Temporary horizontal lifeline for formwork – MARCELINO AEM-04
Slab formwork and rebar fixing are among the most dangerous stages on any construction site: the worker moves along the edge of a slab that does not exist yet, and guardrails have nothing to fix to. The MARCELINO AEM-04 system solves this differently – structural posts raise the anchor point roughly 185 cm above the working level, so the worker can move freely while laying the formwork, being simultaneously secured from above with a fall factor of 0. It is a much lighter alternative to heavy systems such as ALSIPERCHA: the entire assembly and relocation is done completely by hand, without the need for a crane, and once a floor is finished the set is easily moved on to the next working area. The system has been present on the Polish market since April 2016.
Where it is used – slab formwork and other concrete works
The MARCELINO system is a temporary solution, intended for the duration of the works on the topmost storey. It is used wherever the risk of a fall from height appears in the area being worked on:
- erecting and striking slab formwork,
- assembling wall formwork and column formwork,
- laying slab reinforcement,
- concreting and trowelling the slab surface,
- works at the slab edge and around service openings,
- work on steel structures – using steel sockets directly attached to the structure.
Where possible, collective protection systems (like safety nets) should be chosen first. The MARCELINO system is used when such a solution cannot be installed, or when the work front moves quickly and a temporary horizontal lifeline is more efficient.
How the MARCELINO AEM-04 system works
The principle is simple. BKPL-04 plastic sockets are embedded into the poured and vibrated concrete wherever the work will need protecting. Once the concrete reaches the required strength of 200 kg/cm², the AEM-04 steel posts are placed in those sockets, and the LBHT-2.12 horizontal webbing lifeline is tensioned between them. The worker can then attach their retractable fall arrester to this lifeline. After the work is finished, the hole left by the socket is simply filled with concrete.
The AEM-04 post is 200 cm high and sits 15 cm into the concrete, resulting in an anchor point about 185 cm above the working level. This height allows protecting the user from above, maintaining a fall factor of 0.
The allowed distance between the posts is 3 to a maximum of 12 metres. The AEM-04 posts must not be placed at a greater distance, nor can any intermediate anchor points be used between them. On wider fronts, the LBHT-2.12 horizontal lifeline is installed every two posts on each side, including perpendicularly. This allows creating safe rectangular or square safety zones. For example, a set of 4 posts, 2 horizontal lifelines, and 4 retractable fall arresters secures 4 workers simultaneously on a working front of up to 36 running meters.
What a standard MARCELINO set contains
- 2 AEM-04 structural anchor points – steel posts 60 × 40 mm, 200 cm high, with a double bracket in the upper part,
- 1 LBHT-2.12 horizontal webbing lifeline, 12 m long,
- 1 retractable fall arrester with a length of 2.5 m or 3.5 m,
- 2 galvanised 25 kN karabiners for each lifeline,
- BKPL-04 plastic post bases to be set into the concrete,
Four ways of anchoring the AEM-04 posts
The fixing method is chosen to suit the stage of the works and the type of structure:
| Element | When | How it works |
|---|---|---|
| BKPL-04 plastic socket | concrete freshly poured | The cheapest and most commonly chosen option. The socket is pressed vertically into the vibrated concrete; the upper part remains on the surface and does not interfere with the flooring execution. |
| BASE-06 steel socket | concrete already hardened | Screwed onto a hardened concrete slab using four 16 × 220 mm rods with chemical anchors (pull-out strength of 2400 kg) or four M16 steel anchors. |
| MLD-04 mould (patented) | concrete freshly poured | Leaves no foreign body in the concrete. The mould is removed once the concrete hardens and reused on subsequent projects, avoiding the cost of lost sockets. |
| BASE-06 on Steel structure | steel-framed buildings | The socket is welded or bolted directly to a structural pillar or beam, or clamped using PM-01 plates on both sides of the element. |
Required concrete element dimensions: 30 × 30 cm for pillars and 30 cm for walls and beams. For pillars and walls, the manufacturer recommends additionally two 8 mm stirrups, 5 and 15 cm below the level of the poured concrete.
MARCELINO or ALSIPERCHA – what decides it on formwork works
The MARCELINO AEM-04 system is widely used as an alternative to the ALSIPERCHA system. From our own experience talking to site managers, five things decide the choice:
- Light weight and speed of relocation. Every assembly operation is done by hand, with no crane. Once work on one storey is finished, the set is moved to the next working area without waiting for a free tower crane. This is the reason site managers name most often for why the system speeds formwork up, and it cuts operating costs on site significantly.
- Reach along the whole work front. The operative is protected along the full length of the lifeline, with post spacing of up to 12 m, rather than within a single workstation.
- Cost of the set. The difference in purchase price is noticeable, particularly where several working zones have to be protected at the same time.
- Two people working on one line at once. In the middle spans, where sections are connected, the system allows two operatives to work simultaneously on one LBHT-2.12 horizontal lifeline, which lifts productivity sharply during slab formwork.
- Crossing lifelines (square zones). A single AEM-04 post can connect up to 4 lifelines, one from each of its 4 sides. That makes it possible to build safe square working zones, ideal where the reinforcement layout is complex.
