Guidelines To Installing A Zip Line 1

GENERAL INSTALLATION
AND SAFETY GUIDE

FOR ZIP LINES
SECTION ONE – BEFORE YOU BEGIN

SITE SELECTION 2
ANCHORS 2
TOOLS 5
CABLE SLOPE & SAG 5
ZIP LINE WORKSHEET (Calculations) 6
WORKSHEET EXAMPLE 9
SECTION TWO – CABLE INSTALLATION 10
SECTION THREE: IMPORTANT INFORMATION/ CARE/WARNINGS & DISCLAIMERS 13
SECTION FOUR – COMPONENTS

TYPES OF TROLLEYS 16
TYPES OF SEATS & HARNESSES 17
TYPES OF BRAKING SYSTEMS 18
SECTION FIVE – PROFESSIONAL ZIP LINE INSTALLERS IN CANADA 24
DISCLAIMERS
ACTIVITIES INVOLVING THE INSTALLATION AND USE OF ZIP LINES, TROLLEY, HANRESSES, BRAKING SYTEMS AND OTHER RELATED GEAR ARE
POTENTIALLY HAZARDOUS BY THEIR VERY NATURE.
ALL INSTRUCTIONS IN THS MATERIAL ARE EXTREMELY IMPORTANT. OVERLOOKING OR IGNORING ANY OF THE FOLLOWING INSTRUCTIONS COULD
RESULT IN RIDER INJURY OR DEATH. PLEASE TAKE ALL THESE INSTRUCTIONS SERIOUSLY.
ANYONE PURCHASING, INSTALLING OR USING EQUIPMENT FROM ZIP LINES CANADA MUST:
 READ ALL INSTRUCTIONS REGARDING ITS CORRECT INSTALLATION AND SAFE USE;
 ENSURE PROPER OVERSIGHT, SUPERVISION AND INSTRUCTION (INCLUDING THE USE OF APPROPRIATE SAFETY EQUIPMENT) FOR
THEMSELVES AND OTHERS USING THE EQUIPMENT;
 ENSURE ALL EQUIPMENT IS PROPERLY MAINTAINED AND INSPECTED FOR DAMAGE OR WEAR PRIOR TO EACH USE;
 ASSUME ALL RISKS AND ACCEPT FULL RESPONSIBILITY FOR ANY DAMAGE OR INJURY, INCLUDING DEATH THAT MAY ARISE FROM ITS USE.
 READ AND FOLLOW IMPORTANT INFORMATION AND CHECKLIST SHOWN ON PAGE ________
**WARNING** DO NOT ATTEMPT TO RIDE YOUR ZIP LINE WITHOUT FIRST TESTING
**WARNING** DO NOT ATTEMPT INSTALLATION OF USE OF ZIP LINE EQUIPMENT WHILE UNDER THE INFLUENCE OF INTOXICANTS OR WHILE
DRINKING ALCHOL, SINCE THESE IMPAIR JUDGEMENT AND REASONING, THEREBY MAKING INSTALLATION MISATAKES MORE LIKELY.
Please note these are guidelines only. No information provided in this booklet shall be viewed as professional instruction or advice. All written or
spoken material is opinion and does not guarantee safety. All persons are wholly responsible for the safe selection, installing and operation of their
zip line equipment. Obtaining professional advice and instruction when installing your zip line is strongly encouraged.
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SECTION ONE: BEFORE YOU BEGIN
SITE SELECTION
The site selection process must be performed by a competent adult after all instructional material has been completely
reviewed and understood.
Determine the most accessible locations for your rider to launch and dismount. This will dictate the installation of your
zip line. Depending on the terrain, the dismount location may be at the end of the zip line rather than the low point of
the cable. A platform may be required for access.
CLEAR THE ZIPLINE AVENUE of obstructions at least 7 feet below and 5 feet on both sides of the zip line over the
entirety of the zip line avenue while supporting the heaviest riders. Remove large rocks, logs, branches, sharp objects,
and other potential hazards.
SAFETY RIDING GEAR IS REQUIRED FOR ANY HEIGHT AND TERRAIN WHERE A FALL COULD RESULT IN INJURY.
ANCHORS
A typical zip line cable can apply 800 to 3,000 pounds of horizontal force to an anchor when loaded.
Do Not Use
 Building or Playground structures unless specifically built for zip lines
 Live power/telephone poles
 Dead trees or stumps
 Trees with rot, disease, structural cracks, excessive lean or exposed roots
 Trees in boggy, wet, sandy or loose soil.
This is only a partial list, you must use your good judgement to determine as to what is an appropriate anchoring point.
If in doubt, call us to discuss.
ANCHORING OPTIONS
TREES:
Tree trunks must have a minimum 12 inch diameter, at the attachment point. Do not attach to any limbs/branches
other than a central trunk.
If you can’t find two trees with a minimum 12 inch diameter, you can use an assisting anchor to stabilize your anchoring
tree by two differing methods. Both methods require the anchoring tree to be a minimum of 9” in diameter.
a) Run a slackline leading from your anchoring tree back to a larger tree behind the anchoring tree. Make sure the
slackline is tight and that it runs from the height of the cable that attaches on to your anchoring point. This will
relieve some of the horizontal loading pressure of the zip line on your anchoring tree.
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b) Attach a second cable to your anchoring tree that leads to two anchoring pins, firmly set into the ground. It is
suggested that the anchoring pins be buried 2 feet into the ground and set in concrete or if you have bedrock –
drill and set the anchors firmly in place. Run the cable around your anchoring tree and have either end of the
cable attached to an anchoring pin – set at least 10 feet behind and off to each site of the beginning anchor tree.
Make sure the cable you are wrapping begins at the same height as the zip line so that the horizontal loading
pressure of the zip line is equally abated by the anchoring pins.
FREE STANDING POLES:

