information to builders -english - ultra-safe-belay. · pdf fileassembling the usbasic cable...

ultra-safe-belay.com USBasic USBasic Information Notice to Ropes Course Builders (English)

Assembling the USBasic Cable Holder Set Revision 04 dd 29/05/2012.

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USBASIC INFORMATION NOTICE TO ROPES COURSE BUILDERS(English) Revision 100306/V03 ASSEMBLING THE CABLE HOLDER SET Art.Nr.: -Part Number:V081221/CHSet

#1.GENERAL REMARKS: 1.The USBasic Belay Series of Ultra-Safe-Belay.com is a flexible clone between a Continuous Belay System(CBS) and the Self Belay System (with two Carabiners) specifically designed for high adventure courses (ropes courses, aerial treks, via ferrata etc). The system differs from flexible anchor lines according to EN 795 class C in the sense that the system consists of independent or continuous cable sections between anchor points, thereby allowing one user per cable section and one user per USBasic Connector. Another difference is that the USBasic Belay Series is designed to withstand repeated falls without deformation. The USBasic Belay Series conforms to EN795B (mobile anchor standard) and EN-15567-1 (Ropes courses - safety requirements and test methods). 2.The design force of the USBasic Belay Series is 30 KN. When allowing for a sag-to-span ratio of 12.07%, this results in a maximum force on a cable section of 6 KN, which also conforms to EN-15567-1. 3.The USBasic Belay Series series can be installed in trees, on poles, steel beams, rocks or buildings. The installation is only permitted by installers licensed by Constuction Van de Walle, the manufacturer, who have been trained to follow this installation manual, and take into consideration the strength of the supporting structure(s).



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4.The USBasic Connector shall only be connected at the beginning of the safety cable by a trained ropes course instructor, as defined in EN-15567-2 (article 3.1) 5.The USBasic Connector can only be disconnected by participants at pre-determined points where the participant’s safety is not dependent on the safety cable. #2. ASSEMBLING THE CABLE HOLDER SET Art.Nr.: -Part Nr.:V081221/CHSet

#2.1. Manufacturer’s warnings and limitations of use concerning the USBasic Cable Holder

Set Part Nr.:V081221/CHSet

The USBasic Cable Holder Set should only be used in combination with USBasic Connector. It is the ropes course instructor’s duty to ensure that participant’s are correctly attached to the safety system. When installed on a ropes course, the ropes course operator and instructors should adhere to the provisions laid out in EN15567-2“operation requirements”. No alterations or additions should be made to the USBasic Cable Holder Set without the prior written consent of the manufacturer. It is essential for the safety of the user that, should the product be re-sold outside the original country of destination, the reseller shall provide instructions for use, for maintenance, for periodic examination and for repair in the language of the country in which the product is to be used. The Ropes Course Builder will remain bound to the instruction hereafter. Jammed Nuts on the Cable Holder V05 or tightening with an incorrect torque will void all warranty. The Ropes Course Builder should conduct record keeping of the installation meticulously as per instruction hereafter. The absence of decent records will void all warranty.



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#2.2.Scope of delivery

#2.2.1. Quick Reference on the Name of the Parts: Figure 01

Figure 02



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#2.2.2 Induvidual Description of the Parts #2.2.2.1 The Skirt (only delivered in the EU on woodworm concern) Skip this item when building Pole Courses. On ordering the Cable Holder set, you will be asked the diameter of the tree in particular. This enables us to adapt the format of the wooden skirt. The skirt consists of pickled planed pine beams, held in place by two plastic ropes. Between each pine beam there are stainless steel spacers. The skirt covers the trunk of the tree at least 75%. The function of the skirt is to convert the point load of the Anchor Cable to a uniform load, thus giving a tree maximum breathing space. Figure 03

#2.2.2.2. The Anchor Tube On ordering the Cable Holder set, you will be asked the diameter of the tree in particular and the corner between the incoming and outgoing lifeline. This enables us to adapt the format of the Anchor Tube. The function of the Anchor Tube is to form a spacer between both Cable Holders.



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#2.2.2.3. The Handrail Tube On ordering the Cable Holder set, you will be asked the diameter of the tree in particular and the corner between the incoming and outgoing lifeline. This enables us to adapt the format of the Handrail tube. The function of the Handrail Tube is both providing the participant a handgrip and enabling the USBasic Connector to travel safely from one Cable Holder to the next Cable Holder. #2.2.2.4 The USBasic Cable Holder V05 This part is the centerpiece of the USBasic Continuous Belay System. Upon delivery it is partly pre-assembled with the Cable Clamps, Long Cable Clamps, Hexagon Nuts and Hexagon Domed Cap Nuts. The Domed Cap Nuts can be made in S/S or plastic. Figure 04



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#2.3.Assembly of the USBasic Cable Holder Set Part Nr.:V081221/CHSet

