Installation procedure


Locating the post Mark out required position of post and base plate fixing centres using the post base plate as a template. NB: For Bituminous membranes, it is recommended that a small section of membrane is removed around each fixing point prior to the installation process commencing. Using the 25 mm hole saw tool (part no: 00797-00) and arbor extension (part no: 65010-03) drill through the membrane and insulation until the concrete is reached.	Drill into membrane Using the 56 mm counter bore tool (part no: 00795-00), drill 4 holes centrally over the first set of holes to a depth of approximately 10 mm. The drilling device will ensure the hole will not be too deep.	Mark the tube Insert plastic tube into the hole until it stops at the concrete layer. Mark the tube so it is just below the recessed insulation. Cut to length.	Inserting the tube Re-insert the plastic tube into the hole making sure it is pushed all the way through the membrane layer. This will protect the insulation while drilling into the concrete.

Drill into concrete Using the Hilti TE-CX 16/47 drill bit (part no: 370157), drill a minimum of 50mm/maximum of 55mm deep into the concrete layer.	Pump It is extremely important to ensure that all debris is removed from the hole using the Hilti hole cleaning pump (part no: 60579). This must be done to ensure the Latchways depth gauge seats correctly with the top of the concrete surface	Check depth of hole Once the excess debris has been removed, insert the depth gauge (part no: 00783-00), ensuring the outer tube of the gauge sits firmly on top of the concrete surface. Push the handle of the depth gauge downwards so that the inner part of the gauge reaches the bottom of the concrete hole to check that the hole has been drilled deep enough. Check the hole depth indicator is aligned with the top of the outer casing. If the hole depth indicator is above the top of the outer tube, repeat the process again from point 5. To ensure the Hilti fixing is embedded correctly into the concrete the hole depth is critical.	Insert anchor When the concrete has been drilled to the correct depth and all debris removed, insert the anchor fixing making sure the treaded end is uppermost.

Hammer down plug Pre-check the anchor depth using the depth gauge, ensuring the inner part of the gauge reaches the top of the anchor fixing plug and take a reading. Using the specialist Hilti setting tool (part no: 00790-00), set the drill to hammer position and drive the anchor fixing plug into the concrete to ensure that it is securely fitted in the hole. Hammer down plug cont. Check the depth by re-inserting the depth gauge. The anchor should be driven down a further 5 mm from the initial reading. If necessary, repeat the process until the plug is correctly fixed. Repeat steps 2-9 for the other remaining fixing points.	Mark bolt Place the post over the four fixing points. Drop the base plate fixing bolts into the holes. Hand tighten the fixing bolts so they are fully engaged into the anchor. Measure distance of bolt protruding from the base plate to underside of washer. Subtract 7 mm from this distance and cut excess from bottom of bolt. Cut the bolt to the length required using a hack saw or angle grinder. Repeat this process for the other fixing points.	Protective cap The bolts are correctly tightened when the sealing washers are compressed. A plastic protective cap is fitted on top to sit flush in the recess.	Welding membrane Cut four pieces of membrane to cover the edges of the base plate then: Weld the outer edge to the roof. Weld the sides and inner edge to the base plate. Repeat process on all four sections overlapping where necessary, to ensure the post is fully weathertight. NB: For Protan, a weathering sleeve is pre-assembled on each post. When using Bituminous membranes the weathering detail must be approved by the relevant membrane manufacturer prior to installation.

End posts On both end posts a D ring should be attached using a single M12 bolt. It should be tightened to a torque of typically 20 Nm, ensuring that the spring washer is flat.	Intermediate posts On the intermediate post attach the cable support with an M12 bolt, tightened to a torque of typically 20 Nm, ensuring that the spring washer is flat. Ensure the D ring and hanger bracket are placed in the correct orientation for the cable to pass through.	Corner posts On the corner post, fix a corner unit with an M12 bolt tightened to a torque of typically 20 Nm, so that the spring washer is flat. Ensure the unit is orientated in the correct direction for system use.	Variable posts The variable bracket should be bent using the tube bending tool supplied by Latchways (part no: 85170). NB: It is recommended that the variable bracket should only be bent when the cable has been threaded through the tube. Slide the tube bending tool along the arm of the bracket to the point where a bend is required and tighten by twisting the bar on the top. A maximum angle change of 40° is achieved on each end of the bracket. To attach to the post follow the instructions in point 15.

Fix the swageless terminal to yoke Fit the swageless terminal according to the instructions supplied with the post. NB: If tension adjustment is required at both ends of the system, fit a threaded swageless termination to line tenser, as supplied with the alternative end sets.	First end post Attach the swageless terminal to yoke: Remove the clevis pin and attach yoke to D ring securing by replacing the clevis pin. Fit the split pin and open arms out fully	Thread the cable When all posts and bracketry are installed, thread the cable through the support brackets, checking that it is not twisted and is free from kinks. Ensure that the cable is threaded through all necessary brackets such as hangers and corner brackets.	Second end post Fit the long run line tenser, turnbuckle and swageless terminal unit to the D ring, ensuring that there is a maximum adjustment available in the turnbuckle. Fit the split pin and open arms out fully.

Cut the cable Remove the cable slack from the system, mark the position for cuttingand cut the cable to length.	Connect the system Remove the swageless terminal from the turnbuckle body and attach the cable as per instructions provided. When the cable is locked in place, re-attach to the turnbuckle.	Tension the system Twist the turnbuckle to tension the system.	Check the tension The correct pre-tension is achieved when the disk can be turned freely with your fingers. If this is not the case then the system will need to be adjusted prior to use. When the correct pre-tension has been achieved, fit split pins to the long run line tenser and the swageless terminal to prevent the turning of the turnbuckle and also maintaining system pre-tension. Always check the tension indicator before system use.