Rigid rails EN 795 Type D – ALTIRAIL overhead rail system
A rigid rail is a profiled guide track permanently fixed to the supporting structure. A trolley travelling along it acts as a mobile anchor point, allowing the worker to move freely along the entire workstation without unclipping a single time. This solution is used where cable lifeline systems fail: low fall clearance below the working level, high dust levels and drafts, or where side or overhead rigid rail protection is required. In such situations, traditional flexible cable lifelines may prove insufficient due to excessive dynamic deflection during a fall. ALTIRAIL horizontal rigid rails are certified as a Class D anchor device according to EN 795:2012, along with the CEN/TS 16415 technical specification for multi-user access.
Where a rigid rail system earns its place - applications
A rigid rail fall arrest system is a permanent solution engineered for specific workstations. It is most commonly installed where the same task is performed daily in a fixed location:
- filling and discharge stations for road and rail tankers,
- roofs of freight wagons, locomotives and trams in maintenance depots,
- aircraft hangars – servicing aircraft wings and fuselages,
- silos, process vessels and pipe racks bridges,
- loading docks and logistics transfer bays,
- overhead cranes, maintenance walkways and production lines in industrial plants,
- façades and listed buildings: a discreet aluminium profile, with the option of anodising or powder coating in any RAL colour, blends into the architecture of the building,
- roof maintenance work: rigid rails give a permanent rail anchor point that makes it safe to work along edge zones, rooflights and smoke vents.
The common denominator across these sites is twofold: minimal fall clearance between the working level and the ground (where a cable system is too “soft”) and the necessity to traverse the entire length of the workstation without disconnecting.
As with any anchor device, where collective protection can be installed it comes first – freestanding guardrails or a permanent platform with handrails. A rigid rail is implemented where collective protection cannot be physically mounted.
How a rigid rail fall arrest system works
The system consist of three parts: the guide rail, the mounting brackets securing it to the supporting structure, and the trolley. The trolley is what sets a rigid rail apart from all other anchoring devices – it acts as the mobile anchor point and travels smoothly alongside the user.
The worker connects to the trolley via a connecting and energy-absorbing subsystem: an EN 360 retractable fall arrester, an EN 353-2 guided-type fall arrester on a flexible line, or an EN 355 lanyard with an energy absorber, always combined with an EN 361 full-body harness and an EN 362 connector. The dynamic impact force acting on the user is limited to a maximum of 6 kN, while the fall load transferred to the structure is limited to a maximum of 12 kN.
An essential structural advantage: the fall impact load is distributed across all brackets along the entire track, rather than concentrating exclusively on end and intermediate points as seen in cable lifelines or single Class A anchor points. Consequently, structural load requirements on the host building are significantly reduced, and system deflection is far smaller.
Trolleys – matched to the type of work
- WVRCF2 – roller trolley for standard horizontal overhead and side applications,
- WVRCF3 – Trolley certified for suspended work and rope access,
- WVRCBC – designed for structures inclined from 0 to 180°; a downward pull locks the trolley automatically in position,
- WVRCLR – LR series trolley, stainless steel 316 body, plastic wheels on bearings, with dual safety catches to prevent accidental detachment.
The rule is straightforward: One dedicated trolley per user along the track.
Changing direction without unclipping
The rail track does not have to be a straight line. 90° curves with a 250 mm radius allow the rail to navigate around building corners, whether configured for side or underside travel, wall-mounted, or ceiling-mounted. Manual and motorized 3-way or 4-way switches enable users to switch tracks seamlessly without unclipping from the trolley. Motorized switches are operated via a remote control capable of managing up to 9 separate junction points. This versatility allows a single rigid rail structure to cover an entire industrial hall rather than just a single axis.
ALTIRAIL and ALTIRAIL LR – which rail to choose
Both systems are rigid horizontal Class D anchor devices. They differ in one crucial parameter that determines overall installation costs: the maximum allowable bracket span. The further apart the mounting brackets can be placed, the less structural drilling is required, speeding up installation.
| Parameter | ALTIRAIL | ALTIRAIL LR |
|---|---|---|
| Maximum spacing between brackets | 4 m (2 m for suspended work) | up to 8 m |
| Rail lengths | 1 m, 1,5 m and 3 m | 4.4 m, supplied drilled and milled |
| Rail material | aluminium 6060 T5, anodising on request | aluminium; aggressive environments require surface treatment |
| Compatible Trolleys | WVRCF2, WVRCF3, WVRCBC | WVRCLR (stainless steel 316), also compatible with WVRCF2 and WVRCF3 |
| Brackets | WVRSUP; fixings WVREQG (hot-dip galvanised steel) or WVREQI (stainless steel 304L) | WVRSUPLR1, LR2 and LR3 in galvanised steel, adaptable to any structure thickness |
| Number of users | maximum 2 between two supports | tested to TS 16415 for up to 3 users |
| When to choose it | when the structure allows fixings every 4 m | when the available fixing points are far apart |
In practice, ALTIRAIL LR is selected when the supporting structure restricts bracket placement – when fixings can only go to every second roof truss. For the same track length, the required number of mounting points is reduced by up to 50%.
Rigid rail or cable system – which to specify
This is the most frequent question during the engineering design phase. Both rigid tracks and cable lifelines solve fall arrest requirements, but they behave differently during a fall event:
- The dynamic deflection of a rigid rail is capped at a maximum of 800 mm . A cable lifeline under the same span deflects significantly more, which in low-clearance facilities makes cable installation unsafe or impossible. Minimal rail deflection allows safe operation at very low heights (e.g. over loading platforms, tankers, or low machinery) where cable sag would risk ground impact.
- Load Distribution. A rigid rail distributes fall impact energy across all supporting brackets along the line, whereas a cable system concentrates force on terminal anchors, requiring heavier structural reinforcements.