A free standing pole must be a minimum of 12” in diameter at the top and sunk a minimum of 5 feet in the ground, or 2
feet plus 10% of the pole’s total length if it is greater than 20 feet. Once the pole is put in the hole and is braced to
stand straight, fill the hole with concrete 6 inches thick around the post for stability and then back fill.
Soil such as sand, rock or in high ground water environments may require alternative installation techniques and
consultation with an engineer.
For wooden poles, eyebolts or cable slings should be anchored 12” or lower from the top of the pole and as close as
possible to the zip line attachment point, and any attachment that passes through the wood should have a washer
backup on the outside that can be visually inspected.
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 Posts with guy cables and ground anchors must be a minimum of 8 inches in diameter.
 Install guy anchor post at a distance equal to or greater than attachment height.
 Ground anchor posts must be sunk 4 feet into the ground, or 10% of post length
plus 2 feet (whichever is greater). Secure with concrete 6 inches thick around post.
Soil such as sand, rock or in high groundwater environments may require
alternative installation techniques and consultation with an engineer.
 Additional depth, bracing, or guy wires may be needed for soft of unusual soil
types.
Ask your power company about “retired” power poles and possible installation.
Installing a ground anchoring pin –

make sure tension is tight between
the ground anchor and the tree or
post it is attaching to.
PLATFORMS:
There are many ideas available on the internet that will give you guidelines on the correct way to attach your zip line to
a deck, playground platform or to a platform you can build yourself. For some ideas check out the photos at
https://www.google.ca/?ion=1&espv=2#q=platforms+for+attaching+ziplines+photos . Your local building contractor can
provide you with guidance as well.
PLEASE NOTE: Most building or backyard play structures are not designed to withstand the horizontal loading of a zip
line cable. Design or retrofit accordingly to ensure your structure is not damaged and participants are not put at risk.
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TOOLS
The following tools are recommended for measuring elevation change of your zip line site.
Measuring Tape
Sight Level or Laser Ladder
We recommend finding a landscape with a natural slope of 3% to 6% (a 3 feet to 6 feet drop per 100 feet)
CABLE SLOPE & SAG
CABLE SLOPE
The maximum allowable slope is 3% (3 feet drop per 100 feet of distance) for zip lines that will not utilize a bungee
brake. The maximum allowable slope is 6% (6 feet drop per 100 feet of distance) for zip lines that utilize a bungee brake.
**WARNING** Zip line must never exceed 6% (6 ft drop per 100 ft. of distance) riding slope. High speed collision with end point
may cause injury or death.
CABLE SAG
Cable tension is measured by cable sag:
 The cable, when bearing a test weight, should sag below the end where cable is attached.
 The sag needs to be approximately 2% of zip line’s total length (2 feet per 100 feet of cable)
 The sag is measured at the cable’s lowest point
**WARNING** Do not attempt to ride your zip line without first testing.
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ZIP LINE WORKSHEET
To assist in helping you set up your zip line, follow these steps to determine the length, slope, sag, elevation change (if
any) in your landscape and your starting and ending anchor points. Use this worksheet to fill in your information and do
your calculations. (A worksheet example follows to provide more information)
STEP 1 - LENGTH
Measure the DISTANCE between START and END ANCHORS.
LENGTH = ___________________________________
Distance Between Anchors in Feet
STEP 2 – SLOPE
To calculate the SLOPE of the zip line, MULTIPLY LENGTH from Step 1 by .06 if you are using a braking system (multiply
length from Step 1 by .03 if no brake is being utilized)
SLOPE =
Length x .06 (or .03 if no brake)
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STEP 3 – SAG
To calculate the SAG, MULTIPLY LENGTH from Step 1 by .02
SAG MEASUREMENT =
Length X 0.02
STEP 4 - ELEVATION CHANGE

