Safewaze and could result in serious injury or death. This system is only to be used by trained users in workplace applications.
Review the user instructions and the measurement parameters marked on the side of the gauge. (See Fig.9)
WARNING: The Sub-Edge Gauge is designed for measurement of wood edges only! If the edge in question is composed of any other material, an LE certified SRL must be used! SRLs used with the Subdued Edge Gauge must be cable units. Web SRLs are not authorized!
Firmly place the Sub-Edge Gauge on the edge requiring inspection. Any edge measuring out at 1.0 mm or greater is acceptable. If an edge has a smaller radius than the allowed 1.0 mm, the Sub-Edge Gauge will not properly fit. In any cases where the radius is smaller than the allowable amount, this system must not be used. (See Fig.10) For use on WOOD EDGES ONLY! Misuse of this system could result in serious injury or death. These instructions must be provided to the user of this equipment. WARNING: For proper operation, installation, maintenance and servicing, refer to these User Instructions including all manufacturer recommendations, see your supervisor, or contact Safewaze. Minimize swing falls by working as directly below the anchorage point as possible.
Hazards: Use of this equipment in areas where surrounding hazards exist may require additional precautions to reduce the possibility of injury to the user or damage to equipment. Hazards may include, but are not limited to: high heat, caustic chemicals, corrosive environments, high voltage power lines, explosive or toxic gases, moving machinery, or overhead materials that may fall and contact the user or fall arrest system. Avoid working where your lifeline may cross or tangle with that of another worker. Avoid working where an object may fall and strike the lifeline; resulting in loss of balance or damage to the lifeline. Do not allow the lifeline to pass under arms or between legs.

SAFELINK—CLEARANCE REQUIREMENTS

Using Retractable Devices – Clearance Chart
Table 2 indicates the required clearance from the walking/working surface to the ground or nearest obstruction below, when using a Class A/B/1 SRL (Does not include LE or Class 2 SRLs).

*Distance from walking/working surface. Clearances are calculated using only the SafeLink Horizontal Lifeline System, fully assembled per the User Manual.

NOTE: D-ring extenders are not suitable for use with the SafeLink System

SAFELINK — CLEARANCE REQUIREMENTS

**WHEN INSTALLED USING 42 INCH STANCHIONS***

Using Retractable Devices – Clearance Chart (When Installed with 42 inch Stanchions)
Table 3 indicates the required distance needed from the walking/working surface to the ground or nearest obstruction below, when using specified Safewaze retractable devices. Intermediate anchorage connectors may be used to reduce span length and required clearance distances.

Distance from walking/working surface. Clearances are calculated using only the SafeLink Horizontal Lifeline System, fully assembled per the User Manual.
Installation/use of the SafeLink System with the 42 in Stanchions allows a maximum of 2 Users.

NOTE: If 12 in (304.8 mm) D-Ring Extender is used, an additional distance of 12 in (304.8 mm) must be added to the above clearance height requirements. DO NOT attach fixed-length lanyard equipment to this system.

SAFELINK—MAXIMUM SPAN LENGTHS

SafeLink System Installed with Rigid Anchor Points
If rigid anchor points are used for installation of the

SafeLink System, the following stipulations are required:

Anchor installation height must be 6’6” (or greater) above the walking/working surface.
Maximum span allowance when using rigid anchor points:
- 1-2 Users – 65’ Maximum
- 3-4 Users – 45’ Maximum
With 3-4 Users, the use of rigid anchor points on spans greater than 45’ (up to a maximum of 65’) is conditionally accepted provided the following:
- A 2nd inline energy absorber is required (Safewaze Coil 019-8028 is recommended)
- 10,000 lb anchor point is required
- 4’ must be added to fall clearance calculations indicated in Table 2 on Page 15 of this manual.

