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OWNER'S MANUAL

Design, installation, load testing and inspection of the Ronstan Series 32 I-Track safety rail for pilot launches and commercial vessels: fastening rules, span limits, how far the track can be sprung, and the track parts list.

DocumentRonstan Series 32 I-Track Safety Rail System Product Manual
FormatPDF · 11 pages · 0.7 MB
LanguageEnglish
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Ronstan Series 32 I-Track Safety Rail System — Product Manual

Compliance & System

  • Meets the Australian National Standard for Commercial Vessels (NSCV), Edition 2.0, Part C, Section 1, 6.19.4.d (Pilot Launches – Equipment).
  • Tethers crew to the vessel during pilot transfer or similar operations, with personal protection equipment. Not for lifting, mooring or any other purpose.
  • Load requirements met: 3.0kN static load with no permanent deformation; 6.0kN static load without breaking. NSCV recommends harnesses, tethers and lanyards to ISO12401, AS2227 or equivalent.
  • One user per car. Maximum 2 cars/users on the system at any time, and never more than one car locked in a single span of rail between mounting brackets.
  • Marine grade stainless steel car with lanyard attachment point, running on a continuous rail of S32 I-Track sections mounted to handrails, superstructure or support brackets. RC63221 plunger stop cars can be fixed "on-station" during pilot transfer or locked disengaged to run freely.

Installation Requirements

  • Install only by competent persons or organisations. The rail mounts on a vertical (0°) or horizontal (90°) surface; cars must travel in a horizontal plane within ±5° (exceptions where needed for deck slope or camber).
  • Track fastenings: M6 or 1/4" 316 stainless countersunk fasteners, minimum tensile strength 700MPa (101ksi), A4-70 DIN7991, torque no more than 7.1Nm (5.2ft lbf).
  • Mounting brackets are specified and installed by the designer / builder; brackets, substrate and backing plates must support a minimum 600kg (1320lb) ultimate static load.
  • Unsupported spans up to 900mm (35 7/16"). Each span or join needs at least two fasteners at each end at a maximum of 100mm (3 15/16") centres, with a joiner and a bracket or splice plate. Across a join of standard rails the fastener spacing is 96mm.
  • Standard lengths can be shortened on site. RC6320R500A (90°, 500mm radius A-bend) can be shortened to suit broader angles.
  • RC63286 end stops (rubber buffer) take a minimum of 2 fastenings; through-bolts recommended.
  • Isolate dissimilar metals: the rail includes RC7320-INS nylon insulator bushes; use isolating compound on all fastenings and joins, and plastic isolating pads between stainless brackets and aluminium track.
  • Fit cars with the lanyard attachment points facing downward or outboard (the fall load path), check they run freely, then fit the end stops.
Track length Max. horizontal deflection when sprung Max. vertical deflection when sprung
1m 50mm 25mm
1.5m 90mm 45mm
2.0m 150mm 75mm
3.0m 300mm 150mm

Straight track may be "sprung" on site into shallow bends without permanent bending, within these limits.

Track Parts

Part No. Description
RC6320-1.0 Track, 996mm (39 3/16"), black View part →
RC6320-1.5 Track, 1496mm (58 7/8"), black View part →
RC6320-3.0 Track, 2996mm (117 15/16"), black View part →
RC6320R125A Track, 293mm (11 9/16"), black, 90° × 125mm radius, horizontal A-bend View part →
RC6320R500A Track, 1196mm (47 1/16"), black, 90° × 500mm radius, horizontal A-bend View part →
RC6320R515A Track, 1996mm (78 9/16"), black, 15° deflection, horizontal A-bend View part →
RC63286 End stop, rubber buffer View part →
RC6320P Track splice plate, stainless steel Ask us to source it →
RC6320J Track joiner Ask us to source it →
RC63221 Plunger stop car Ask us to source it →
RC7320-INS Nylon insulator bush Ask us to source it →

Standard bends are A-bend configuration with the track on a horizontal surface (90°). Custom lengths, configurations and radius bends are quoted by Ronstan on request; the manual shows a typical design layout.

Load Testing & Documentation

  • After installation and before first use, and then at intervals of not more than 5 years or after a fall or incident: apply 3.0kN (300kg) to a single car for at least 30 seconds at each extremity and near the midpoint, oriented to simulate the fall load path, then check for permanent deformation.
  • Record results with photographs in the installation documentation (Appendix A) or 5-yearly inspection record (Appendix D). Keep the documentation with the user, on site.
  • Use only by trained, competent persons with approved personal protective equipment, and with a rescue plan in place.

Inspection & Maintenance

Before each use

  • Rail securely fixed to its brackets / surface, both end stops in place.
  • Cars run smoothly and freely along the track; plunger operating correctly.
  • No excessive wear, corrosion, deformation or breakage.

Annual and 5-yearly

  • Annual inspection by a competent person (Appendix C): fastenings, wear and damage, plunger function, light grease on the plunger assembly, corrosion, fresh-water cleaning, free-running wheels.
  • 5-yearly (Appendix D): remove an end stop and all cars; check wheels and bearings rotate smoothly and replace cars with worn bearings or wheels. As a minimum, replace all cars at the second 5-yearly inspection (10 years cumulative service).
  • Damaged parts or any doubt: remove from service until repaired and approved by a competent person (Appendix B). After any fall, do not use until inspected and confirmed safe.

Maintenance

  • Rinse regularly with fresh water; a mild soapy solution may be used, then rinse thoroughly.
  • No spray lubricants on the rail and wheels.
  • Keep an equipment record for each component (Appendix B).

Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.

Products in this Manual