Useful information about horizontal rail systems

What are horizontal rail systems and what are they used for?

Horizontal rail systems are permanently installed anchorage devices with a rigid guide rail. A compatible roller traveller moves along the defined rail route and connects the user to the safety system. Horizontal rail systems therefore provide continuous fall protection along roof edges, façades, working platforms and technical installations.

SKYLOTEC horizontal rail systems are used in rope access applications, for work on masts and towers, and on mobile platforms, among other areas. Depending on the system, the rails can be installed at floor level, on a wall or overhead. The selection depends on the work route, installation position, number of users, substrate and required freedom of movement.

What advantages do horizontal rail systems offer over individual anchor points?

Individual anchor points are suitable for specific work areas and short maintenance routes. However, when a user regularly needs to cover longer distances, they often have to reconnect repeatedly between several anchor points.

A horizontal rail system, by contrast, enables largely continuous protection along the entire work route. The roller traveller follows the user’s movement and can pass correctly planned rail connections and curves without the connection to the system having to be detached. This makes work processes smoother, more ergonomic and safer.

What advantages do horizontal rail systems offer over horizontal cable systems?

Horizontal rail systems have a rigid guide and therefore exhibit significantly less system deflection than flexible cable systems. This can reduce the required fall clearance and ensures that the traveller is guided particularly precisely along the intended work route.

Horizontal cable systems, by contrast, often offer advantages over very long distances, on complex roof geometries and where fixing substrates vary. Rail systems are particularly suitable for frequently used work routes, rope access applications, overhead protection and areas where controlled, low-resistance movement is the main priority.

Which horizontal rail systems does SKYLOTEC offer?

The SKYLOTEC range includes two flexibly configurable rail systems for professional work at height: SKYRAIL and SECU® TRACK.

SKYRAIL is designed as a continuous horizontal rail system for up to three people. SECU® TRACK can be used by up to six people at the same time, depending on the system configuration, and offers compatible roller travellers for horizontal, vertical and overhead applications. This allows different working areas and installation positions to be protected using a coordinated system family.

What advantages does the SKYRAIL rail system offer?

SKYRAIL provides continuous protection with a high degree of freedom of movement for up to three people at the same time. The system is particularly suitable for horizontal work at height and rope access applications on buildings and technical structures.

The SKYRAIL RAIL is made from a special aluminium alloy and is available in different lengths up to a maximum of six metres. Straight rail elements, horizontal curves, internal and external curves, and suitable adapter plates allow the system to be adapted to different building geometries and fixing substrates.

What advantages does SECU® TRACK offer?

SECU® TRACK is a flexibly configurable rail system for up to six people. It provides continuous protection with freely positionable roller travellers and, depending on the system design, can be used horizontally, vertically or overhead.

Aluminium and stainless steel rails, as well as different traveller types, are available for the system. This allows SECU® TRACK to be adapted to different environmental conditions, numbers of users and working movements. Its high system flexibility offers particular advantages on larger industrial installations and frequently used work routes.

When is a horizontal rail system suitable for overhead applications?

In an overhead application, the guide rail is installed above the user. This keeps the lanyard comparatively short and can significantly reduce a potential free fall. This is particularly relevant where only limited clearance is available below the working area.

Overhead rails are suitable, for example, for production halls, loading areas, vehicle maintenance, industrial workplaces and mobile platforms. The SECU® TRACK OVERHEAD RUNNER is designed specifically for horizontal overhead rails made from aluminium or stainless steel.

What function does the roller traveller perform in a horizontal rail system?

The roller traveller forms the movable connection between the user and the rail. Its rollers guide it in a controlled manner along the rail profile and enable smooth movement with low resistance.

A removable horizontal roller traveller is available for SKYRAIL. SECU® TRACK offers both a conventional and a hinged horizontal roller traveller. The traveller must always be compatible with the respective rail profile and intended installation position. A horizontal traveller must not be used for vertical or overhead applications without the manufacturer’s approval.

When is a removable or hinged roller traveller useful?

Removable roller travellers can be inserted into the system at defined points and removed again once the work has been completed. This allows each user to carry their own personal traveller while the rail remains permanently attached to the structure.

Depending on the system, hinged roller travellers make it easier to attach the traveller to the rail and offer advantages where there are separate rail sections or changing work locations. However, insertion and removal may only take place at the designated points and in accordance with the manufacturer’s instructions.

How are horizontal rails routed around curves and building corners?

Building edges, façade routes and technical structures often require changes of direction in the rail system. Prefabricated curve elements are available for this purpose and can be passed by the roller traveller without disconnecting.

SKYRAIL offers horizontal curves with a standard radius of 220 millimetres, as well as 90-degree internal and external curves made from a special aluminium alloy. The curves must be installed and supported so that they align precisely with the straight rail profiles and the traveller can move through the system without blocking.

How are individual rail profiles connected?

As rail profiles are only supplied in defined individual lengths, longer system routes are constructed from several sections. Connector plates align the individual profiles precisely with one another and create a smooth transition for the roller traveller.

In SKYRAIL, the SKYRAIL RAIL CONNECTOR connects individual rail sections. For aluminium profiles of SECU® TRACK, the SECU® TRACK JUNCTION AL is used. The transitions must be aligned precisely so that the traveller can roll smoothly across the connection point.

What function do rail brackets and adapter plates perform?

Rail brackets connect the rail profile to the load-bearing structure and transfer the forces generated into the building. Their position, fixing and spacing are defined specifically for each project.

