Molift Rail System Technical manual

Efficient project planning and installation
of Molift Rail System
designed
for
life
molift rail system
handbook

MOLIFT RAIL SYSTEM - HANDBOOK PART.NO TM19101 - REVISION E /09/2011

Table of content
How to use this manual .............................................................................................2
The expert in moving and handling .................................................................................3
Explanation of symbols ...................................................................................................4
Responsibility ..................................................................................................................4
Chapter 1 – Ceiling hoist systems............................................................................5
Why choose a ceiling hoist system .................................................................................5
Denitions .......................................................................................................................6
Chapter 2 – Specification of ceiling hoist system.................................................13
How to plan and mount a rail system? ..........................................................................13
Choosing Rail system and hoist....................................................................................22
Chapter 3 - Choice of parts and ordering...............................................................25
Structure of the Molift Rail System (MRS) ....................................................................25
Description of the elements of MRS..............................................................................26
Schedule of rail proles.................................................................................................27
Schedule of curves........................................................................................................30
Schedule of telescope brackets ....................................................................................33
Schedule of wall and rafters securing devices ..............................................................36
MRS tool .......................................................................................................................38
Schedule of MRS mounting screws ..............................................................................39
Schedule of end stops for MRS proles........................................................................41
Schedule of MRS trolleys..............................................................................................42
Transition coupling ........................................................................................................45
Switch systems .............................................................................................................46
Standard securing devices to be used for MRS:...........................................................49
Chapter 4 – Mounting of Molift Rail System ..........................................................53
Safety regulations .........................................................................................................53
General information on MRS tting: ..............................................................................53
Mounting procedure for drop-in anchor.........................................................................54
Mounting procedure for chemical anchor in ceiling.......................................................56
Mounting procedure for chemical anchor with mesh sleeve in wall ..............................58
Mounting in concrete with lowered ceiling.....................................................................60
Mounting directly in concrete (directly in ceiling)...........................................................63
Mounting in rafters layer with lowered ceiling ...............................................................66
Mounting directly in rafters layer ...................................................................................70
Mounting procedure for rafted bracket ..........................................................................72
Mounting procedure for wall bracket .............................................................................74
Mounting procedure for joining of rails ..........................................................................77
Rev E 10/2011 Page 1 of 100

How to use this manual
This manual is primarily intended for persons who are to sell, mount and maintain Molift Rail Sys-
tem (MRS).
Molift Rail System may only be mounted by Molift authorised staff who have received the re-
quired training by Molift Group AS.
Molift Group AS will only be responsible for the system provided that the motor has been supplied
by Molift. Molift Rail system has been CE-marked according to directive 92/42/EEC.
The manual is divided into ve main chapters:
Chapter 1 – Ceiling hoist system
Describes solutions and options oered by a ceiling hoist.
Chapter 2 – Specication of ceiling hoist system
Descriptions of requirements and conditions for mounting of a ceiling hoist system in a building,
whether new or old.
Chapter 3 - Choice of parts and ordering
Description of Molift Rail System and all parts of the system, to be used for ordering, etc.
Chapter 4 – Mounting of Molift Rail System
Describes mounting details for dierent systems and buildings, with check lists included for each
system.
Chapter 5 - Maintenance
Annual checks of Molift Rail System are recommended
Enclosure 1
Survey form, MRS Installation
Mounting procedure for traverse ...................................................................................78
Traverse combinations ..................................................................................................79
Assembly of wall rail for traverse ................................................................................86
Assembly procedure for transition coupling .................................................................89
Mounting of Switch........................................................................................................92
Procedure for cleaning of proles after mounting .........................................................97
Checklist for tting Molift Rail System .......................................................................100
Chapter 5 - Maintenance........................................................................................103
Page 2 of 106 How to use this manual Rev E 10/2011