#2.3.1.Unpacking, checking quantities, next assembly Upon receipt of your package, you should unpack and check the quantities of the shipment. An unbalance between the invoice and the content of the shipment should be notified within one week. When you unpack, ship to the construction site, store on the construction site, utmost care should be taken to protect the threads of the clamps and the nuts. Since all clamps and nuts are in stainless steel moisture cannot harm. However exposure to dirt can harm stainless steel threads much faster than the same threads in steel. So work dirt free. In case a thread is dirty, a soft stainless steel brush or compressed air to blow the dirt away will be sufficient. NEVER ASSEMBLE DIRTY THREADS; DIRT WILL CAUSE FRICTION OF THE THREADS IMMEDIATELY. Before shipping to the construction site an assembly of the Handrail Tube and the Cable Holders V05 should be absolved. Take one Handrail Tube and two pre-assembled Cable Holders V05. None of the Nuts are tensioned. Disassemble all the Cap Nuts and store them in a closed box. Disassemble the Tension Nuts of the Long Cable Clamps.



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Figure 05

Assemble the Cable Holders V05 and the Handrail Tube by means of the Long Clamps shown in the following figure and secure with the tension Nuts by hand.



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Figure 06

Now you are ready to ship to the construction site. #2.3.2. Mandatory Type of Safety Cables In case Construction Van de Walle supplies your safety cables, you can skip this item. In case you supply yourself the safety cables, this item is very important. The USBasic Continuous Belay System is certified by TÜV Süd Tec Sport using stainless steel cables of 10mm; composition 7 x 19; material quality AISI 316. NO OTHER CABLE TYPE IS CERTIFIED. Using all other types of cable will result in a different holding force in assembly with the Cable Holder V05. However, when you supply us, free of charge, 3 meters or 10’ of the cable you intend to use, we will conduct a test to determine the holding force of the Cable Holder V05 with your type of Cable. This additional test will be conducted free of charge to you.



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#2.3.3. Assembly of the Skirt on the trunk. In case you work on poles, you can skip this item. On ordering the Cable Holder set, you will be asked the diameter of the tree in particular and the corner between the incoming and outgoing lifeline. This enables us to prefabricate for each anchor point the trunk protection skirt. Look for a parallel part of trunk to apply the protection skirt to. Keep in mind that the USBasic Continuous Belay System has its lifeline on eye level. Apply the skirt to the trunk and tighten the plastic rope with double knots in such a way that the protection skirt is holding on the trunk. The knots should be on the back side of the anchor point for esthetical reasons. Figure 07

#2.3.3. Cutting of Stainless Steel Cables Few Ropes Course Builders have a Rope Cutter & most Builders use an angular disk grinder to cut the stainless steel cables. A couple of precautions should be taken in cutting with a disk grinder. The grinding wheel shall be a thin cutting disk of 1.3 mm specially built for cutting stainless steel. The Cable will be gripped in a bench screw.



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Figure 08

Figure 09



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Figure 10

Figure 11



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#2.3.4. Assembly of Anchor Cable Before tensioning a Safety Cable or Lifeline the Anchor Cable for the Cable Holder Set should be mounted on the USBasic Trunk Protection Skirt. On Poles this Skirt is skipped. To start you should determine the length necessary for the Anchor Cable. The necessary length is calculated by the formula:L = 4.5 x D x Pi In which: L=necessary length Pi=3.14 D=diameter of the tree Cut the Anchor Cable to its length by using a disk grinder as per #2.3.3. Chamfer and deburr the cable ends. Fix the middle of the cable with a couple of staple nails at the back of the tree or pole as in fig 12. Knotting the Anchor Cable or not? In the U.K. and the U.S.A. knotting the Anchor Cable into a Clove Hitch is a common accepted practice. However certain European Notified Bodies to obtain EN 15567-2 may object this for an unknown reason. So please check with your surveyor before installing. When the surveyor objects knots use three parallel slings around the tree. Why we prefer the Clove Hitch can be found on our website. Turn the Cable into a Clove Hitch as in fig 17 around the tree and fix the knot with two cable clamps at the back of the tree or pole as in fig 12. Take care that position of both these cable clamps really at the back of your anchor point, well behind line AA’ of figure 18. Use only clamps according to EN14311-5. Both extremes of the Cable should have at least 0.6m or 2’ free as in fig 13 & 15. Make a loop with both extremes with two cable camps as in figure 13. Tension the Anchor Cable with a mechanical or hydraulic Jack to max 400 lbs or 200kg as in fig 14. Avoid tensioning too hard, remember that the life juice of the tree flows straight under the bark of the tree. Open and close both cable clamps at the back of the tree. This will fix the tension of the anchor cable. Disassemble the loop. Assemble the Cable Holder Set & Anchor Tube as in fig 15. Both extremes of the Anchor Cable are connected with 8 Cable Clamps according to EN15567-1 and EN14311-5 as in fig 16. Notice the distance between the Cable Clamps should be at least 35mm.