To measure and calculate ELEVATION CHANGE. If Ground is level, enter “O” in Box C. If not, use a sight level and have
a friend assist in measuring. *As an alternative to a sight level you can use an Altimeter App.
Determine your SIGHTING HEIGHT and enter it in Box B.
Sight a level line to your end anchor through your sight level. Tilt sight level up or down until bubble aligns with centre
crosshairs, find a level line and have your friend mark the end anchor. Measure the height of the mark from the ground
and enter in Box A. A-B = C (elevation change) – not to be confused with cable slope.
A B C
ELEVATION CHANGE __________ minus ____________ = ___________
End Level Mark Start Sight Height Change
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STEP 5 - ENDING ANCHOR POINT HEIGHT
To determine your ENDING ANCHOR POINT HEIGHT, ADD together SAG calculation from Step 3 plus 7 feet, This is the
height of your ending anchor point.
________________ plus 7 feet = ________________

Sag Measurement End Anchor Height
STEP 6 - STARTING ANCHOR POINT HEIGHT

To determine the HEIGHT OF YOUR STARTING ANCHOR POINT, add your SLOPE calculation (from Step 2) to your ENDING
ANCHOR HEIGHT (from Step 5) and then subtract your ELEVATION CHANGE (from Step 4). This is the height of your
starting anchor point.
plus minus =
Slope Ending Anchor Height Elevation Change Start Anchor Height
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WORKSHEET EXAMPLE
Nick’s backyard is perfect for a zip line. He ordered a 200 foot line and in order to install it, Nick needs to figure out
where to anchor the cable on each of his two trees. Here are the steps. First Nick reads through the entire zip line
installation guideline. He also asks a friend to come along to help him out
First he paces off the distance to make sure he knows the 180
Step 1
exact distance, in this example is will be 180 feet, he fills in
LENGTH The distance from start to end anchors =
this amount as Step 1 - Length
LENGTH
Next, figured out the amount of slope he will need, he is 11
Step 2 using a braking system, he will be calculating for a 6% slope.
SLOPE He multiplied 180 x 0.06 to get 10.8, which he then rounded The amount of drop from your start anchor to
to the nearest whole number and enters as Step 2 - Slope your end anchor = SLOPE
Using his length of 180 from Step 1 he multiplies it by 0.02 4

Step 3
to get 3.6 which he then rounds to nearest whole number
SAG The amount the zip line drops when a riders
which is 4 and enters it in Step 3 - Sag
weight is added = SAG
To figure out how much his yard elevation changes between
the 2 anchor points he is uses a sight level. Nick is 6 feet tall,
so he writes 6 in box B, next he looks through the sight level
until the bubble lines up with the center crosshairs on the
end anchor tree. Nick’s friend sets a ladder against the tree A B C
Step 4
and climbs up and marks the tree where Nick sees the level
ELEVATION
point. Nick & his friend then measurs with a tape measure 14 - 6 = 8
from the mark on the tree to the ground. Let’s say it is 14
feet, he pencils 14 in Box A and then calculates what Box C
is (14-6=8) and pencils that in Box C.
Nick then can sit down and calculate his ending anchor
Step 5 height. He takes his SAG amount and adds 7 feet 4 + 7 feet =
ENDING ANCHOR 11 for the end anchor height 4 + 7 = 11
Step 6 To calculate his starting anchor height he uses the Slope # +

