CAI RL60 Series User manual
INSTALLATION MANUAL
FOLD DOWN LADDERS
Distributed by
CAI Safety Systems
2
MUST READ PRIOR TO USE
1. This system must only be installed by competent persons trained in the selection, use and maintenance of access
systems.
2. Persons installing this system are required to have a comprehensive knowledge of the relevant standards, codes
of practice and industry guidelines that relate to the selection, use and maintenance of access and fall protection
systems and equipment.
3. Integrity and suitability of the structure to which this system is attached must be approved by a structural engineer
unless it is clear to a competent person as to the suitability of connection to structure.
4. Read installation and operation instructions carefully before commencing any work. Consent to deviate from the
installation guide must be obtained in writing from the manufacturer.
5. Conduct an initial work/risk assessment, and take all reasonable precautions to eliminate or control potential hazards
and risks during the installation of this product.
6. Complete all necessary OH&S documentation, including a Job Safety Analysis and Work Method Statement and
obtain consent from responsible person in workplace prior to commencement of work.
7. Do not modify or remove any element of the support structure without prior authorization by a qualied engineer.
8. Decorative coatings and coverings must be removed to ensure correct evaluation of structure prior to attachment of
system.
9. Any re-routing of electrical and/or other services must be carried out by qualied or authorized personnel.
10. Appropriate temporary access and safety equipment must be used during installation, such as platform ladders or
scaffolding and fall protection anchor points.
11. In case of emergency access and fall protection systems must be installed by a minimum of two persons.
12. Do not tamper with, modify or remove any part of this system unless authorized by the manufacturer in writing.
13. Appropriate labels or markings must be attached to each system and include; service entry date, next examination/
service due date, maximum designed load ratings and installer/certier details.
14. Documentation conrming correct use and maintenance of the system and equipment must be provided to the
workplace manager on completion of installation. (See operation manual)
Fixfast USA instructions and recommendations, drawings and diagrams, and all other documentation are copyright, errors and omissions
excepted, and must be carefully read and implemented. Any assistance or guidance given is without prejudice, and Fixfast USA cannot be held
responsible for any inaccuracy or misinterpretation whatever. Failure to follow site installation requirements and warnings, may result in serious injury or
death. Fixfast USA accepts no direct or indirect responsibility and/or consequential liability whatever, for any products and systems incorrectly installed
or certied. Fixfast USA cannot warrant the integrity or suitability of the structure to which the products may be attached. Prior assessment must be
made by a qualied structural engineer, unless the structure is authorized or approved by a competent person.
3
MUST READ PRIOR TO USE
1. Minimum structural requirements for attachment of RL60 Series Ladders:
• Steel purlin 4” x 5/8” base metal thickness
• Timber truss 3 1/2” x 1 3/8” F7 structural grade
2. Structure must be designed to support 440lb load.
3. RL60 Series Ladders are for single person use only rated at 500lb.
4. This system, under normal use and environment, has a life expectancy of up to 10 years. This will depend on
location, usage and scheduled maintenance as per manufacturer and legislative requirements.
5. Do not tamper with or make alterations to system components without manufacturer’s consent.
6. This system is not to be used for tethering or lifting machinery or equipment.
7. RL60 Series Ladders must not be used in the following environments:
• External areas exposed to elements
• Moist or damp areas
• Corrosive/harsh environments
Fixfast USA recommends that persons using access and fall arrest systems do not work alone in case of an emergency and help is required.
Should any part of the system/equipment have been subjected to abnormal loading, use must be discontinued until replaced/re-certied by a
competent height safety inspector.
4
Tools Required for RL60 Series Fold Down Ladder Installation
• Cordless Drill
• 5/16” Metal Drill Bit
• 5/16” Nut Setter
• 1/2” Wrench
• Tape Measure
• Marking Pen
• Spirit Level
MAINTENANCE
1. The RL60 fold down ladder system needs to be checked and re-certied by a competent height safety inspector every 12 months for
non-corrosive environments or 6 monthly for corrosive or harsh environments. (To be determined by competent person depending on severity of
surrounding conditions.)
2. Never clean using acids or other chemicals that could damage the system components.
3. Any deterioration or damage to the system or equipment must be reported to the person in control of the workplace and relevant correction action
undertaken.
4. Fixing and support structure attachment and suitability must be checked by competent person.
5. Any signs of distortion or excessive load to the fold down ladder system must be inspected and re-certied by competent person.
6. The identication label must be completed conrming certication, maintenance and recertication of the system.
7. Maintenance inspections must be clearly documented. Any non-conformance must be clearly identied and tagged ‘Do Not Use’ until corrective
action by a competent person has been completed.