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Tension all cable clamp nuts to the torque prescription of the supplier. EN14311-5 prescribes a torque of 9Nm. Figure 12



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Figure 13

Figure 14



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Figure 15

Figure 16



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Figure 17



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Figure 18

#2.3.5. Assembly of Safety Cable on the Cable Holder Depending on the means (wire rope pulling hoist or “tirfor”) you use to tension the safety cable the cable will be cut to a suiting overlength. The extreme of the Safety Cable will be deburred and chamfered. Unscrew the cable clamps to their largest position without losing the nuts. The on delivery supplied cap nuts were already temporarily remover while unpacking and pre-assembly see #2.3.1. Unpacking, checking quantities, next assembly Guide the safety cable through the clamps. Supposing the Safety Cable is already tensioned in the Cable Holder V05 at a previous anchor point you can start tensioning the safety cable with the rope pulling hoist after the guided through Cable Holder V05 . Once you have reached the tension you want, you can start tensioning the Cable Clamps of the Cable Holder V05. The Nuts of the Cable Holders will be tensioned by means of a USBasic torque wrench.



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IMPORTANT NOTICE: Incorrect tightening to the requested torque, or tightening in an incorrect sequence will result in a decreased holding force of the Cable Holder. This is dangerous. The end clamping torque for the Cable Clamps in the Cable Holder V05 is 16Nm. Only a USBasic supplied torque wrench should be used. VERY IMPORTANT NOTICE: The Sequence for the tension nuts of the Cable Clamps is: 1)tension all nuts with the torque wrench until the bent inside of the Cable Clamps reach the diameter of the safety Cable without exciting a force. 2)tension each clamp with 90° of both tension nuts of each clamp in alphabetical order A->B-> C->D->E->F as seen in Figure 20. 3)After tensioning the tension nuts 90° for the first time, you will restart this sequence in the same order until you reach 16Nm for each tension Nut. 4)Remember that reaching 16Nm for a particular tension Nut doesn’t guarantee this tension will remain while tensioning. The Cable Holding force of the assembly is only guaranteed when all tension Nuts have the tensioning Torque of 16Nm. 5)Mount the Cap Nuts on the extremes of the Cable Clamps with a moderate force (16Nm is not mandatory while the Cap Nuts only serve an esthetical purpose)



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Figure 20



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#2.3.6 Assembling a Ropes Course Entry/Exit Point with the Cable Holder V05 A simplification to the USBasic Cable Holder Set is the Assembly of a Single Cable Holder V05 as an Entry/Exit point of the Ropes Course in figure 21. All the assembly instructions of #2. remain valid. Figure 21

#3. RECORD KEEPING OF THE ASSEMBLY OF THE USBASIC CABLE HOLDER

SET Art.Nr.: -Part Nr.:V081221/CHSet #3.1. The mandatory content of the records: A record should be kept for each FIXED ANCHOR POINT CONTAINING A CABLE HOLDER SET. The lack of proper record keeping will void all warranty. Proper Records contain the following information:



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ULTRA-SAFE-BELAY.COM/USBasic Cable Holder Set Manufacturer: Constuction Van de Walle J. Parijslaan 30 B 9940 Evergem Belgium Tel +(32)(0)92535858 Fax +(32)(0)92537172 Year of manufacture Purchase date Date first put into use PERIODIC EXAMINATION AND REPAIR HISTORY Anchor Point Name or Number Date Reason for entry Defects noted Repairs carried out Torque of the Cable Clamps Other relevant information Name and signature of competent person Periodic examination Next due date Name and address of supplier: ULTRA-SAFE-BELAY.COM Constuction Van de Walle J. Parijslaan 30 9940 Evergem Belgium Notified Body Number 0123 TÜV SÜD Product Service GmbH TEC SPORT Ridlerstr. 65 D-80339 München Germany



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A competent person is a person designated as such by the manufacturer. Any repairs should be carried out at the manufacturer’s premises. #3.2. When should you make an entry in the records? -on initial installation. -4 weeks after commissioning the ropes course. -after every 2.500 participants passing the anchor point. -regular annual inspections by a competent person designed by Constuction Van de Walle. -after every irregularity which might affect the anchor point #4. BASIC MAINTENANCE OF THE USBASIC CABLE HOLDER SET Part

Nr.:V081221/CHSet The USBasic Connector does require particular maintenance operation: #4.1. Check of the torque on the tension nuts of the Cable Holder V05 After experiencing multiple falls the torque of the tension nuts may decrease. #4.1.1. When to check? -on initial installation. -4 weeks after commissioning the ropes course. -regular annual inspections by a competent person designed by Constuction Van de Walle. -after every irregularity which might affect the anchor point #4.1.2. How to retension? -disassemble the Cap Nuts -Tension the tension Nuts with a USBasic torque wrench to 16Nm following the sequence of figure 20. -assemble the Cap Nuts #4.2. Visual Checks to detect metal fatigue After experiencing multiple falls a visual detection for metal fatigue is necessary. #4.2.1. When to check? -on initial installation. -4 weeks after commissioning the ropes course. -regular annual inspections by a competent person designed by Constuction Van de Walle.



