COMBISAFE System Mk II User manual
Loading System MkII
Including SkyReach Anchor
USER INSTRUCTIONS
0158 - EN 795:2012-E
CONTENTS
General............................................................................................................3
Quick Guide..................................................................................................4
Safety Instructions ...........................................................................................5
Remember....................................................................................................8
Technical Data.................................................................................................9
Main Parts....................................................................................................9
Loading System MkII Base.........................................................................10
Top Column 4.7..........................................................................................11
SkyReach Adaptor 5.9................................................................................11
SkyReach Anchor.......................................................................................11
Optional Items............................................................................................17
Assembly.......................................................................................................20
Assembling the Loading System MkII ........................................................20
Dismantling.................................................................................................34
Transportation................................................................................................35
Storage..........................................................................................................37
Loading System MkII Base.........................................................................37
SkyReach Anchor.......................................................................................38
Recommended operating method..................................................................39
Single Unit usage.......................................................................................39
Double Unit usage......................................................................................40
Maintenance ..................................................................................................42
Check list prior to usage.............................................................................42
Cleaning.....................................................................................................44
Recycling....................................................................................................44
© Combisafe International AB
UI Loading System MkII-EN-1634
Subject to changes.
Loading System MkII General
3
General
The Loading System MkII has been designed to enable the loading and
unloading of equipment from a flatbed truck or trailer in a safe manner.
The Loading System MkII incorporates a SkyReach Anchor unit which is
connected by a Self-Retracting Cable Lifeline to the full body safety harness
worn by the operative.
The SkyReach Anchor is designed to deform, absorb the energy and reduce
the resulting forces, when a fall occurs.
When working at lower heights, the system can be equipped with the Top
Column 4.7. In this configuration the anchor point is located 4,7 m above
ground level. When working at higher positions the system can be equipped
with the SkyReach Adaptor 5.9 which locates the anchor point 5,9 m above
ground level. The combination of Loading System MkII and SkyReach
Anchor, is tested to prove compliance to EN 795:2012 Type E, and is CE-
certified by DEKRA EXAM GmbH, Dinnendahlstraße 9, 44809 Bochum,
Germany, with identification no 0158.
The Loading System MkII can be used on a construction site or in a loading
yard and it can be moved to alternative locations as needed. To ease
transportation and storage, the Loading System MkII is designed to be flat
packed and stackable. When flat packed the total height of the base is 0,6 m.
The SkyReach Anchor itself can be separated and folded for ease of transport
between locations.
When used for unloading a trailer up to 8 m in length, the Loading System
MkII Single Unit can be used. If unloading a trailer between 8 and 14 m in
length, the Loading System MkII Double Unit should be used.
Read carefully through this user instruction before use of the product. In case
of questions and for clarification, please contact Combisafe for support.
Loading System MkII Safety Instructions
5
Safety Instructions
The Loading System MkII is intended for the purpose stated in this user
instruction only, any other usage is not recommended. The product is used to
protect workers operating at height and if used incorrectly, there is a potential
risk of accidents to both the user and other people in the vicinity. Please read
this manual carefully before any usage.
• Under no circumstances may the product be used as a makeshift crane or
lifting/lowering device.
• Under no circumstances may any items other than those provided with the
system be used either in replacement or through choice as this may affect
the performance of the product.
• Care should be taken in the transportation of the product between
locations. If any damage is found on any part, the item must be withdrawn
from use, inspected by a trained person and replaced if required.
• Care should be taken while installing the product and if any damage
occurs or is found in any part, the item should be withdrawn from use,
inspected by a trained person and replaced if required.
• The site location where the Loading System MkII is being used should
have a rescue plan in place, in case of a fall incident.
• The device is intended for use by one person at a time only. Under no
circumstances may multiple persons be attached to the device.
• Where the base is positioned directly onto rough ground, as opposed to
hard standing concrete, sole plates of suitable size and strength should be
placed under the feet of the base to safely transmit and sustain a load of
up to 2,5 N/mm².
• Do not lift the Loading System MkII unit or any of its components by crane,
except for the SkyReach Anchor unit itself.
• When a crane is lifting the SkyReach Anchor unit, be aware of the
movements made by the crane and keep workers at a safe distance.