5
maximum
ceiling
height
10ft
minimum
clearance
15”
minimum clearance 76”
48 1/2” x 31”
rung
spacing
11 3/4”
rung width
20 3/4”
frame
width
30 3/4”
DIMENSIONS
maximum
ceiling
height
14ft
minimum
clearance
19”
minimum clearance 90 1/2”
64 1/4” x 31”
rung
spacing
11 3/4”
rung width
20 3/4”
frame
width
30 3/4”
DIMENSIONS
RL62 RL63
6
Design and Layout
Ceiling Space Floor Space
A A1 A2 B B1
15 3/4 11 59 94 1/2 35 1/2
31 1/2 15 1/4 63 1/2 98 1/2 36 1/2
47 1/4 19 3/4 67 3/4 102 1/4 37 3/4
63 23 3/4 72 106 1/4 39
78 3/4 28 76 1/2 110 1/4 39 3/4
94 1/2 32 1/4 80 3/4 114 1/4 41
110 1/4 37 85 118 42
118 38 1/4 87 122 43 1/4
N/A N/A N/A 126 44 1/2
Ceiling Space Floor Space
A A1 A2 B B1
15 3/4 11 59 130 46 1/2
31 1/2 15 1/4 63 1/2 133 3/4 47 3/4
47 1/4 19 3/4 67 3/4 137 3/4 48 3/4
63 23 3/4 72 141 3/4 50
78 3/4 28 76 1/2 145 3/4 51 1/4
94 1/2 32 1/4 80 3/4 149 1/2 52 1/2
110 1/4 37 85 153 1/2 53 1/2
118 38 1/4 87 157 1/2 54 3/4
N/A N/A N/A 161 1/2 56
N/A N/A N/A 165 1/2 57
N/A N/A N/A 169 1/4 58 1/4
KEY
A Ceiling Height
B Distance from back of fold down
ladder to front of ladder
C Internal Ceiling Height
D Distance Between Purlin Hangars
E Distance from Purlin Hangar to Back
of Ladder Frame
*All measurements are in inches and
approximate only
RL62
RL63
(available separately)
(available separately)
7
RL60 Suspension Kit
KIT INCLUDES
1x Ladder Support Frame
4x Suspension Hangers
2x Purlin Hangers - 63” (4” x 2” x 1/4” angle)
2x Side Mount Brace 118” (2” x 2” x 1/8” angle)
2x Front/Rear Braces 94 1/2” (2” x 2” x 1/8”
angle)
2x Frame Extensions 47” (standard splice
section)
1x Fixing Pack
FIXINGS
4x M12/1 1/8” Purlin Bolt Screws
12x 12G/1 1/8” Series 500 Tek Screws
50x 12G/3/4” Self Drilling Tek Screws
AL732 - 4” x 2” x 1/2”
Angle @63” (L)
QTY:2
AL731 - 2” x 2” x 1/2”
Angle
QTY:4
Suspension Frame
AL766 - 2 1/4” x 1 1/2” RHS
Welded 1 Piece
Frame Extension
AL781 - Splice Section @61”(L)
QTY:2
AL730 - 2” x 2” x 1/8” Angle Bracing
QTY:2
AL730 - 2” x 2” x 1/8” Angle Bracing
QTY:2
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Front Purlin Hanger
Rear Purlin Hanger
4” x 2” x 1/4” Aluminum Angle
M12 x 1 1/4” Bolt
Purlins
See table on page 6
Mount front purlin hanger +/- 2” from front face of
roof hatch. Fix temporarily with (2) 12G/1” tek screws.
Once nally aligned and positioned, drill (2) 1/2” holes
through purlin hanger and purlin.
Insert (2) M12/1/2” purlin bolts, tighten securely.
Determine correct mounting position of rear purlin
hanger.
Mount and x rear purlin hanger as per Step 1.
1
2
3
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Attach the angle ‘droppers’ to the main support angle
with (1) M8 x 3/4” cup head bolt. Space droppers at
34” apart.
(Angles will need to be cut to suit length required)
Slide the splice sections into the ladder support frame.
Then bolt the splice sections and the frame to the
‘droppers’. Fix with (1) M8 x 2 1/4” cup head bolts.
Fasten a 3/4” tek screw through the frame, into the
splice section to lock in position.
34”
M8 x 0.8” Cup Head Bolt
Splice Sections
Main Frame
3/4” Tek Screw
M8 x 2 1/4” Cup Head Bolt
2” x 2” Aluminum Angle (Droppers)
4
5
10
Bracing
3/4” tek screw
Purlins
Main Support Angles
20”
Secure bracing to all four sides using (2) x 3/4” Tek
Screws for each connection.
Should the purlins run in the direction as shown, the
main support angles will need to change direction. It
may be possible to suspend the ‘droppers’ directly
from the purlins without having to use the main
support angles.
Determine direction of fold
down ladder in relation to
direction of purlins. If not in
line with purlins, see below.
Rear bracing to be xed
at least 20” from bottom
of suspension hangar to
allow for ladder assembly
clearance when closed.
All assembly and xing
procedure as per ‘in line
purlin’ option.