The expert in moving and handling
As the expert in moving and handling Molift
supports caretakers by providing them with
the greatest possible relief of loads on the job,
thereby helping them avoid strain injuries. The
caretakers will enjoy and improved life without
injuries, and the user will experience that the
caretakers have additional energy to provide
tender loving care and nursing.
Too much strain can result in irreparable dam-
age. Many caretakers suer injuries to the mus-
culoskeletal system as a result of lifting and
moving patients.
We claim that the well-being of a user depends
on whether the caretaker is well. Through un-
derstanding when strain injuries arise and by
working using the right techniques plus the
proper equipment, the caretakers will benet
from a better life, on the job and at home, and improved health. The users will not have to suc-
cumb to a constant ow of new, unknown substitutes and low stang owing to caretakers acutely
reporting in sick. The employer will get healthy employee with less sickness absence and society
will benet from increased productivity and reduced costs.
In most countries it is compulsory that employers place the required resources at the disposal of
their employees, to help them avoid physical strain.
Nursing homes/hospitals designed with pre-mounted ceiling hoist systems benet greatly from
these devices. They are easy to use for the caretakers and the patients feel comfortable with them.
They are easily accessible, prevent lifting injuries – and are not in the way when not in use.
Molift has supplied ceiling hoist systems for many years and has now developed an entirely new
rail system, Molift Rail System. It is simple to mount and at the same time we have adapted it to
our high standards for design and user friendliness. The system can be mounted openly or in built-
in versions in a lowered ceiling.
It is our hope that you – when planning a new building within the care sector – will nd this man-
ual to be of use in your work. Here you will nd dierent alternatives adjusted to patient needs as
well as technical specications and denitions which will hopefully contribute to making your job
easier.
Manufacturer:
Molift Group AS
Hadelandsveien 2
N-2816 Gjøvik
Tel: [phone]
Fax: [phone]
www.molift.com
Rev E 10/2011 How to use this manual Page 3 of 100
The expert in moving and handling

Explanation of symbols
This symbol is used to point out instructions and information related to work place safety where
injury may occur if the information is disregarded or ignored. Follow these instructions, be care-
ful and attentive at all times.
This symbol indicates important information regarding the use of the equipment. If not taken
into consideration, it may lead to damage or functional defects to the lifter or other equipment.
Responsibility
Molift Group AS assume no liability for damage or malfunctions resulting from failure to comply
with the instructions in this handbook. Warranty claims must be made immediately on detecting
the defect. Consumable parts are not subject to the warranty.
All technical information, data and instructions contained in this handbook were up-to-date at
time of print and are compiled on the basis of our experience and to the best of our knowledge.
We reserve the right to incorporate technical modications within the scope of further develop-
ment of the product described in this manual. No claims can be derived from the information, il-
lustrations or descriptions contained in these instructions. We assume no liability for any dam-
age or malfunction caused by operating errors, non-compliance with the mounting instructions
or inappropriate maintenance. We expressly point out that only genuine Molift spare parts and
accessories approved by us may be used. For safety reasons, the tting and use of spare parts or
accessories, which have not been approved, and unauthorised modication or conversion of the
product, are not permitted. Molift Group AS will accept no liability for damages resulting from
such acts.
With the exclusion of product liability, Molift Group AS is liable for faults or omissions on its part
within the scope of the warranty obligations stated in the purchase contract. Claims for damages
are excluded, irrespective of the legal reason from which such claims are derived. Only documen-
tation belonging to the actual equipment is valid.
Any failure to comply with the safety regulations and precautionary measures stated in these op-
erating instructions renders the declaration of conformity supplied with the system in accordance
with Council Directive (93/42/EEC) concerning medical devices invalid.
Page 4 of 106 How to use this manual Rev E 10/2011
Explanation of symbols

Chapter 1 – Ceiling hoist systems
There are dierent demands to the purpose of a ceiling hoist system. Everything from full freedom
or moving from A to B. No matter what, you will benet from our experience. At Molift we supply
rail systems covering all needs. This makes it easier for you to choose the system most suitable for
your building.
Why choose a ceiling hoist system
- For a permanent lifting need/future need
As for instance patient rooms at a nursing home.
- Prevent injuries to caretakers
Investigations show that easily accessible devices for lifting and moving make the job of the care-
takers essentially easier.
- Space-saving
Ceiling hoist systems are out of the way when not in use, and at the same time always available
when needed.
- Demand from owner
The tendency is that it is dicult to build hospitals/nursing homes without having planned ceiling
hoist systems already in the planning phase.
- Easy to use
Ceiling patient hoist systems are “intuitive/easy” to use for the caretakers.
- Easy handling of heavy patients
Because ceiling hoist systems run easily on the trail, the patient’s weight is of less importance.
- Good feeling of safety
The patient regards a ceiling hoist to be safe and secure.
Rev E 10/2011 Chapter 1 – Ceiling hoist systems Page 5 of 100
Why choose a ceiling hoist system

