GRAVITY GLOBAL (PTY) LTD

GRAVITY VERTICAL SYSTEM INSTALLATION MANUAL

Version 1.3 – May 2022

1. Scope and intent
This manual is a guideline for all technicians for the installation of the Gravity Vertical System.

2. Abbreviations and definitions

Abbreviations and words meaning:

Ø Diameter

8.8 Class used for metric fasteners to designate the fastener strength.

A2 304 Stainless Steel

A4 316 Stainless Steel

Galv A zinc coating that is applied to steel parts as well as bolts and nuts.

Kg Kilogram

kN Kilo Newton

Nm Newton-Meter – the measure of force used to tighten (torque) bolts and nuts.

PPE Personal Protective Equipment

Torque The measure of the resistance of a fastener to further tightening.

 3. General information

3.1. Description
The Gravity Vertical System provides fall protection for persons climbing fixed ladders or similar
structures.

The Gravity Vertical System is designed to eliminate or substantially reduce the risk of a fall that would
otherwise lead to serious injury or death of persons working on elevated structures.

The Gravity Vertical System is fixed to the structure via the top, intermediate, and bottom bracket
assemblies. The lifeline is supported at intervals with intermediate brackets, and the intermediate
brackets help to reduce the loads in the event of a fall.

3.2. Design
Before installation, a site study is essential, either by a survey of the premises with necessary
measurements taken or by the supply of precise and technical drawings.

This study will allow the determination of the layout and utilization modes resulting from the following
technical elements: appropriateness of the structure and fixings, centre distances of anchor assemblies,
cable length, etc.

This study will take into consideration the design requirements of the standard EN 353.

3.3. Requirements
3.3.1.Structure
The structure on which the Gravity Vertical System is to be installed on must be capable of withstanding
the possible forces in case of a fall. The structural integrity and the structure’s ability to sustain the
imposed loads must be verified by a Professional Engineer.
 The top anchor of the system must be able to sustain the following loads without failing:

3.3.1.1. 15KN for 1 User

3.3.1.2. 16KN for 2 Users
3.3.1.3. 17KN for 3 Users
3.3.1.4. 18KN for 4 Users

3.4. Fall clearance

It is essential to check the free space between the user and an obstacle. The operator’s fall distance is
influenced by the PPE that they use and the methods they employ to work at height.

Work that takes place close to the ground is often the highest risk in terms of fall distance and additional
precautions should be taken when connecting and disconnecting PPE.

In the event of a fall, the textile shock absorber can deploy 16cm when exceeding 100kg load and a max
of 30cm.

3.5. Fall arrester: Glider

The fall arrest Glider incorporates a shock-absorbing textile element. This shock absorber limits the forces
(on the structure and the person) during a fall event to a maximum of 6kN. The textile shock-absorbing
element must be protected against exposure to the elements – in particular to UV light, as this damages
the textile fibres.

It is forbidden to manipulate the ZIP fall arrester during ascent or descent as handling the ZIP may interfere
with the fall arresting mechanism. If necessary, handle the fall arrester by its connector, never handle the
body of the fall arrester in service.

3.6. Torque requirements

When installing the Gravity Vertical System, fasteners on the various components must be tightened to
the torque values indicated in this document.

The installer must ensure that torque tools are calibrated and have a current, valid torque certificate.
 General torque values (not lubricated):

3.6.1.M10: 32Nm
3.6.2.M12: 50Nm
3.6.3.Cable clamp grub screws: 20Nm

3.7. Usage
The Gravity Vertical System may only be used in a vertical orientation.

Maximum one (1) user per Zip fall arrest Glider.

Safe use of the system is limited to a user weight range, including tools and clothing, of 50kg (110 lbs) up
to 150kg (330 lbs).

The PPE (personal protection equipment) that is selected will form an essential part of the fall protection
system. A full-body harness with a sternum (chest) attachment point and a helmet rated for work at height
must be used with the system.

Ascend and Descend the structure in the following manner:

ASCENT: Climb in the methodical and recommended manner where 3 points are in contact with the
structure at all times, i.e., two hands one foot, one hand two feet, and be aware that impeding any part
of any safety device potentially exposes the user to risk.

