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Twin Overhead Bypass Rigid Rail System

Maximize teamed maintenance efficiency with multi-user bypass rigid rail systems. Pass seamlessly without disconnecting while eliminating swing fall risks.

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Performance Beyond Compliance

When service, maintenance, loading and unloading requires work at height on the top of railcars, aircraft, or loading trucks and trailers, workers are exposed to severe hazards that generic compliance frameworks fail to mitigate. While standard OSHA compliance serves as a baseline, true risk management requires moving Beyond the Hierarchy to eliminate hidden pendulum dynamics and swing fall risks. To achieve this, our engineering approach strictly aligns with the comprehensive hierarchy of fall protection established by ANSI, rather than relying on broader OSHA administrative controls. Traditional horizontal cable lifelines allow for significant lateral deflection, which drastically increases total fall distance and creates a dangerous arc where a falling worker can strike vehicles or equipment. By leading with an evaluation of these specific application hazards and tight clearance mathematics, facility managers can replace dangerous, sagging lines with a secure, highly efficient environment.

The ideal solution is an engineered rigid rail track and trolley system designed specifically for active fall arrest and fall restraint. Engineered under the direct supervision of a Qualified Person and fully compliant with the ANSI Z359.6 design standard, these overhead systems neutralize swing fall hazards by keeping the anchorage point securely locked directly above the user. For environments demanding maximum operational efficiency, our multi-track and patented Twin Rigid Rail innovations allow teamed maintenance crews to bypass one another seamlessly, enabling multiple workers to complete tasks simultaneously and get the job done quicker without ever disconnecting. Backed by our team of licensed engineers and project managers who expertly bridge the gap between complex structural design and field-verified life safety. Flexible Lifeline Systems provides complete single source project management, from initial survey and structural calculations, to design and engineering, certified fabrication, installation and inspection services ensuring your facility achieves long-range safety and compliance.

Aircraft Overhead Fall Protection Hanger Demo

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Compliance

  • Federal Standards: Engineered to meet or exceed OSHA 29 CFR 1910.140, General Industry, and 1926.502, Construction, criteria for fall arrest systems. 
  • Design Engineering: Every system is designed and verified according to ANSI/ASSP Z359.6, Specifications and Design Requirements for Active Fall Protection Systems. 
  • Structural Safety: Structural components are hot-dip galvanized in accordance with ASTM A-123 to maintain load-bearing integrity and corrosion control. 
  • Canadian Standards: Systems are compliant with CSA Z259.2 standards for engineered fall protection. 
  • Qualified Supervision: All rigid rail solutions are designed and installation-verified by a Qualified Person, ensuring the host structure can sustain the necessary dynamic loads.

Twin Rigid Rail Fall Protection System Features & Benefits

No More Dust/Debris Build-Up

No More Dust/Debris Build-Up

The enclosed track completely eliminates dust and debris build-up, providing a maintenance free fall protection system. Old style I-beam trolley systems are prone to dust and debris build-up on the exposed flanges which is knocked off the beam when the trolley passes by and potentially into the railcar or truck, resulting in contaminated product. In addition, dust and debris build-up prevents the trolley from rolling smoothly resulting in the user having to drag the trolley behind him, sometimes as far back as the retractable extends. This causes an extremely unsafe situation known as a swing fall. This is no longer a concern with the FlexRail.

No More Ice and Snow Build-Up

No More Ice and Snow Build-Up

The FlexRail enclosed track completely eliminates snow or ice build up, providing unprecedented ease of movement when you need it most. With the 1:100 movement-to-weight ratio, the retractable lifeline remains overhead at all times providing additional support on slippery surfaces. We recommend that the user “lock” the retractable lifeline and use it as additional support while walking.

Future Expansion

Future Expansion

The modular style of the FlexRail system makes it easy to add sections when you expand your capacities. We’ll even design your system with your expansion plans in mind to further reduce costs when you are ready to increase capacity.

Curves

Curves

The FlexRail System can be designed to accommodate curved rail sidings providing complete coverage of all of your railcars.

Sealed Bearing Man-Rated Trolley

The trolley is manufactured from zinc plated steel plate with teflon wheels. The teflon wheels prevent damage to the protective coating of the enclosed track which occurs with a metal-on-metal contact typical of old-style beam trolley systems. The trolley has an ultimate capacity that exceeds 5,000 lbs. and is specifically designed with a 1:100 movement-to-weight ratio, which means it remains overhead simply from the tension in the retractable lifeline.

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