SafeLink System Maximum Span Lengths
Table 5 indicates the Maximum Allowable Span Lengths when the SafeLink System is installed with the FS-EX5501-5 Aluminum Posts and Bases (including inermediate anchorage point(s))

NOTE: Number of users indicates the maximum number individuals connected to the system at one time

SafeLink System Maximum Span Lengths
Table 6 indicates the Maximum Allowable Span Lengths when the SafeLink System is installed with the FS5501-5 Aluminum Posts and Bases (including inermediate anchorage point(s)), and a 2nd Inline Energy Absorber.

NOTE: Number of users indicates the maximum number individuals connected to the system at one time

SafeLink System with 2 Energy Absorbers Fall Clearance Chart
In the event that the SafeLink System is installed with 2 Inline Energy Absorbers, the Fall Clearance requirements increase. Table 7 indicates the increased minimum required Fall Clearance for spans greater than 45 ft., where 3-4 users are anticipated on the system. *Distance from walking/working surface. Clearances are calculated using only the SafeLink Horizontal Lifeline System, fully assembled per the User Manual.

NOTE: If 12 in (304.8 mm) D-Ring Extender is used, an additional distance of 12 in (304.8 mm) must be added to the above clearance height requirements. DO NOT attach fixed-length lanyard equipment to this system.

INSTALLATION—MULTIPLE SPANS

Multiple Span Systems :
A Multiple Span System is a Mobile SafeLink Horizontal Lifeline System that includes the use of an intermediate anchorage connector. Intermediate anchorage connectors must be used for total system lengths over 65 ft (19.81 m). For span lengths greater than 65 ft (19.81 m), intermediate anchorage connectors may be added to help reduce the required clearance, by decreasing the length of the span.

Intermediate Anchorage

SAFELINK / LEADING EDGE SRL FALL CLEARANCE CHART

SafeLink System use with a Leading Edge SRLs
Leading Edge (LE) SRLs are authorized for use with the SafeLink System. If LE SRLs are used with the SafeLink System, minimum Fall Clearance distances are indicated in Table 8. *Distance from walking/working surface. Clearances are calculated using only the SafeLink Horizontal Lifeline System, fully assembled per the User Manual.

NOTE: If using an LE SRL, D-ring extenders of any type ARE NOT permitted
NOTE: Safewaze LE SRLs were used in determining Fall Clearance calculations

TYPE II INTERMEDIATE ANCHORAGE / SWING FALL

Type II Intermediate Anchorage Posts for Beam Conditions
When Mobile SafeLink Horizontal Lifeline System spans exceed 65 ft (19.81 m), or when a span needs to be reduced to accommodate low clear-story height work, the use of an intermediate anchorage post should be considered. Temporary intermediate anchorage posts are only permitted for use in beam soffit conditions and the system limits the number of users to one (1) as outlined: NOTE: If using standard FS-EX5501-5 posts as intermediate anchorages, i.e., embedded in concrete, the number of users can be up to four (4) per system. Intermediate anchorage connectors may be added to a system to help reduce the required clearance by decreasing the length of the flexible horizontal lifeline span. The Type II Intermediate Anchor Post requires its base installation to be secured to the soffit with four (4) 3/8in (9.55 mm) x 1-1/2 in (38.1 mm) lag bolts with at least two(2) of these lags into the runner beneath. Only one (1) employee may be tied off to the system at one time. Refer to Table 2 on Page 15 of this manual for fall clearance values for a single user.

Type II Intermediate Anchorage Post (FS-EX2517
FOR BEAM USE ONLY and is defined as a walking/working surface, not more than 4 ft (1.22 m) wide.