DESCENT: To descend, climb normally down the ladder or ladder rail rungs at a steady rate, as described
above. If the Glider locks onto the cable, move upward slightly to release the Glider and then continue
descending.
 Resting at a non-designated position: The Glider should not be used as a work positioning device – it is
not designed to suspend the user on. When stopping or resting during a climb, users must:

• Use an approved work positioning device or stop at a designated resting platform.

• Remain in positive contact with the ladder at all times, with both hands and feet.
• Push the traveller above the chest position so that the cam is actively engaged with the wire, without
suspending full body weight on it, before attaching a work positioning device.

3.8. Usage limitations

The strength of the system is directly influenced by the structure onto which it is installed. All structural
materials must be free of any manufacturing defects or damage (such as ageing, overload, chemical or
climatic attack, etc.).

The safe use of the Gravity Vertical System is only assured if it is used in combination with the correct fall
arrest PPE (harness, helmet, etc.), that complies with the relevant standards and that are used in
accordance with the manufacturer's recommendations.

The installation and use of the parts and accessories, as well as the position and quality of fixing of the
anchorage points, must be strictly adhered to as described in this document.

WARNING: The Gravity Vertical System is designed to protect operators against falling from a height and
should never be used as a suspension system.
3.9. Site work
Safety on site must be managed in accordance with the applicable laws and client specifications for the
site.

3.10. Before use checks

3.10.1. Check the tension of the cable using the tension indicator attached to the tensioner.
3.10.2. Check that the attaching parts have been tightened properly.
3.10.3. Check the condition (in particular the shock-absorbing textile) and operation of the fall arrest Glider
on the cable by up and down movement on the cable, with a function test to confirm that the Glider locks
on the cable with a sudden downward pull.
3.10.4. Check the validity of the system on the certification sign at the entry point to the line.
3.11. Maintenance
If required, the system can be wiped clean with a soft non-scratch cloth and fresh, cool water.

All bolt and screw tightness can be checked, and the tensioner should be adjusted if necessary.

3.12. Dynamic testing

Dynamic testing is not allowable on the Gravity Vertical System as this test is destructive.

3.13. Static testing

Static testing is not allowable on the Gravity Vertical System as this test is destructive.

3.14. Warranty
The components of the Gravity Vertical System are covered under limited warranty against any
manufacturing defects. The limited warranty covers any Gravity Vertical System parts found to be
defective. This limited warranty is applicable for 10 years on fixed structural components and 2 years on
mechanical components.

3.15. Warranty limits

The warranty does not apply to:

3.15.1. The supporting structure.

3.15.2. Parts that are damaged by testing, use of the system outside the provisions, or in the event of a fall.
3.15.3. Any non-Gravity Vertical System components.
3.16. Training
It is the responsibility of the installation technicians to understand these instructions and to be competent
in the correct installation, use and maintenance of the system. Installation technicians must be aware of
the consequences of incorrect installation or use of the system.

Training and re-assessments for installers must be undergone annually to ensure installer proficiency.
Only Gravity Global may train and declare installers competent for the Gravity Vertical System.
 Before each installation, it is essential to validate the strength of the support.

When installing the Gravity Vertical System, it is recommended that the system be installed on the
structure starting from the top end of the structure working down.

3.17. Basic installation steps:

Step 1. Position and mount the Top Anchor Assembly on to the ladder.

Step 2. Thread the cable through the cable clamp and then through the top anchor, ensuring that it is
seated in the thimble. Thread the cable end back through the cable clamp and tighten the cable clamp
bolts.

Step 3. Install the intermediate anchor assembly onto the ladder rung.

NOTE: The Intermediate bracket and Intermediate anchor should preferably be assembled as a sub-
assembly on the ground, this will eliminate handling multiple loose components that could lead to
dropped objects.

NOTE: If Intermediate anchors are needed on the installation, it is advisable to slide the Intermediate sub-
assembly onto the cable and hold them in place with a plastic cable tie before attaching the top of the
cable to the top anchor. This will allow you to affix them to the ladder when climbing down.