- A rigid track requires no periodic cable re-tensioning, replacement, or terminal shock absorber replacement. However, annual safety inspections remain mandatory.
- Direction of work. A rail can run overhead, to the side and underneath the workstation, and the WVRCBC trolley handles structures inclined up to 180°. Cable lines almost exclusively function above the user.
- Draughts and dust. : In environments where wind or air currents cause cable oscillation, a rigid track remains completely stable – a key reason why overhead rigid rail systems dominate aircraft hangars and tanker bays.
Fall Clearance below the user – how to calculate it
Before a system is commissioned, it is essential to verify that adequate fall clearance exists below the working level. Values are calculated additively starting from the user’s feet level:
| Component | Value |
|---|---|
| Rail track deflection | 800 mm maximum |
| + length of the connecting and shock-absorbing subsystem | Per equipment technical data sheet |
| + energy absorber extension | Per equipment technical data sheet |
| + user height | typically 1,80 m |
| − rail mounting height | According to installation design |
| + safety margin | 1,00 m |
| = required fall clearance | Calculation result |
If an adjustable lanyard is used, shortening it to the minimum practical length reduces potential fall distance and minimizes user trip hazards.
Legal compliance – EN 795 Class D anchor devices
The EN 795 standard (Personal fall protection equipment – Anchor devices) categorizes anchoring systems into six classes. Horizontal rigid rails fall under Class D: anchor devices employing rigid horizontal structural lines along which a mobile anchor point travels. For systems designed for multiple simultaneous users, the CEN/TS 16415 technical specification applies. The remaining classes – from A1 through to E – are described in full in our guide to EN 795 anchor devices.
Class D certification testing involves rigorous criteria: a static load of 0.7 kN held for one minute at any point without permanent deformation exceeding 10 mm, a dynamic test at 9 kN across all configurations, and static strength verification from 12 kN upward depending on user capacity. The ALTIRAIL LR version underwent additionally TS 16415 testing at 12 kN simulating a two persons fall plus 9 kN for a third simultaneous user.
The certificate of conformity for the ALTIRAIL system was issued by DEKRA Testing and Certification GmbH, with manufacturing surveillance conducted by APAVE SUDEUROPE SAS (notified body no. 0082).
AITANA SAFETY – comprehensive anchoring and fall protection systems
For over ten years, we have supplied anchor devices tested by independent notified bodies according to EN 795. Alongside rigid horizontal rails, our range includes:
- vertical lifeline system – VERTIRAIL and COMBIRAIL vertical rails to EN 353-1, which connect to the horizontal installation,
- fall protection slings EN 795 – single anchor points for one person, cast into concrete,
- Class A anchor points – for concrete, timber, steel and trapezoidal sheeting,
- the MARCELINO temporary horizontal lifeline – for formwork and concrete works,
- counterweight roof anchors – Class E, for flat roofs.
Every rigid rail layout is engineered for the specific facility: track routing, bracket spacing, trolley selection, and fall clearance calculations.
FAQ – Frequently asked questions about rigid rails
Do rigid rails require annual inspection?
Yes. Under EN 795 and health and safety regulations, the complete rail installation and the trolleys are subject to mandatory inspection at least once every 12 months. The inspection must be carried out by a competent person authorised by the manufacturer (Delta Plus). The ten-year warranty applies on condition that annual maintenance is carried out by an authorised company. Independently of that, a visual check of the rail and the trolley applies before every use.
Compared to cable lifelines, rigid rails reduce ongoing maintenance costs: the track requires no tension adjustments, cable replacement, or terminal absorber replacement after minor impacts.
How many workers can use one rail at the same time?
It depends on the version. The ALTIRAIL system is intended for a maximum of 2 users between two supports. The ALTIRAIL LR version was tested to the TS 16415 specification for a maximum of 3 users – a dynamic test at 12 kN simulating the fall of two people plus 9 kN for a third, with static strength of 14 kN. Each user must have their own trolley. The exact number of people for a given installation follows from the design and is stated on the system’s information sign.
What is the maximum distance between rail brackets?
In the ALTIRAIL system brackets are spaced at 4 metres maximum, reduced to 2 metres for work in suspension. The ALTIRAIL LR version was designed precisely to increase that spacing: it permits fixings every 8 metres. This is the most important difference between the two versions and usually decides the choice, because over the same route the number of fixing points can drop by half.
What type of anchor allows workers to move both vertically and horizontally?
A rail-based anchor device. A rigid rail is a Class D device under EN 795, in which the anchor point is a trolley that travels along a fixed guide rail — so the user moves along the whole route without ever unclipping. For movement in the vertical plane the horizontal rail is combined with a vertical rail system (VERTIRAIL or COMBIRAIL) certified to EN 353-1, and the two installations are connected. That combination is what lets someone climb up to a tanker or a wagon roof and then move along it, protected the whole time.
Are rigid rails suitable for corrosive or aggressive environments?
Yes, with proper material selection. ALTIRAIL profiles are manufactured from 6060 T5 aluminium and can be anodized on request. Brackets are available in hot-dip galvanized steel or 304L stainless steel, while WVRCLR trolleys feature a 316 stainless steel body. In marine, petrochemical, or heavily polluted industrial settings, powder coating or anodizing is recommended.
Planning a rail installation on your facility?
Are you seeking a proven solution to secure workstations at height in your plant, depot or construction site? We will select the optimal ALTIRAIL or ALTIRAIL LR configuration, calculate bracket spacing and the type of trolleys, and determine the fall clearance required below the workstation. Explore our main section for anchor points and safety systems or visit our dedicated permanent rooftop safety systems section.
Unsure which system fits your project? Contact our B2B engineering team for full technical support – from initial risk audit to certified installation and annual inspection.