Swing Fall Conditions
Swing falls are dangerous and must be avoided. Swing falls occur when the anchorage point is not directly above the point where a fall occurs. The force of striking an object while swinging (horizontal speed of the user due to the pendulum effect) may cause serious injury. In a swing fall with an SRL, the total vertical fall distance will be greater than if the user had fallen when directly below the anchorage point. The user must therefore account for an increase in the total free fall distance. SRL’s provide greater horizontal and vertical mobility than lanyards, increasing the opportunity for swing falls. Minimize swing falls by working as close to directly below the anchorage point as possible. To reduce the possibility of a swing fall, work

directly under the lifeline. Striking objects horizontally, due to the pendulum affect, may cause serious injury. When working on beam soffits, swing falls may be controlled by using anchorage connectors that move with the worker to a point overhead. When working on deck soffits, swing falls are controlled by keeping the anchorage connectors behind the worker and by limiting how deck centering (e.g., stringers, runners and plywood membrane) are installed. Whenever possible, consider installing stringers and runners from the floor below by use of “push-up sticks,” scissor lifts or mobile scaffolds.

CONNECTING TO THE SYSTEM

Number of Users
The Mobile SafeLink Horizontal Lifeline System is designed for up to four (4) users at one time, with a capacity (including clothing, tools, etc.) up to 310 lbs (140.6 kg) per user along the entire system, NOT PER SPAN. Installation/use of the system with the Safewaze 42 in Stanchions allows for a maximum of 2 users.

Full-Body Harnesses
Only full-body harnesses may be used with the Mobile SafeLink Horizontal Lifeline System Attach the housing connector of the self-retracting device to the cable of the Mobile SafeLink Horizontal Lifeline System. The opposing end is connected to the Dorsal D-ring of the full-body harness.

NEVER ATTACH AN ADDITIONAL ENERGY-ABSORBING LANYARD OR SELF-RETRACTING LIFELINE TO LENGTHEN THE LIFELINE. NEVER USE COMBINATIONS OF COMPONENTS OR SUBSYSTEMS THAT MAY AFFECT OR INTERFERE WITH THE SAFE FUNCTION OF ANY OTHER COMPONENT(S) OR SUBSYSTEM(S).

Self-Retracting Lifeline (SRLs) & Dual-Leg SRLs Only use SRLs that meet the requirements as specified in ANSI Z359.14-2014. Attach a dual-leg SRL directly to the Dorsal D-ring of the full-body harness. Attach one leg of the dual-leg SRL to the cable using a metal O-ring or approved carabiner of the Mobile SafeLink Horizontal Lifeline System. Attach the unused leg to the lanyard storage keeper on the full-body harness. When using the dual-leg SRL to move between aluminum post supports (spans), attach one leg to the next span before disconnecting the previous leg. Connection of both legs while transitioning between spans is acceptable and recommended.

NEVER ATTACH ONE LEG OVER THE CABLE AND CONNECT THE SNAP HOOK BACK TO THAT LEG. NEVER ATTACH AN UNUSED LEG OF THE DUAL-LEG SRL BACK TO THE HARNESS AT ANY LOCATION OTHER THAN THE LANYARD STORAGE KEEPER.

MAINTENANCE, SERVICE and STORAGE

The Mobile SafeLink Horizontal Lifeline System requires no scheduled maintenance, other than repair or replacement of items found defective during inspection. The Stoplink Brake must be serviced when subject to an in-service arrested load.

TRAINING
It is the responsibility of all users of this equipment to understand these instructions, and to be trained in the correct installation, use, and maintenance of this equipment. All users must be aware of the consequences of improper installation or use of this equipment. This User Manual is not a substitute for a comprehensive training program. Training must be provided on a periodic basis to ensure proficiency of the users.

FIELD INSPECTION
All components of the Mobile SafeLink Horizontal Lifeline System shall be inspected before each use and annually by a “competent person”, as required by the OSHA standards. If inspection reveals any defect, inadequate maintenance, or unsafe condition, remove from service immediately until a “qualified person” can determine the need for authorized repair or disposal.