Step 4. Install the captive Glider and Glider Enclosure, if applicable.

 Step 5. Install the Bottom Anchor Bracket onto the ladder.

Step 6. Attach the certification plaque and tensioner to the Bottom Anchor Bracket.

Step 7. Thread the cable through the cable clamp and then through the bottom anchor, ensuring that it is
seated in the thimble. Thread the cable end back through the cable clamp and tighten the cable clamp
bolts.

Step 8. Trim the cable.

Step 9. Tighten the nut on the tensioner to tighten the lifeline until the tension indicator shows that the
correct tension has been reached.

Step 10. Quality assurance and certification checks.

4. Parts list and installation instructions:

The following is a parts list for the Gravity Vertical System, along with installation instructions.

4.1. Top Bracket Assembly

The top anchor bracket is designed to take the loads generated in the event of a fall occurring.

Designed to be adaptable for most ladder/rung designs (10-40mm rung size).

Constructed from 316-grade stainless steel

Consists of fixing bar, U-bolts and anchor eye, with a thimble.

Net weight: 1.6 kg

 To install the top bracket assembly, follow these instructions:

4.1.1.Fix the anchor eye to the flat side of the fixing bar, through the middle hole, using an M12 bolt with flat
washers (one each side), nut and thread locking compound. Tighten the bolt to a minimum of 40Nm,
making sure it is vertically aligned in line with the fixing bar. Punch the protruding thread to ensure the
nut is mechanically locked. This attachment is usually done by Gravity before installation on site.
4.1.2.It is recommended that the thimble be inserted onto the anchor eye and the cable attached to it before
the top anchor assembly is installed onto the ladder rung.
4.1.3.Position the fixing bar along the back of the ladder rungs with the flat side against rungs.
4.1.4.Insert the U-bolts from the front side of the ladder rungs through the slots in the fixing bar. Insert the flat
washers and the nuts with thread locking compound onto each threaded end of the U-bolts and tighten
to 25Nm.

NOTE: Ensure that the rung insulation tube is inserted over the rung before tightening the U-bolts. The
rung insulator tube must be positioned in such a way as to avoid direct contact between the ladder rungs
and the lifeline brackets and U-bolts.

NOTE: Ensure that the U-bolts have sufficient thread length to be fixed tightly onto the ladder rungs – i.e.,
that the nuts are tightened to the correct torque without running out of thread on the U-bolt shaft. If
necessary, change the U-bolts to the correct size.

4.2. Cable and cable clamp

4.2.1.Cable:
Stainless steel cable of 8mm diameter.

Breaking strength >35kN.

Net weight: 0.21kg per metre

4.2.2.Cable clamp:
Aluminium body with stainless steel grub screws.

Breaking strength: N/A

Weight: 0.1kg

4.2.3.Connection of the cable:

Slide the end of the cable through the cable clamp from the right side, with the cable clamp screws at the
top. Loop the cable through the anchor eye of the top anchor assembly, over the thimble, and back
through the cable clamp. At least 3cm cable must protrude from the cable clamp. Pay attention to the
graphics on the cable clamp and ensure that the cable tail end and eye are correctly orientated.

X
Figure 1: Cable clamp used incorrectly.

Tighten the grub screws on the cable clamp in the correct order (centre then closest to the eye then
furthest from the eye) to 20Nm each. Insert the cable end cap onto the cable end.
4.3. Intermediate bracket
Used to mount the intermediate anchor to the ladder.

Material: stainless steel 316.

Net weight: 0.315kg

The Intermediate bracket is fitted to the backside of the ladder rung (similar to the top and bottom fixing
bar) using a stainless-steel U-bolt and two A4 flange nuts. Tighten the nuts to 25Nm, ensuring to apply
thread locking compound.

NOTE: Ensure that the rung insulation tube is inserted over the rung before tightening the U-bolts. The
rung insulator tube must be positioned in such a way as to avoid direct contact between the ladder rungs
and the lifeline brackets and U-bolts.

The distance between two successive Intermediate brackets may not be more than a maximum of 10m,
the distance may be less than 10m apart.