Denitions
There are dierent demands to the purpose of a ceiling hoist system. Full freedom or transfer from
A to B?
The size and exibility of the ceiling hoist system’s lifting area depend on the structure of the in-
dividual system.
Straight rail system
A single rail is installed above the areas which are dened as most important. The use will mainly
refer to the most important lifts for getting up or transferring from bed to chair or similar.
The straight rail can be extended by combining one or more curves and straight rails, to allow the
nished rail system to pass through one or more rooms. An example of this is a rail from bed to
bath/toilet.
Figure 1. Straight rail system
Advantage: The most simple and sensible form of a ceiling hoist system is a single straight rail.
Page 6 of 106 Chapter 1 – Ceiling hoist systems Rev E 10/2011
Denitions

Switch systems
Systems with switches divide the rail into two paths.
If you want a routing with several pick-up points this is possible by introducing one or more switch-
es to the system. In this way it is possible to reach a larger part of the available area.
Figure 2. Switch system
Advantage: Divides a rail system in two with the opportunity of more pick-up points.
Molift Rail System switch and attachment brackets are ordered and supplied separately. The MRS
switch system can be tted directly to the ceiling or be suspended from the ceiling using 2 tele-
scopic brackets. The MRS switch system is manually controlled. The system does not therefore re-
quire the installation of an additional power source.
Rev E 10/2011 Chapter 1 – Ceiling hoist systems Page 7 of 100
Denitions

Traverse
Traverse is the most versatile variable with a primary rail which is fastened to the ceiling or wall
and a secondary rail which is fastened to the primary rail by means of trolleys.
A traverse system will cover the entire room, this provides the most versatile solution. A solution
which enables lifting regardless of the patient’s location in the room. Future refurnishing of the
room will be possible, as the traverse system will continue to work.
Figure 3. Traverse system
Advantage: The most versatile solution.
Page 8 of 106 Chapter 1 – Ceiling hoist systems Rev E 10/2011
Denitions

Lifting areas
The lifting area is the area of a room in which it is possible to carry out lifts.
The size of this area will depend on the choice of rails and the form and furnishing of the room.
The shaded elds of the illustrations below show the lifting area.
Figure 4. Lifting area for a single straight rail system
Figure 5. Lifting area for a single rail system with curve in one room.
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Denitions

Figure 6. Lifting area for traverse system in a single room (covering the entire room).
Page 10 of 106 Chapter 1 – Ceiling hoist systems Rev E 10/2011
Denitions

Pick-up point
Ceiling hoist systems have a clearly dened lifting area and it should therefore be dened where
lifting to/from is required. Typical places are: bed, toilet, resting chair etc.
Bed: The pick-up point is 90 cm from the head end of the bed or 100 cm from the wall behind.
Bath tub: The pick-up point is 5 cm before the end of the slanting part of the bath tub.
Toilet: The pick-up point is 5 cm in front of centre of the toilet pan.
Resting chair: The pick-up point is the centre of the seat.
Figure 7. Pick-up points
Rev E 10/2011 Chapter 1 – Ceiling hoist systems Page 11 of 100
Denitions

Page 12 of 106 Chapter 1 – Ceiling hoist systems Rev E 10/2011
Denitions

Chapter 2 – Specification of ceiling hoist system
How to plan and mount a rail system?
A ceiling hoist system is supposed to make everyday life as simple and as eective as possible, for
both caretakers and patient. When planning a ceiling hoist system, the type of mounting must be
based on many conditions and evaluations. We will here present a survey of the existing condi-
tions and the evaluations to be made in connection with the mounting of a ceiling hoist system.
Planning
Type of patient/user
• Is/are the patient/patients to be lifted or moved only in connection with the bed/wheelchair
(commode) (linearly solutions along an axis)?
• Must there be full freedom for lifts and moving all over the room (traverse solution)?
• Should it be possible to combine several rooms using the system?
Type of building/room
The rst thing to clarify is the kind of institution in which the system is to operate:
• Private home?
• Several rooms in a department of a nursing home or a hospital?
• Wet rooms (bath room)?
In general
The sooner in a building process the planning of ceiling hoist systems is included, the better the
planning can allow for the various considerations. This will result in an eective mounting proce-
dure of a system which is optimal to all parties.
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How to plan and mount a rail system?

