Anchor Testing, Compliance AND Installation

Anchor testing is the process of applying tensile or shear force to height safety anchor points to verify their strength and confirm they have been installed correctly and can withstand the loads they are rated for.

In Australia, building owners and PCBUs (Persons Conducting a Business or Undertaking) have a legal obligation to maintain safe working conditions for anyone accessing heights on their property. This requirement is critical for any site where workers rely on anchors, including roof anchors, ground anchors and facade anchor systems.

On site testing confirms that each fixing can handle its specified load requirements without failing, and that the installation quality and base material meet the standard required. Without regular site testing and certification, your height safety system cannot be considered compliant with Australian safety regulations.

In New South Wales, anchor points must be tested and certified at least once every 12 months. This annual cycle applies to all types of height safety systems, including individual anchor points, ground anchors, horizontal lifelines and vertical lifelines.

If an anchor has been subject to a fall arrest event or any structural modification to the building, site testing should be carried out immediately rather than waiting for the next scheduled inspection. Test reports from each annual assessment must include detailed inspection results and be kept on record as evidence of compliance. This information helps building owners and property managers find any issues early and address them before the next scheduled time.

Non-destructive testing is the standard method used for annual compliance checks. It involves pulling an anchor to a designated test load, which is a predetermined force calculated to confirm the anchor's integrity without damaging it. The proof load is typically calculated using a 0.67 capacity reduction factor applied to the anchor's rated working load. This method verifies the anchor's performance and confirms the effectiveness of the installation while leaving the anchor fully functional. The applied test load must meet defined acceptance criteria for the anchor to receive a passing result.

Destructive testing, also known as Ultimate Load Testing, is a different process used to determine the absolute maximum load capacity of an anchor. It pushes the anchor to its ultimate load, meaning it is tested to the point of failure. Destructive tests include tensile and shear tests and typically require 5 to 15 test trials for proper evaluation. This method is generally used during product development, engineering validation or when there is a critical concern about the stability of an anchor system. There is no substitute for destructive testing when the goal is to establish the absolute load capacity of post installed anchors or ground anchors in variable base materials.

For fall arrest systems, 100% of anchors must be tested. There is no sampling approach permitted for anchors that are part of a fall arrest system, because every single point in the system is a potential life-safety connection. The scope of site testing covers all anchor types within the system, including roof anchors and ground anchors.

For post-installed concrete anchors assessed under AS 5216:2018, a minimum of three test specimens is recommended per anchor type and installation condition on a case-by-case basis. The number of test trials can range from 5 to 15 depending on the testing method and the level of certainty required around installation quality and base material performance.