Annex B - Over-Side Working Systems

B1 - Introduction

(1) The use of Over-side Working Systems are now considered standard on vessels, especially commercial yachts. Such installations allow crew members to work outside conventional guardrails for cleaning and maintenance purposes.

(2) Most over-side working systems consist of one or a combination of the following:

(a) “Rail and car” or “rail and trolley” systems comprising of two travellers, cars or trolleys linked in tandem that can be separated if necessary into independent units. These cars are fitted to a metal rail which allows them to glide along it and to which support harnesses are attached.
(b) Harnesses, lanyards, fall arresters, energy absorber and similar devices.
(c) Single anchoring points, pad eyes and eye bolts

(3) Traditionally many of the early “rail and car” systems were designed for the sole purpose of sail handling and not for supporting crew members working over the side of the yacht. Equipment which is used for supporting persons shall be designed for that purpose and it is not acceptable to use a “rail and car” system designed solely for sail handling for the purpose of supporting crew members working over the yacht’s side.

(4) Below is an example of a “rail and car” system showing its construction.

(5) Below is a typical set up for the attachments to the traveller cars.

1. Full-body safety harness
2. Working harness.
3. Additional options, such as supporting a tool service car

B2 - Installation

(1) Over-side working systems shall have their fixed components tested, certified and approved to a recognised European Union standard for fall protection equipment such as BS EN 795: 1997, Class D, and shall display the CE mark, or a similar International Standard

(2) If it cannot be confirmed that the design of the attachment to the substrate is identical to that used in the type approval process completed by the over-side working system’s manufacturer, or through approval of the design on another vessel, separate pre-installation testing is required to be satisfactorily completed prior to the system being installed.

(3) In addition to the over-side working systems requiring type approval, the installation of the system to the substrate of the yacht shall be tested to meet the requirements of BS EN 795. For new vessels, this shall be in accordance with the 2012 version of BS EN 795.

(4) Yacht substrates can be of many differing thicknesses and materials, as can the fixtures and fittings that secure the over-side working systems to the substrate. In all cases the method of installation to the particular substrate needs to be tested in accordance with BS EN 795 in order to be considered approved and suitable for supporting crew members working over the yacht’s side. If a particular method of attachment of the over-side working systems to the yacht’s substrate has been previously approved and documentary evidence can be provided only post-installation testing shall be required.

(5) Trackway orientation to be within manufacturer’s approval certificate considering the path of the harness line and resultant wear.

B3 - Pre-installation testing

(1) When the method of attachment to the substrate has not been approved, additional static and dynamic load tests shall be required to prove the strength of the individual installation for each type of base material/fastener type. These tests effectively ‘type approve’ the method of attachment to the underlying structure. It is recommended that such testing is carried out in a workshop on a section of track of at least 400 millimetres in length attached to a representative mock-up of the vessel’s superstructure. Tests shall be witnessed by a Recognised Organisation and if successfully carried out, suitably endorsed records shall be retained.

(2) The specifications for such tests are as follows:

(a) Static load test – this requires the application of a 12kN load in at least 3 locations, typically at both ends and at any rail joint or in the middle. This load shall be applied for 3 minutes.
(b) Dynamic load test – this requires the use of a test lanyard manufactured from rope conforming to BS EN 892 with a 100kg solid test mass dropped through a predetermined distance in order to apply a fall arrest load of 9kN. Direct reference shall be made to BS EN 795:2012 as to how this shall be achieved.
Following the dynamic load test, the car(s) and section of track used for testing shall have been overloaded and shall be discarded.

B4 - Post-installation testing

(1) As with all lifting appliances, once the device has been installed onto the yacht a post-installation load test shall be carried out before the system is taken into use.

(2) Testing post-installation shall be completed as follows:

(a) A test load of 6kN shall be attached to a single car or single anchor point for at least 15 seconds in at least 3 locations, typically at both ends and at any rail joint or in the middle.
(b) Such testing shall be carried out along with any additional requirements specified by the system manufacturer.
(c) The testing shall be witnessed by an approved party acceptable to the Administration and recorded on a suitable load test certificate, which is duly endorsed by the witnessing parties.