At least once each day before using the system, each user should complete a brief inspection that consists of the following points (as a minimum):

All components and subsystems of the Mobile SafeLink Horizontal Lifeline System must be inspected. Any equipment that has been subjected to the forces of arresting a fall must be removed from service.
Any equipment that has a deployed fall indicator must be removed from service. All markings must be legible and attached to the product.
Check the Stoplink Brake to ensure that no more than 6 in (152.4 mm) of webbing extends from the housing.
Cable must be inspected for kinks, broken strands, corrosion, abrasion, or other signs of wear and damage.
All snap hooks and carabiners must be able to self-close and lock. All hardware shall be free of cracks, sharp edges, deformation, corrosion, or any evidence of defect.
Inspect all components of the body harness for excessive wear and for damaged or worn buckles and rings before putting it on. Check the fit after you put it on and verify all buckles are properly secured. Tests have shown that with the severe impact incurred during a fall, it is possible for the worker to slip out of a poorly fitting or loosely worn full body harness. It is good practice to use the buddy system to check that the harness straps are correctly positioned on your back.
Check that the SRL and full body harness meet all specifications. Test the SRL by giving the line a quick pull. The SRL should lock firmly when pulled with a quick snap. The line should self-retract when released. There should be no knots in the line.
Check that aluminum posts are properly seated and secured in sleeves.
Ensure the horizontal lifeline is attached to proper anchorages at or above the height of the users Dorsal D-ring.

OSHA does not have a specific regulation when it comes to annual lifeline inspections. They only have a general duty clause stating a company should follow manufacturer’s instructions, which may include a yearly inspection requirement. This means that OSHA would not fine companies or individuals for a lack of annual lifeline systems inspections. On the other hand, OSHA does have very strict requirements that all fall protection equipment must be inspected for visible wear or damage prior to each use.

ANSI, however, does provide a detailed requirement for annual lifeline inspections that is found in code Z359.2 – “Minimum Requirements For A Comprehensive Managed Fall Protection Program.” Section 5.5.2.2 states that, “Fall protection and fall rescue equipment shall be inspected on a regular basis not to exceed one year (or more frequently if required by manufacturer’s instructions) by a competent person or competent rescuer, as appropriate, to verify that the equipment is safe for use. The inspection shall be documented.”

The following, as outlined by ANSI guideline 5.5.2.3, is a list of items that should be looked for during annual lifeline inspections:

Absence or illegibility of markings or tags
Absence of any elements affecting the equipment form, fit and function
Evidence of defects in, or damage to, hardware elements, including cracks, sharp edges, deformation, corrosion, chemical attack, excessive heating, alteration or excessive wear
Alteration, absence of parts or evidence of defects in, damage to, or improper function of mechanical devices and connectors
Any other condition that calls to question the suitability of the equipment for its intended purpose

ANSI also recommends keeping written or electronic records of annual lifeline inspections on file for the service life of the equipment.

LABELING

INSPECTION TABLE
Product lifetime is indefinite as long as it passes pre-use and Competent Person inspections. User must inspect prior to each use. Competent Person other than the user must complete formal inspection at least annually.

Competent person to inspect and initial table below:

Date| Inspection

Items Noted

| Corrective

Action

| Initials
---|---|---|---
| | |
| | |
| | |
| | |
| | |
| | |
| | |
| | |
| | |
| | |
| | |
| | |

Erection, Use, and Maintenance
Follow the instructions provided in this manual precisely for the proper erection, use, and maintenance of the SafeLink System. Failure to do so may result in serious personal injury or death. Custom designs or components should be analyzed and authorized by a qualified person before installation.

Warnings:
Alterations or misuse of the product can lead to severe injury or death. Users must read and understand all instructions before using the equipment.

HORIZONTAL LIFELINE SYSTEM
Safewaze | 225 Wilshire Ave, Concord, NC 28025
Copyright Safewaze 2023 V3

FAQ

Q: What should I do if I have questions about the equipment?
A: Contact Safewaze for any queries regarding the use, care, or suitability of the equipment for your application.