4.4. Intermediate anchor

Intermediate anchors are fitted at 10m intervals, guides the lifeline and assists in absorbing shock loads
during a fall event.

Material: stainless steel 316.

Net weight: 0.20kg B

Distance between two successive anchors 10 m or less.

A
To install an Intermediate Anchor:

Place an A4 stainless steel flat washer on the M12x30 A4-70 bolt.

Insert the M12x30 A4-70 stainless steel bolt in the hole of Part A of the Intermediate anchor, through the
hole of the Intermediate bracket and then through Part B of the Intermediate anchor.

Place an A4 stainless steel flat washer on the M12x30 A4-70 bolt and then start threading the nut unto
the bolt.

Apply thread locking compound and tighten the A4 stainless steel nut until the screw head and nut come
up against the sides of the Intermediate bracket. The bolt should protrude two threads from the nut.

*It is advisable to not tighten the intermediate anchor assembly until the top and bottom anchor
assemblies are set in place.

The exit angle of the cable should not be more than +/- 5° when exiting an intermediate bracket. This will
avoid creating point loads on the cable when the system is tensioned.

NOTE: It is strongly advised that the Intermediate bracket and Intermediate anchor should be assembled
as a sub-assembly so it can be installed as a unit.
 Apply thread locking compound and tighten the U-bolts to 25Nm.

Apply thread locking compound and tighten the fixing bolt between the intermediate anchor and its
bracket to 25Nm.

The intermediate anchor assembly helps to reduce the shock loads during a fall event and ensures that
the cable is kept in place at all times.

4.5. Tensioner
Tensions the Gravity Vertical Systems as part of the Bottom Bracket Assembly.

Material: stainless steel 316 with aluminium tubing.

Breaking strength: N/A

Net weight: 0.635kg.

The cable tensioner is used for setting the tension of the lifeline to the required value, and to absorb any
movement in the cable (for example caused by wind loads).

The tension indicator on the tensioner allows instant checking of the correct tension on the lifeline.

Tension
Indicator

To install the tensioner, follow these instructions:

4.5.1.Fix the L-bracket to the flat side of the fixing bar, through the middle hole, using an M10 bolt with flat
washers (one each side), nut and thread locking compound. Ensure that the certification plaque is fitted
in between the L-bracket and the fixing bar. Tighten the bolt to a minimum of 25Nm and making sure
that the L-bracket is vertically aligned in line with the fixing bar and with its short side in contact with the
fixing bar (its long side should be horizontally orientated below the vertical short side).
4.5.2.Position the fixing bar along the back of the ladder rungs with the flat side against rungs. NOTE: If a Glider
Enclosure is fitted to the line (for captive Gliders) the fixing bar must be fitted to the front of the ladder
rung and the U-bolts from the back.
4.5.3.Insert the U-bolts from the front side of the ladder rungs through the slots in the fixing bar. Insert the flat
washers and the nuts with thread locking compound onto each threaded end of the U-bolts and tighten
to 25Nm.
4.5.4.Remove the bottom nut and washer from the tensioner and push the tensioner threaded rod through the
hole in the L-bracket. Thread the washer and nut back on so that the tensioner is attached to the L-bracket,
with the anchor eye towards the top. (It is recommended that the thimble be inserted onto the tensioner’s
anchor eye before the tensioner is installed onto the L-bracket).

NOTE: Ensure that the rung insulation tube is inserted over the rung before tightening the U-bolts. The
rung insulator tube must be positioned in such a way as to avoid direct contact between the ladder rungs
and the lifeline brackets and U-bolts.

NOTE: For captive Gliders, ensure that the Glider/s are threaded onto the lifeline before the cable is
terminated onto the tensioner. Also, ensure that the Glider Enclosure is threaded onto the lifeline before
the cable is terminated onto the tensioner. The fixing bar must be positioned on the front of the ladder
rung to ensure minimal deflection of the cable through the Glider enclosure.

Figure 2: Bottom fixing bar is attached at the front of the ladder rung to ensure minimal deflection of the cable caused
by the Glider Enclosure.
 Terminate the cable end through the cable clamp, as per instructions under step 16, making sure the pull
any excess cable through the cable clamp before tightening the cable clamp screws.