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-after every irregularity which might affect the anchor point #4.2.2. What to check in particular?

#5. MANUFACTURING GUARANTEE FOR THE USBASIC CABLE HOLDER SET: The USBasic Cable Holder Set is guaranteed for one year against all flaws in manufacturing. This guarantee does not cover fair wear and tear, alterations or modifications, improper storage, damage caused by an accident, or improper usage.



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#6.ANNUAL INSPECTION OF THE USBASIC CONTINUOUS BELAY SERIES: The inspection and maintenance of the USBasic continuous belay series should be undertaken by a ULTRA-SAFE-BELAY.COM licensed installer, at least once a year. However, a checklist is provided for the operator for regular inspection. In case of doubt on any of these items on the checklist, please contact a ULTRA-SAFE-BELAY.COM licensed installer The yearly inspection will contain: ANCHOR POINTS: • General impression • Welds • Threaded rods, bolt connections, nut tension • Bending or cracking of parts • Position of anchor points in respect to connecting elements and cable CABLE: • General impression • Corrosion • Broken wire or strands • Kinks • Flattening of the cable • Cable tension



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USBASIC INFORMATION NOTICE TO ROPES COURSE BUILDERS(English) Table of Contents: #1.GENERAL REMARKS page 1

#2. ASSEMBLING THE CABLE HOLDER SET Part Nr.:V081221/CHSet page 2

#2.1. Manufacturer’s warnings and limitations of use concerning the page 2

USBasic Cable Holder Set Part Nr.:V081221/CHSet

#2.2.Scope of delivery page3

#2.2.1. Quick Reference on the Name of the Parts: #2.2.2 Individual Description of the Parts #2.2.2.1 The Skirt (only delivered in the EU on woodworm concern) #2.2.2.2. The Anchor Tube #2.2.2.3. The Handrail Tube #2.2.2.4 The USBasic Cable Holder V05 #2.3.Assembly of the USBasic Cable Holder Set Part Nr.:V081221/CHSet page 6

#2.3.1.Unpacking, checking quantities, next assembly #2.3.2. Mandatory Type of Safety Cables #2.3.3. Cutting of Stainless Steel Cables #2.3.4. Assembly of Anchor Cable #2.3.5. Assembly of Safety Cable on the Cable Holder #2.3.6 Assembling a Ropes Course Entry/Exit Point with the Cable Holder V05 #3. RECORD KEEPING OF THE ASSEMBLY OF THE USBASIC CABLE page 20

HOLDER SET Part Nr.:V081221/CHSet #3.1. The mandatory content of the records: #3.2. When should you make an entry in the records?



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#4. BASIC MAINTENANCE OF THE USBASIC CABLE HOLDER Page 22

SET Part Nr.:V081221/CHSet #4.1. Check of the torque on the tension nuts of the Cable Holder V05

#4.1.1. When to check? #4.1.2. How to retension? #4.2. Visual Checks to detect metal fatigue #4.2.1. When to check? #4.2.2. What to check in particular? #5. MANUFACTURING GUARANTEE FOR THE USBASIC CABLE Page 23 HOLDER SET: #6. ANNUAL INSPECTION OF THE USBASIC CONTINUOUS BELAY Page 24 SERIES: Document history: -initial document:”Howto’s to the USBasic Cable Holder Set” 09/2008. -Revision01 on 17/01/2009 -Revision02 on 19/12/2009 -Revision03 on 12/03/2010 -Revision04 on 29/05/2012 Keywords: USBasic Continuous Belay System, USBasic Ligne de Vie Continu, USBasic Connector ,Cross Beam , Double Cross Beam , Cable Holder , Cable Holder Set , Crossover , Non Return Device , Lindapter Cross Beam , Control Gauge, Multiple Tracs , Mobile Ropes Course Stystem , failsafe security , continuous belay , connector set , major axis load , minor axis load , failsafe security , glider , shuttle, Ropes Course , Adventure Course , Belay , Continuous Belay, Ropes Course Safety , EN354 , EN 354 , EN795B , EN 795B, EN15567 , EN 1556, Intelligent Belay System, superselfbelay , super self belay , super selfbelay , self belay , safe self belay , smart self belay , super safe belay , supersafebelay, Connector Set

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