Survey
Molift Group AS oers survey and planning in connection with your ceiling hoist systems.
A survey will uncover most aspects of an installation. It is recommended to go through the inspec-
tion scheme (see enclosure 1) and assess the assumptions stated. A survey should be done by per-
sonnel with detail knowledge of the building structures and knowledge of the need for and use
of a ceiling hoist system.
Fill in the table with as much information as possible giving details on the following:
• Ceiling structure
• Wall structure
• Room
• Planned MRS system
• In general
Conditions for installation of MRS
MRS has been developed and produced in accordance with the current version of NS EN-ISO 10
535. Molift Group AS is responsible for the products supplied, including fasteners, where our fas-
teners are used and where they are tted as specied in the instructions (Refer to chapter 4 - Fit-
ting of MRS). Fitters must be able to present a valid installation certicate that has been issued by
Molift Group AS.
Molift Group AS bears no responsibility for the ability of ceiling structures to carry the point loads
specied in the load tables below. Molift Group AS’ liability ends at the point where Molift’s fas-
tener’s terminate in the ceiling structure, as shown in chapter 4 - Fitting MRS. Fasteners other than
those described in chapter 3 and 4 can be used. Molift Group AS however bears no responsibility
for these fasteners where used.
Molift Group AS recommends the use of HILTI fasteners when tting MRS.
It is important that fasteners comply with the specied pull-out load safety margins and that fas-
teners are suitable for the underlay they are to be used in. Refer to examples in chapter 4.
Page 14 of 106 Chapter 2 – Specification of ceiling hoist system Rev E 10/2011
How to plan and mount a rail system?

Securing points
The ability of the ceiling/wall structure to bear the loads applied at the securing points by the
planned system must be assessed. Current standards stipulate that each securing point is to be
able to bear 1.5 x SWL. The current requirements for EACH for ceiling hoist system securing point
are therefore as follows:
Vertical load:
SWL (weight class)
Max load for the hoist
Requirements in accordance
with EN/ISO 10535
The load each securing point must be
able to bear (maximum working load)
160 kg 1,5 x 160 kg 240 kg ≈ 2,4 kN
205 kg 1,5 x 205 kg 307,5 kg ≈ 3,1 kN
230 kg 1,5 x 230 kg 345 kg ≈ 3,5 kN
255 kg 1,5 x 255 kg 382,5 kg ≈ 3,8 kN
300 kg 1,5 x 300 kg 450 kg ≈ 4,5 kN
Table 1. The table species the maximum working load requirements in relation to SWL, for
fastener elements used to t a bracket.
Ceiling hoist systems are to also be able to withstand the lateral loads that are applied when the
patient is in a position of up to 25 degrees from the vertical plane at the very start of the lifting
process.
Horizontal load:
SWL
Max load for the hoist Molift specication
Max allowable horizontal load
in ceilings
160 kg 160 kg x sin 25°68 kg
205 kg 205 kg x sin 25°87 kg
230 kg 230 kg x sin 25°97 kg
255 kg 255 kg x sin 25°108 kg
300 kg 300 kg x sin 25°127 kg
Table 2. Maximum lateral load applied to brackets when the hoist is outside of the vertical
plane
Figure 8. Illustration of vertical load and horizontal load with Molift Nomad
1,5 X SWL SWL
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How to plan and mount a rail system?