Cut the cable with a cable cutter, (making sure not to damage the lifeline in the process) ensuring the
remaining tail length is at least 3cm long so that the cable end cap can be inserted.

To ensure that the cable end cap remains on the cable, heat the cable tip up using a cigarette lighter (this
will heat the cable end cap up enough to stick to the cable as it cools down), or alternatively place some
glue on the cable tip. Place the cable end cap on the cable end.

Tension the cable by tightening the tensioning nut, until the green tension indicator can be seen below
the anchor eye of the tensioner.

CAUTION: Excessive tension must not be applied through the tensioning unit. If the red indicator shows,
tension must be released.

Then check the performance of the system over its entire length in the operating configuration. If not
done yet, ensure that intermediate anchor fixings are torqued correctly.

4.6. Glider enclosure

The Glider Enclosure protects captive Gliders from exposure to the elements.
 Material: stainless steel 316 with aluminium tubing.

Breaking strength: N/A

Net weight: Different according to capacity (single, double or triple Glider Enclosures).

The Glider enclosure is installed at the bottom end of the lifeline. It is fixed to a ladder rung, just above
the lifeline's bottom anchor assembly. Once installed, the Glider enclosure serves as a protective housing
for the Glider, to protect it against exposure to the elements.

Care should be taken to ensure that the Glider enclosure is correctly positioned and aligned, so it allows
for easy insertion and removal of the Glider, while not deflecting the cable or interfering with the bottom
tensioner.

The Glider enclosure is installed by fixing it onto the rung above the bottom anchor assembly, using the
bolts provided. The bolts are tightened to 25Nm.

NOTE: Ensure that the rung insulation tube is inserted over the rung before tightening the Glider Enclosure
bolts. The rung insulator tube must be positioned in such a way as to avoid direct contact between the
ladder rungs and the Glider Enclosure and bolts.

4.7. Anti-pivot bar

The anti-pivot bar prevents the single-glider enclosure from pivoting around the ladder rung on which it
is fixed.

Material: stainless steel 304.

 Breaking strength: N/A

Net weight: 0.20kg.

The anti-pivot bar is installed at the same time as the glider enclosure. It is located between Glider
Enclosure and the ladder rung. When the Glider Enclosure bolts are tightened, it keeps the anti-pivot bar
in place.

During installation, it is important to ensure that the anti-pivot bar is adjusted vertically so that its bottom
end overlaps the rung below the Glider Enclosure. This will ensure that when the Glider Enclosure pivots
downwards around the ladder rung, the anti-pivot bar stops it from moving, as it presses against the front
of the rung.

4.8. Glider with shock absorber

The Glider is used to connect the user to the lifeline and is designed to absorb the forces during a fall
event.

Material: stainless steel 316 with textile shock absorber.

Breaking strength: N/A

Net weight: 0.64kg.

The Glider is the PPE that attaches the user to the lifeline. It is fitted with a connector that must be
attached to the user’s chest D-ring of their harness.

Gliders are either removable or captive. A removable Glider must not be left on the lifeline. A captive
Glider must be stored in the Glider Enclosure when not in use.
 The fall arrest glider ZIP accompanies the progression of the user and passes the anchors smoothly, it will
lock automatically in case of a fall. The Textile energy absorber will develop between 160mm up to 300mm
in the event of a fall expected at 100kg.

To install a captive Glider on the lifeline system, the Glider must be installed, and the locking bolt engaged
and tightened. It is sealed in place using the thread locking resin which must fill the hole completely, to
prevent the bolt from being removed afterwards – see below. NOTE: This is usually done by Gravity before
the components are dispatched for installation.

Once the Glider is installed onto the lifeline, it must be used along the full length of the lifeline as a function
test, before the system can be certified.

4.9. Certification plaque and tag

The certification plaque and tag contain important information and is used to identify the lifeline.

Material: stainless steel 316 with aluminium tubing.

Breaking strength: N/A

Net weight: 0.25kg.

Recertification must be performed annually in accordance with EN 365.

The manufacturer’s label is installed in the immediate vicinity of the line, where users attach themselves
to the line (in this case, it is fixed on the bottom anchor assembly, between the L-plate and the fixing bar).