• The SkyReach Anchor is intended to be used within a zero factor fall
arrest system. Make sure that the anchorage is always overhead and the
lifeline is taut between the anchorage point and the worker.
• The maximum vertical deflection of the anchor point that can occur during
service is 0,7 m.
• In case this product is re-sold outside the original country of destination, it
is essential that the reseller provides user instructions in the
language of the country in which the system is to be used.
• When referring to any components of the system not produced by
Combisafe, please refer to the specific user guide/manual for that item.
Safety Instructions Loading System MkII
6
• PFPE to be used together with the Loading System MkII must be
CE-certified and approved in the specific country of usage.
• It is forbidden to use the products stated in this user instruction when
pregnant, suffering from cardiovascular disease, affected by alcohol or
drugs or other health issues that might affect your mental or physical
capacity.
Always check products and equipment before use
Check all component parts of the Loading Systemm MkII before assembly.
Never use damaged or rusty parts, as this can affect safety. Refer to the
check list in the Maintenance chapter which must be followed prior to use.
Never combine products
It is not recommended to install, combine or interconnect products other than
those supplied by Combisafe. Combisafe product liability is limited to correctly
installed Combisafe products only.
Always use Personal Fall Protection Equipment
Personal Fall Protection Equipment (PFPE) must always be worn during
assembly and dismantling when a risk of falling exists, see Figure 1. This also
applies to work carried out from MEWPs (Mobile Elevating Working
Platforms).
Figure 1. Personal Fall Protection Equipment.
Loading System MkII Safety Instructions
7
Fall clearance
Note that it is essential to verify that adequate free height exists to the closest
underlying object, please see Figure 2 below.
A
A+B
A+B
C
Figure 2. Explanation of fall clearance.
A: 0,7 [m] Maximum vertical deflection of the SkyReach Anchor Point
B: X Braking distance of the SRL. Please refer to the
manufacturer´s user instructions for specific values.
C: 1 [m] Safety distance.
Total required fall clearance = A+B+C
Safety Instructions Loading System MkII
8
NOTE
Periodic inspection/inspection after a fall
To ensure the function and safety of the system, a safety inspection of the
Loading System Base, the SkyReach Anchor and the PFPE, needs to be
done by a competent person at least once every 12 months. The inspections
must be documented in a component record.
If an accident has occurred, e.g. a person falls, the items must be immediately
withdrawn from use and inspected by a competent person according to the
manufacturer´s safety check.
Please contact Combisafe for more information regarding inspections and
associated documentation.
The SkyReach Anchor is designed to deform when a fall occurs, to
absorb the energy and to reduce the resulting forces. When tested,
the maximum vertical deflection of the anchor point is 0,7 m.
Remember
• Plan fall prevention at an early stage, this will benefit everyone.
• Use only safety-checked products.
• Restrict access below and around installation and working area to prevent
injury to others from any fall hazard.
• Use tools designed for the type of work to be carried out.
• Keep the installation area in order.
• A safe workplace is a good workplace.
• Many fall accidents occur from a low height.
• Parts might be slippery when wet, be cautious when handling.
Loading System MkII Technical Data
9
Technical Data
Main Parts
Figure 3. Main parts of the Loading System MkII with the SkyReach Anchor
installed.
Item
Art no.
Designation
Weight
1
8800
Loading System MkII Base
250 kg
2
11468
Top Column 4.7
25 kg
3
8801
SkyReach Adaptor 5.9
27 kg
4
8100
SkyReach Anchor
25 kg
Technical Data Loading System MkII
10
Loading System MkII Base
When the Loading System MkII Base is equipped with the Top Column 4.7 or
the SkyReach Adaptor 5.9 and loaded with ballast it is a CE certified
attachment to be used as a housing for the SkyReach Anchor.
Material: .................................... Painted steel
Total weight:.............................. 250 kg
Height:....................................... 1,5 m
Width:........................................ 1,4 m
Depth:........................................ 1,4 m
2
3
4
5
1
1,5 m
1,4 m
Figure 4. Loading System MkII Base.
Item
Art. no.