B5 - 5 yearly testing

(1) The post-installation test shall be carried out at 5 yearly intervals and also at intervals prescribed by the manufacturer.

B6 - Non-compliant and pre-existing systems

(1) Yachts fitted with uncertified over-side working systems, shall have the systems decommissioned, unless retrospective certification can be obtained.

(2) Yachts fitted with over-side working systems or which there is evidence that the system is in compliance with either BS EN 795:1997 or 2012 but without evidence that the installation was tested by an approved surveyor.

(a) The system shall not be used until such time as the installation arrangements have been approved by an approved surveyor. This may require the submission of drawings of the existing attachment arrangements and the subsequent conducting of static and dynamic testing of the rail attachment method as deemed applicable. On satisfactory completion of this testing the over-side working systems shall have to be subject to the equivalent of the post-installation testing as defined previously in section 4.

(3) Yachts fitted with over-side working systems for which there is evidence that the system is in compliance with either BS EN 795:1997 or 2012 and there is evidence that the installation was approved but there is no evidence of post-installation testing.

(a) The over-side working systems shall have to be subject to post-installation testing as defined previously in section 4.

(4) In the case of section B6(1) – B6(3), prior to the completion of the required load testing, signage shall be clearly displayed stating the track is not to be used unless the crew member has a fall arrester attached by a secondary line which is secured to a strong point suitably tested to take the full load for fall arrest or around an item of yacht structure substantial enough to withstand the drop loads.

B7 - Operation

(1) Before use the Owner or Company shall ensure that:

(a) the manufacturers’ instructions are read and understood by the persons who shall be using the equipment;
(b) a risk assessment is carried out and an appropriate rescue plan developed to recover persons who fall into the water; and
(c) crew members are competent to use the equipment and are aware of any conditions relating to its use and their safety.

(2) Over-side working systems shall not be used whilst the vessel is underway.

(3) These systems are designed to be used with the appropriate PPE (harnesses, lanyards, fall arresters, lifejackets and other devices).

(4) On systems where one of the travellers is fitted with a locking device, the device which locks the traveller in position along the track rail shall ONLY be disengaged from the track rail while the user is changing position. Once the user is in position, the locking shall be re-engaged to hold the car in position and limit the user’s movement along the track rail.

(5) The user shall NEVER rely on only one attachment point for personal protective equipment. The working harness shall be attached to one traveller and a fall arrestor, or other safety device, to the other. A third traveller could be used to attach work tools.

(6) More guidance can be found in the Code of Safe Working Practices Chapters on the use of permits to work.

B8 - Additional notes

(1) Where any over-side working systems has been subject to a dynamic loading equivalent to fall arrest, the system shall be retired from service and subject to a full review by a representative of the manufacturer to confirm the system remains fit for continued use.

(2) All over-side working systems shall be marked for the use of one user only.

(3) The attachment of the safety harness to the car shall be in accordance with the manufacturer’s instructions, which shall include an energy absorber certified for compliance with BS EN 355 or an equivalent national or international standard.

(4) Regardless of whether the system shall be used for restraint or fall arrest, the more onerous test requirements shall be met.

(5) Documentation retained onboard shall be as indicated in Annex A of BS EN 795:2012 or equivalent and shall include as a minimum:

(a) approved plans;
(b) certificates of load test for installation; and
(c) post-installation and periodical testing.

B9 - Further Information

BS EN 795:2012 Personal fall protection equipment – Anchor devices (It shall be noted that the original BS EN 795 standard has been replaced by BS EN 795: 2012);

BS EN 795:1997 Protection against falls from a height. Anchor devices. Requirements and testing;

BS EN 355:2002 Personal protective equipment against falls from a height. Energy absorbers; and

BS EN 892:2012 Mountaineering equipment. Dynamic mountaineering ropes. Safety requirements and test methods.