SKYRAIL can be installed on system supports, concrete or substructure plates using different adapter plates. SECU® TRACK uses Z-brackets and sliding blocks, among other components, to fix the aluminium rail. The required bracket depends on the installation position, substrate, profile material and structural requirements.

Why are end stops required in horizontal rail systems?

End stops prevent the roller traveller from unintentionally running out of an open rail end. They therefore form a safety-relevant termination of the system.

The SKYRAIL END-STOPPER and the SECU® TRACK END AL secure the respective rail ends. Following installation work, extensions or modifications, it must be checked that all rail ends are completely closed using the designated original components.

Why must temperature-related changes in length be taken into account?

Aluminium rails expand when heated and contract when temperatures fall. On longer rail routes, this can result in significant changes in length that would cause stresses in the profile and brackets if the rail were fixed completely rigidly.

SECU® TRACK uses special sliding blocks to accommodate temperature-related changes in the length of the aluminium rail. Fixed points and sliding fixings must be arranged in accordance with the technical system design. This aspect must be taken into account, particularly on outdoor installations and long profile routes.

What advantages do aluminium and stainless steel rails offer?

Aluminium rails are comparatively lightweight, making transport, handling and installation easier. They are suitable for numerous roof, façade and industrial applications and can be adapted to complex building geometries using straight profiles and curves.

Stainless steel rails offer high corrosion resistance and can provide advantages in aggressive environmental conditions, high humidity or demanding industrial applications. The choice of material depends on the place of use, corrosion exposure, substrate and project-specific requirements.

How many people may use a horizontal rail system at the same time?

The permitted number of users depends on the selected rail system and the respective system configuration. SKYRAIL is designed for up to three people at the same time. SECU® TRACK can be used by up to six people, depending on the configuration.

The maximum number of users is determined by the system approval, bracket spacing, fixing substrate and technical design. It must not be inferred solely from the material or size of the rail profile. Where several users are involved, minimum distances and possible simultaneous fall-arrest loads must also be taken into account.

Which standards apply to horizontal rail systems?

EN 795:2012 Type D is particularly relevant to horizontal rigid anchorage devices. It describes permanently or temporarily installed systems with a rigid horizontal guide.

CEN/TS 16415 is additionally relevant for simultaneous use by several people. Depending on the product and target market, further requirements such as general technical approvals or UNI 11578 may apply. The complete tested system comprising the rail, roller traveller, brackets, connectors, curves and fixings is always decisive.

How is the required fall clearance determined for horizontal rail systems?

Although rail systems exhibit less deflection than flexible cable systems, sufficient clear fall space must be available below the user. The length of the lanyard, the potential extension of an energy absorber, the user’s height and an additional safety clearance must all be taken into account.

In overhead applications, the fall distance can be significantly reduced by the high anchor point. With floor- or wall-mounted rail systems, by contrast, it must be assessed particularly carefully whether a fall arrest system or a restraint system represents the appropriate form of use.

How can swing falls be prevented with horizontal rail systems?

A swing fall occurs when the user moves a considerable distance sideways from the current traveller position and, in the event of a fall, swings in an arc against the structure or other obstacles.

The rail route should therefore be positioned as close as possible to the actual work route. Curves and additional rail sections may be required to limit lateral distances. The length of the lanyard and the user’s working position must also be coordinated with the planned protection concept.

Which personal protective equipment is used with horizontal rail systems?

A suitable fall arrest harness, a compatible system traveller and a lanyard appropriate for the application are required to use a horizontal rail system. Depending on the installation position and available fall clearance, energy-absorbing lanyards, restraint lanyards or retractable fall arresters can be used.

The roller traveller may only be used with the rail system intended for it. The fall arrest harness, lanyard and traveller must be regarded as a complete safety system and used in accordance with the respective manufacturer’s instructions.

Why must horizontal rail systems be planned specifically for each project?

The rail route, installation position, curves, bracket spacing, rail connections and entry and exit points must be matched precisely to the intended work route. Fall edges, technical installations, building corners, swing-fall hazards and rescue routes must also be considered.

In overhead applications, the installation height, working radius and available fall clearance must also be checked. A horizontal rail system must therefore not be assembled solely from individual shop components, but must be planned as a complete, technically tested system solution.

How are horizontal rail systems installed correctly?

Installation begins with an inspection of the fixing substrate and the precise positioning of the rail brackets. The rail profiles are then installed, joined using connector plates and completed with curves and end stops.

All profile transitions must be aligned correctly so that the roller traveller moves smoothly through the system. Fixings, bracket spacing and tightening torques must comply with the installation instructions. Once complete, the system must be fully inspected, marked and documented.

How are horizontal rail systems inspected and maintained?

Before each use, the rail, roller traveller, end stops and visible fixings should be checked for damage, corrosion, deformation and loose components. The traveller must move smoothly and must not block at rail connections or curves.

Regular inspections by a competent person are also required. Following a fall arrest event, structural modifications or exceptional loads, the system may only be used again after assessment by a competent person. Inspections, repairs and modifications must be fully documented.

How do you choose the right horizontal rail system?

SKYRAIL is suitable for continuous horizontal safety routes and rope access applications with up to three people. SECU® TRACK offers advantages for larger numbers of users, different installation positions and applications in which horizontal, vertical or overhead travellers are required within one system family.

The substrate, rail material, work route, number of users, curve route, fall clearance and environmental conditions must also be considered. A SKYLOTEC horizontal rail system should always be planned specifically for the project and used exclusively with the approved roller travellers and system components.