Designation
Weight
1
100413
Combistrap, 1 m (2 pcs)
0,1 kg/pc
2
11438
Top Frame
72 kg
3
11431
Corner Post (4 pcs)
10 kg/pc
4
11432
Bottom Frame
108 kg
5
11518
Foot (4 pcs)
2 kg/pc
Loading System MkII Technical Data
11
Top Column 4.7
When working at lower heights the Top Column 4.7 locates the anchor point
at 4,7 m above ground level. The Top Column 4.7 will fit into the Base when
the Base is packed and therefore takes up no extra space when storing the
item.
Material:.....................................Hot dip galvanised/painted steel
Weight:.......................................25 kg
Height:.......................................1,2 m
SkyReach Adaptor 5.9
When a greater working height is required than the Top Column 4.7 provides,
the SkyReach Adaptor 5.9 will give a total height of 5,9 m from the ground to
the anchor point.
Material:.....................................Hot dip galvanised/painted steel
Weight:.......................................27 kg
Height:.......................................2,4 m
SkyReach Anchor
The SkyReach Anchor is designed to be a lightweight product and is easily
foldable for moving and configured to be space-saving when transporting or
storing the item, see Figure 5. To secure both positions (assembled mode and
folded mode) the attached Lock Pin is used.
For lifting SkyReach Anchor by crane there are 2 lifting eyes. For lifting use 2
slings with equal length, each connected to one lifting eye (slings are not
included).
Material:.....................................Hot dip galvanised/painted steel
Weight:.......................................25 kg
Height:.......................................3,1 m
Assembled width:.......................2,0 m
Packed width: ............................0,2 m
NB. Suitable slings are available from Combisafe, order code 100686
Technical Data Loading System MkII
12
Figure 5. The SkyReach Anchor in assembled and folded mode.
SkyReach Anchor Labels and Markings
The Figure 6 below shows all the labels and markings of the SkyReach
Anchor. The following figures (Figure 7, Figure 8 and Figure 9) are showing
these important elements.
Technical Data Loading System MkII
14
Figure 7. A close-up of the ID Plate including the serial number.
www.combisafe.com
© Combisafe International AB 100583-1446 EN 795:2012
0158
SKYREACH Anchor
#8100
#8200
Type B
#8500
Type B #8800
Type E#8100
1234567
Figure 8. Detailed view of the Product Information Label
1. Manufacturer.
2. Name of the product.
3. Identification number of the notified body; DEKRA EXAM GmbH,
responsible for CE production quality control.
4. Compliance with EN 795:2012.
5. Pictogram: Read user instruction before use.
6. Description of usage.
7. Product combination with different attachments.
MAX 5 mm
MAX 5 mm
Figure 9. A close-up on the Insertion Marking Label, which shows accepted
tolerances when inserting the SkyReach Anchor into its attachment.
Loading System MkII Technical Data
15
Personal Fall Protection Equipment
To create a complete system to protect the operative when working at height,
the Loading System MkII needs to be equipped with Personal Fall Protection
Equipment (PFPE). Figure 10 shows an example of how to equip the
SkyReach Anchor with recommended PFPE. All PFPE that is used must be
certified according to valid standards and approved in the specific country of
use.
The following PFPE is approved to be used together with the SkyReach
Anchor and the Loading System MkII:
SRCL .................Fall Arrest Block certified to EN 360
Only the Miller Falcon 6,2 m, or the Miller Falcon 10 m
when a Double Unit is used, has been tested and approved
in combination with the Loading System MkII and SkyReach
Anchor, and thus the only SRCL that will enable the system
to be CE certified. Use of other SRCL will invalidate the
CE certification.
Harness.............. Full body harnesses certified to EN 361
Lanyard ..............Non shock absorbing lanyards certified to EN 354
Can be used separately or in combination with EN 355
certified lanyard, or with a max length of 0,6 m in
combination with the Falcon Fall Arrest Block.
Lanyard ..............Shock absorbing lanyards certified to EN 355
Can be used separately or in combination with an EN 354
certified lanyard. Must NOT be combined with the Falcon
Fall Arrest Block.
Technical Data Loading System MkII
16
Figure 10. The figure shows the SkyReach Anchor equipped with
recommended PFPE.
Item
Part no.