System deflection and fall clearance
We are often asked about the free space required under a worker attached to the MARCELINO temporary horizontal lifeline. Deflection is the distance the system drops while arresting a fall – it includes the stretch of the webbing, the deformation of the posts and the extraction of the retractable fall arrester. Note that the fall factor of the system is 0.
| Post spacing | Lifeline on the narrow side of the post (max. inertia) | Lifeline on the narrow side of the post (min. inertia) |
|---|---|---|
| 3 m | 1,11 m | 1,20 m |
| 6 m | 1,30 m | 1,80 m |
| 12 m | 2,38 m | 2,35 m |
The figures apply to a 2.5 m retractable fall arrester of the FA 20 30x 02 series and are measured from the user’s feet. Standard practice is to add 1.00 m of margin to the result. The user’s own height is NOT added. For the 3.5 m lanyard the figures differ – we give them in the technical quotation. Remember that when arresting a fall, the AEM-04 posts undergo plastic deformation of up to 50 cm, measured at the top of the post in the direction of the fall. That can move the other lifelines anchored to the same post.
Legal basis – Full system EN 795 certification
The manufacturer issues an EN 795 declaration of conformity for the entire fall arrest system, not just for individual elements. This is a crucial difference because the certification is only valid when using the exact set of components on which the tests were conducted:
- the AEM-04 post together with the LBHT-2.12 horizontal lifeline,
- the LBHT-2.12 lifeline only with a retractable fall arrester of the FA 20 300/301/302 02 series (2.5 m), FA 20 504 03 (3.5 m) or FA 20 402 07 and FA 20 504 07 (7 m).
Replacing any of these components with another manufacturer’s equipment invalidates the certification of the system – and the manufacturer is then not answerable for how it performs. Worth keeping in mind, because on site the temptation to use “our own” retractable fall arrester is a strong one.
Under the classification of EN 795, the LBHT-2 horizontal webbing lifeline is a Class B device (portable, temporary), while the AEM-04 post itself is additionally certified as a Class A anchor device for one user – which is what protects the installers themselves while the system is being put up. All six classes of the standard are described in our guide to EN 795 anchor devices.
AITANA SAFETY – anchor points and fall protection systems on construction sites
For over ten years we have supplied fall protection solutions tested by independent notified bodies according to the EN 795 standard. Alongside the MARCELINO system, our offer includes:
- fall protection slings EN 795 – single anchor points for one person, embedded in concrete,
- Class A anchor points – for concrete, timber, steel and trapezoidal sheeting,
- counterweight roof anchors – Class E deadweight, for flat roofs and rooftop lifelines,
- horizontal rigid rails – EN 795 Class D,
- ground anchoring points – for embankments and work on soil.
We match the solution to the individual project: the structure, the works programme and the number of users on the front.
FAQ – Frequently asked questions about formwork fall protection
What standards must a formwork fall protection system meet?
The basis is EN 795 “Personal fall protection equipment – Anchor devices”. In the MARCELINO system, the LBHT-2 horizontal webbing lifeline is a Class B device, that is, a portable anchor device of a temporary nature, while the AEM-04 post is a structural anchor point additionally certified as a Class A device for one user. The certification is valid only for the complete, tested set.
The other components have standards of their own: EN 361 for full body harnesses, EN 360 for self-retracting lanyards and EN 355 for energy absorbers. Selection, use and inspection of the complete system are governed by EN 365.
When can the system be installed after concreting the slab?
Only once the concrete reaches a strength of 200 kg/cm². For residential concrete, this corresponds to roughly 8 days at 10 – 15°C, but this is only an indicative reference, because concrete strength depends on the mix and on the weather. The real value should be confirmed by the concrete quality control carried out on site.
How many people can work on one lifeline at the same time?
Generally one, but in selected configurations up two people on a single LBHT-2.12 lifeline. Two users at once are permitted only in the middle spans, where the sections of the installation are connected. The final number of users in a construction site depends on the particular layout of posts and lifelines, so it is settled at the design stage of the installation, not on site.
Does the MARCELINO system require technical periodic inspection?
Yes, but the scope differs between components. The AEM-04 post has no fixed expiry date; the manufacturer requires a detailed visual inspection by a competent person at least once every two years, recorded permanently in the inspection register supplied with the instructions. What is checked: the presence of the identification label, signs of corrosion, deformation and cracking of the steel structure, and the condition of the welded brackets at the top of the post.
The personal protective equipment elements – the harness, the retractable fall arrester and the webbing lifeline – are inspected at least once every 12 months in accordance with EN 365. Independently of that, a visual check applies before every use: lifeline tension, no cuts or reduction in the thickness or width of the webbing, the condition of the tensioning buckle and correct closure of the karabiners.
Can the MARCELINO system be fixed to a steel structure?
Yes. The manufacturer confirms fixing AEM-04 posts to steel structures – including columns – by means of the BASE-06 steel socket. Two variants are possible: the socket welded or bolted directly to the structural support, or an assembly with PM-01 plates clamped on both sides of the beam. This is useful above all in steel-framed buildings and wherever there is no concrete to set a socket into.
Does installing the AEM-04 posts require heavy equipment as a crane?
Absolutely not. This is the biggest advantage of the system compared to alternatives like the ALSIPERCHA system. The set is light enough that all assembly activities and moving between floors are done completely by hand.
Are you planning formwork at height?
Protecting the people who carry out formwork and concrete works calls for certified, modern solutions that do not slow the job down. Explore our full range of fall protection solutions and find the one that suits the particulars of your project. See the complete catalogue of EN 795 certified anchor points for construction.
Not sure which system fits your project? Get in touch and we will help you find the most suitable solution.