PURLINS 90 DEG TO SUSPENSION FRAME
7
11
RL60 Fold Down Ladder
KIT INCLUDES
1x Fold Down Ladder Assembly
1x Ladder Body (2nd Stage)
1x Ladder Body (3rd Stage)
2x Adjustable Splice Feet
1x Pull Stick
1x Eye Hook
1x Fixing Pack
FIXINGS
6x M8/1/4” Setscrew Sets
4x M10/3/4” Bolt Nyloc Nut Sets
12x M10 Washers
4x 12G/3/4” Self Drilling Tek Screws
12
CEILING CUT OPENING
RL62 - 48 1/2” x 30”
RL63 - 64” x 30”
Determine suitable location, ensuring all structure or
services are relocated or disconnected appropriately
(by authorized / qualied personnel).
Mark out and cut opening in ceiling.
The above ceiling cutout
dimensions allow for frame
clearance including a
1”cover on all four sides
provided by the main frame
extension.
8
DRYWALL
DRYWALL
13
Remove complete assembly from box.
Remove any packaging material, and place second
and third ladder sections or ladder assembly aside.
Be careful not to scratch
pre-nished surface of fold
down ladder frame and
door. Use packing box as
protective surface.
9
14
OPTION 1 - IF SUSPENSION KIT IS NOT USED
OPTION 2 - IF SUSPENSION KIT IS USED
Spring
clips
Lift main ladder frame into position.
Fix unit to support structure (rafter/battens) utilizing
pre-drilled holes with (6) M8 x 3” set screws or 14G
type 17 timber xing (3 screws per side).
Fix (4) ‘spring clips’ to fold down ladder frame with (8)
M5 x 1/2” countersunk bolts (2 bolts per clip).
Ensure ladder is facing
correct direction.
Support frame must be
square. Failure to do so will
cause ladder door closure
difculties.
‘Spring clips’ are not
required, during installation
if fold down ladder can be
supported by any other
device. ie ‘duct lifter’. Spring
clips are temporary holding
device until structurally
secured.
10
11
15
Spring clips
6” +
2”
Lift complete assembly into position - ensuring the ladder
folds down in the correct direction.
Firmly push assembly until it ‘clicks’ into position. (Clips will
hold assembly in position until structurally xed.)
Unfold rst stage ladder section.
Check nal position and make necessary adjustments.
Fix ladder to the suspension frame with (4) M8 x 3” set
screws utilizing pre-drilled holes. (3 sets screws per side)
When ladder closes, top of ladder protrudes
1 3/4” beyond ladder frame
Allow 2” gap to ensure ladder assembly does not
impact on the void end. Insert packer to close
gap if aesthetically required.
Two person lift is recommended.
Do not attempt to climb ladder
until installation is complete.
If ceiling opening is a boxed
out design greater than 6”
thick (such as a concrete or
trimmed out opening), a 2” gap
is required at the head of the
ladder to allow clearance for
the protruding ladder assembly
when stowed away.
12
13
14
16
Align rst and second stage ladder sections. Insert (2)
M10 x 3/4” bolts through hinges - ensure (3) washers
are in place.
Tighten bolts sufciently. Ensure hinges move freely.
Measure distance from bottom of second stage ladder
section and oor and then subtract 2” from adjustable
feet insertion.
Cut third stage ladder section to suit required height.
Install third stage ladder section as per the step above.
Cut ladder to X less 2”
X Dimension
Floor
15
17
Insert (2) adjustable feet into third stage ladder section.
Fold out complete ladder - ensure all sections are fully
unfolded.
Adjust feet to suit oor level.
Once adjusted correctly, x in place using (2) 12G x
3/4” tek screws per foot.
Ladder feet must be positioned
to ensure 500lbs working load is
fully supported.
16
17
18
Position the pull stick locator in between the last 2
rungs of the third stage ladder section.
Fix in place (4) 3/4” tek screws.
Close ladder system and check all ladder sections,
door and components close correctly.
Open ladder system.
Position the pull stick through the tube, then locate the
hook onto the top end of the tube.
Pull down the Vista ladder half way down towards you
until you can safely pull the remainder of the ladder by
hand and remove the pull stick from the tube.
Unfold the complete ladder, ensuring all hinges are
fully extended and check all parts are safe/secure
before using the Vista ladder.
Pull stick locator
Approx 10”
Fix Sleeve to Pole
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19
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Ceiling Ladder
KIT INCLUDES
1x Ceiling Ladder (47 1/2” or 94 1/2”)
2x Fixing Angles
1x Fixing Pack
FIXINGS
2x M8/1/4” Cup Bolt Sets
4x M8/2 1/4” Cup Bolt Sets
2x RHS Plastic End Caps
20
Fix ladder support angles to top of ladder support
frame using (2) 12G x 3/4” tek screws. (1 per bracket)
Fix ladder xing bracket to front purlin hanger, or to
purlin trimmers, using (2) M8 x 1” cup bolt sets.
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