Requirements to materials
Requirements/conditions to be met by some know materials are stated below. If materials not
mentioned below are used, and if the materials for some reason have been weakened, these must
be evaluated specically. At any rate the conditions for the strength of the securing device are
stated in Table 1 and Table 2 on page 15.
Concrete structures
The quality of the concrete to which attachment brackets are to be tted, is a crucial factor in the
ability of the concrete to withstand the loads applied by the brackets. Molift species concrete in
accordance with the standard NS-EN 206-1 and underlying standards. Concrete must be minimum
of the following quality if the SWL and minimal tting times for MRS systems are to be achieved:
• Wall : B20 (C20) or better - thickness minimum 150 mm
• Ceiling : B30 (C25) or better - the ceiling must be dimensioned to bear own weight + the
loads applied by the ceiling hoist system.
It is possible to install the system in concrete of a lower quality; then installation of reinforcement
of the concrete to meet the system requirements of MRS should be expected. Molift Group AS is
not responsible for installation or evaluation of necessary reinforcement.
If in doubt about the concrete quality, Molift Group AS recommends that tensile stress tests be
made with the securing devices used and also test loads within the minimum specications for
vertical loads according to the valid standard (see Table 1 on page 15).
Wood structures
Wood structures are essentially wooden beams. It is important that the beams be dimensioned
to carry the load of the ceiling hoist system (see Table 1 and Table 2) and that the rail system be
placed in a position as advantageous as possible in relation to the frequency of beams. If a ceiling
hoist system is to be mounted in an existing building, it can be vital for eective installation that
there is free access to beams and loft.
In most cases it is necessary to reinforce the ceiling structure to be able to use MRS telescope se-
curing devices. The type of reinforcement depends on how far apart the beams are situated. An
open beam layer will require reinforcement between the beams. In other cases it may require
quite some work to make the required reinforcement. Molift Group AS is not responsible for instal-
lation or evaluation of the necessary reinforcement.
Leca, Brick, Siporex, Light Bricks and Light Blocks
All of these materials are more or less porous. MRS fasteners require ceiling materials to have a
compressive strength of minimum 25 N/mm2 and wall materials to have a compressive strength
of minimum 3 N/mm2. 2-component chemical anchors with or without composite sleeves are pri-
marily used in these types of materials. Both result in longer tting times than identical tting in
concrete.
Molift requires the producers of the elements in which MRS is planned to be installed, to issue a
statement of whether the tting of a ceiling hoist to the elements at a construction site is recom-
mended.
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How to plan and mount a rail system?

With chemical anchor HY-70 (Standard MRS) in the above materials can achieve maximum SWL
300 kg when tted to a ceiling, depending on the method used and the number of securing ele-
ments.
If the structure requires reinforcement to obtain a satisfactory SWL, Molift Group AS is not respon-
sible for evaluation or installation of this.
If in doubt about the rigidity of the material, Molift Group AS recommends that tensile stress tests
be made with the securing devices used and also test loads within the minimum specications for
vertical load according to the valid standard (see Table 1 on page 15).
Light walls
The walls of large institutions are often boarded with plaster and the bearing of the walls are thin-
walled steel pylons. This combination is not suited for mounting of ceiling hoist systems, since the
wall structures are not load bearing. If, however, it is possible to install reinforcement both in and
below the securing point a wall bracket can be mounted on the wall. Reinforcement can be on the
outside of the wall, but the best solution is of course to place it inside the wall. The sooner we are
involved in the planning of the building, the better the solution we can provide. Molift Group AS
is not responsible for installation or evaluation of the necessary reinforcement.
Surface levelling of ceiling
MRS can be mounted in the ceiling via telescope brackets (built-in) or straight in the ceiling (see
chapter 4 – Mounting of MRS ).
If the ceiling surface varies by more than ±2 mm within a distance of 1200 mm, shims are used to
straighten up the mounted elements. MRS has shims for 0.5, 1 and 2 mm.
If the variations exceed ± 5 mm within a distance of 1200 mm, the surface must the levelled before
the system can be mounted in the ceiling. The reason for this is that the tension of the system will
exceed the allowable load of the mounting screws for major variations. This may result in breaking
of the securing devices because of overload.
Molift Group AS is not responsible for levelling uneven surfaces of the ceiling.
Rev E 10/2011 Chapter 2 – Specification of ceiling hoist system Page 17 of 100
How to plan and mount a rail system?

Door openings
A rail system can cover several rooms and there are then two ways to get from one room to the
other.
One possibility is to install separate systems in the rooms and use the “climbing principle” to get
from one to the other, see the user manual of the hoist for details. If the system used is Molift Hi-
Trac, a hoist is to be installed for each system. When climbing with Molift Hi-Trac, the SWL should
not exceed 160 kg
Molift Nomad requires a trolley for each system, and the hoist is then moved from one trolley to
the other by means of climbing.
Another possibility is to make a split above the door opening so that the rail system can continue
from one room to the other. The gure below states the necessary measures for installation of rails
with a split which is adjusted to the trolley. A trolley with an extended strap for the securing point
is used for Molift Nomad. In this way the hoist cannot go all the way up above the door frame, and
squeezing between hoist and doorway is avoided.
Figure 9. Doorway with continuos rail and Molift Nomad
Page 18 of 106 Chapter 2 – Specification of ceiling hoist system Rev E 10/2011
How to plan and mount a rail system?