Designation
Weight
1
8100
SkyReach Anchor
25 kg
2
-
Full body harness certified to EN 361
-
3
CM1002889
Miller Extra Webbing, 0.3 m
0,2 kg
4
CM1011729
Miller Falcon SRCL, 6.2 m
4 kg
Loading System MkII Technical Data
17
Optional Items
The following items are not delivered as standard together with the Loading
System MkII but can be ordered separately if required, please see Figure 11
for visual clarification of the items.
Precast Kentledge (Art. 11655)
This precast concrete block is one out of three possible ballast options, and
can be ordered from Combisafe. Please see the following chapter Ballast for
more information.
Material:.....................................Concrete
Weight:.......................................800 kg
Height:.......................................0,2 m
Width:.........................................1,4 m
Depth:........................................1,4 m
Formwork Support (Art. 11446)
To use the second ballast option, the Loading System MkII Base needs to be
equipped with 8 pcs of the Formwork Support. These channel section steel
bars with a wooden inlay will give the support needed to the side boards when
the base is filled with gravel or concrete.
Material:.....................................Painted steel/wood
Weight:.......................................11 kg
Length:.......................................1,4 m
SkyReach Reach Hook (Art. 11530)
The Reach Hook is useful to guide the SkyReach Anchor into the Top Column
4.7/SkyReach Adaptor 5.9 when the anchor is lifted and lowered by crane. It
has a telescopic shaft which is extendable from 1,2 to 2,7 m.
Material:.....................................Aluminum/Hot dip galvanised steel
Weight:.......................................1,0 kg
Length:.......................................1,2 – 2,7 m
Loading System MkII Technical Data
19
Ballast
The Loading System MkII Base needs to be loaded with a minimum 1500 kg
of suitable ballast to keep it stable and meet the requirements in the standard.
The ballast can be applied in three different ways, which are presented below.
Further details on how to perform the ballast loading procedures are
described in the Assembly chapter.
•Precast Kentledge
The Precast Kentledge is a 800 kg concrete block designed to fit into
the Loading System MkII Base. Using two units of the Precast
Kentledge is enough to achieve the weight requirement and provide
margin in case of wear of the blocks. These should be ordered as an
option as they are not included as a standard. It isrecommended to
use these blocksdue to its precise weight and safe positioning.
•Concrete box cast on site or gravel box
For this option, the Formwork Supports should be ordered, as they
are not included in Loading System MkII as standard. With the
Formwork Supports mounted, a plywood box inside the Loading
System MkII Base will make it possible to cast concrete into the box
directly on site. It is also possible to fill the plywood box with gravel.
•Other ballast option
In case none of the standard solutions noted above is used, it is
possible to use other ballast types. In this case it is the customer’s
responsibility to ensure that ballast:
•Has a weight no less than 1500kg
•Is distributed centrally on the Bottom Frame of Loading
System MkII
•Has no possibility of movement.
Assembly Loading System MkII
20
NOTE
Assembly
Assembling the Loading System MkII
The following information and illustrations are a step by step guide on how to
rig a Loading System MkII together with a SkyReach Anchor unit successfully.
The Loading System MkII can be used with any of the three ballast options
described. Please refer to the appropriate instruction pertaining to the actual
case.
Before attempting to rig a Loading System MkII unit, please make sure you
have the following tools:
• Hammer, 22 mm spanner or adjustable spanner for adjusting the feet
• Spirit level.
• Crane for installation of the SkyReach unit.
• Fork lift truck, or equivalent, for lifting the component parts.
Except for lifting the SkyReach Anchor unit alone, lifting the
Loading System MkII, or its parts with a crane is not permitted. Use
a fork lift truck and refer to the guides in this document.
Installation instructions for Loading System MkII
1. Make sure that the ground, where the Loading System MkII is placed, is
relatively flat. The Loading System MkII Base has adjustable feet which
are designed to adjust within a 5 degree inclination. Use a fork lift truck to
handle the Bottom Frame, place the forks underneath the horizontal
tubes and spread the forks apart prior to lifting, see Figure 12. Place the
Bottom Frame on the ground. Use a spirit level to make sure that the
Bottom Frame is level. If not, rotate the feet by hand or use a 22 mm
spanner or a hammer to strike on the Adjusting Bar to adjust the feet until
the Bottom Frame is level, see Figure 13.
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