To ensure that the required annual inspections are up to date, the notice board must accompany the
system and must show the date of the last inspection.
 A new inspection date sticker must be applied when the system is recertified.

Once the sign is installed, the red tag must be attached through the bottom eye of the cable and locked
in place. The red tag has the system serial number on it and accompanies the sign.

5. Certification
Gravity Access has a quality assurance program (the Gravity Quality System) to ensure that every Gravity
Vertical System is installed correctly before it is certified.

Following are recommendations and information relating to the documentation required after
installation.

For the installer, user, manufacturer and system owner, the documentation on the installation provides
evidence that the installation was performed correctly. Also, it serves as an essential foundation for
further examination of the installation.

After installation, the installer sends the user copies of the documentation for the installation. This
documentation must be kept in the building for subsequent reviews of the anchor.

Documentation on the installation must contain at least the following information:

5.1. The address and/or location of the installation.
5.2. The name and contact details of the company that carried out the installation;
5.3. The name of the person responsible for the installation;
5.4. The product identification (manufacturer of the anchor, type, model/item);
5.5. The fixing device (manufacturer, product, and transverse tensile forces eligible);
5.6. The schematic plan of the installation, for example, a lattice tower, and information relevant to the user,
such as the position of the anchor points.

Verification is required that the Gravity Vertical System installation:

5.7. Has been installed per manufacturer's installation instructions;

5.8. Is consistent with the plan, where applicable;
5.9. Was attached to the specified support;
5.10. Has been set as specified (e.g., number of bolts, correct materials, position/location correct);
5.11. Was put into service according to information supplied by the manufacturer;
5.12. Came with photographic information / documentation;
5.13. When several anchor points must be photographed for identification purposes, it is recommended
to mark the anchoring devices with numbers and incorporate this numbering in the inspection records of
the anchoring device and the ground plan in the installation area.
5.14. Fixing details and joints must be located as per drawings, where applicable.
5.15. Torque all fixing nuts and bolts as per indicated specifications.

An alternative to the documentation mentioned above – and the preferred method – is to use the Gravity
Access application with a smartphone that has internet access to capture all the required evidence of the
system installation.

All the information is then verified and reviewed to ascertain the correctness of the installation before a
certificate is issued for the system.

No installation can be signed-off without Gravity’s approval. Without Gravity’s approval of an installation,
there will be no certificate for the system and all liability remains with the installer. A certificate will only
be issued once Gravity has confirmed that the installation is correct, based on the evidence submitted by
the installer.
 Maintenance check sheet

Component: Inspection date

Every Year /
The System Inspection: Pre Use Check Yes /No
After a Fall

Visual inspection. Check system for signs of a fall event. X

Check system tag is present and legible X
Check all components for signs of damage, rusting or
severe corrosion X
Check all components are isolated from disimilar metals X
Check integrity of structure X
Check split pins present and in good condition X
Check fasteners are correctly tightened. Use Torque
Wrench as required X
Clean system as necessary X
Check cable condition for fretting, corrosion, signs of
contamination and damage X
Check cable tension X
Inspect brackets for damage, corrosion, or rust. Look for
cracks, bends, or wear that could affect strength or X
operation of the system.

Check inline energy absorbing elements are intact X

Check intermediate brackets X
Check clamps are not overtightened. X
Check that there is no visible damage to the energy
absorber. X
Check that the spring is functioning by lifting the cam
The Glider
arms and letting go, the cam arms should spring back. X
Check the rivet and rivet nuts for signs of damage X
Check the gate of the karabiner opens, closes and locks X
Check for cuts, abrasions and fraying X
IMPORTANT: Extreme working conditions (harsh environment, prolonged use, etc.) may require increasing the
frequency of inspections.

DO NOT USE THE SYSTEM IF ANY DOUBTS REMAIN AFTER PRE USE CHECKS HAVE BEEN CONDUCTED
 Periodic Examination And Repair History
Reason for entry
Defects noted repairs carried out and Name and signature of Periodic examination
Date (Periodic examination or
other relevant information competent person next due date
repair)