STARTING Ending Anchor # minus Elevation # to get his starting anchor 11 + 11 - 8 = 14
ANCHOR height (11+11=22)-(8) = 14 for the start anchor height.
Now Nick and his friend are ready to move on to the next step, installing the cable
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SECTION TWO: CABLE INSTALLATION
The maximum allowable slope is 3% (3 feet per 100 feet of distance) for zip lines that will not utilize a Bungee Brake.
The maximum allowable slope is 6% (6 feet per 100 feet of distance) for zip lines that utilize a Bungee Brake.
WARNING!!! ZIP LINE MUST NEVER EXCEED 6% RIDING SLOPE. HIGH SPEED COLISSION WITH END POINT MAY CAUSE INJURY OR DEATH.
First make sure you have your starting anchor ready **It is a good idea to attach 3 or 4 wood blocks (2x4’s about 8-10”
long will work) to the back side of the starting anchor tree where the cable will wrap around. This helps prevent the
cable from damaging the tree** You can also use “Tree Huggerz”.
Now wrap the chain/wire rope sling around the ENDING ANCHOR TREE at the point you determined in Step 5 of your
Work Sheet. Sometimes it helps to put a few nails in around the anchor to keep the chain in place (it is again good to
protect the tree with some wood blocks, Tree Huggerz or feeding the chain through a large piece of rubber hose to wrap
around the tree).
Next fully extend the turnbuckle to it’s longest length – unscrew

the nut from one end of the turnbuckle, place the two loose ends
of the chain/sling in between the open jaw, slide the bolt through
the chain end loops and then tighten the nut.
Unscrew the one nut from the other end of your turnbuckle. Attach
the thimble end of the zip line cable using 3 of the cable u-bolt
clamps/wire rope clips spaced about 3” apart to hold the thimble in
place and insert the cable wrapped thimble into the open end of the
turnbuckle and replace the bolt and nut. Use a wrench to tighten the
nuts at both ends of the turnbuckle.
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**Protecting your tree’s health will preserve the structural
integrity. Putting wood blocks between your cable and your
tree ensures that the tree won’t be damaged. The living,
vital part of the tree is the thin layer under the bark, a tree
can slowly starve if constricted by a cable. It may take years
to notice the damage, but fewer leaves, fewer branches are
eventual collateral. Dead trees become a safety hazard.
Now to wrap the cable around the STARTING ANCHOR. This may take two people depending on the length of the cable
you are using. Wrap the loose end of the cable around the starting anchor tree (that already has the tree protection on
it) and pull as tightly as possible. A cable puller will help you with this step but is not always necessary.
Complete the loop in the cable using 3 more wire clamps. Attach the first clamp to the cable about 4 feet from the tree
trunk – put the u-bolt clamp/wire rope clip around the cable and the loose end making sure the u-bolt clamp/wire rope
clip part of the clamp is on the loose end of the cable, do not tighten yet.
Have your partner pull the cable as tight as they can, then tighten the first clamp at this point.
Next loosely put the next u-bolt clamp on the cable on the tree side of the first clamp. Slide the clamp about half way
towards the tree then tighten at this point.
Finally put the last clamp on the cable on the tree side of the second clamp. Slide the clamp as close as you can get to
the tree. Tighten at this point. Now go back and tighten all the u-clamps with a wrench moderately past snug.
Another option is to place a large eye bolt through

your tree. DO NOT PARTIALLY imbed an eyebolt into
your tree and expect it to hold a zip line and a rider.
Eyebolts are technically less invasive to the tree’s
health then wrapped cable and are an acceptable
anchoring method. The bolt must penetrate the
trunk entirely to be reinforced by a washer and nut
on the back. Zip lines have failed because the
installer didn’t back up the anchor bolt, don’t let that
installer be you.
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At this point the cable should be fairly tight. To make it even tighter you need to go back to the turnbuckle end and
tighten it down about as far as you can. To make it easier to turn, you can put a bit of lube on the threads of the
turnbuckle. This will help ensure that the turnbuckle spins smoothly.
Note Sag can be used to your advantage at this step to slow down the rate of the rider at the end of the run. A tighter
zip line give you a more consistent speed throughout the length of the run.
A rider’s weight can be multiplied several times when placed on a horizontal cable between two anchors, and this
increases with higher cable tension. Be sure your anchors are sufficient to withstand the sheer loads, and be careful to
not over-tension your cable. A good rule of thumb is to make sure your cable (while being ridden) hands below the
ending anchor by about 2% of the zip line’s length. So the trolley on a 100 foot zip line should, at it’s lowest point, be
about 2 feet lower than where the cable is anchored on at the ending anchor point.
Now it’s time to do the CABLE WEIGHT TEST
Mark the cable at each cable clamp, after using test weight to test zip line, inspect marks for indication of clamp
slippage.
ATTACH A TEST WEIGHT, equal to the weight of the heaviest participant, to the trolley mounted on the cable.
WARNING!!! Never place more than 350 lbs on zip line

WARNING!! Never use a person as a test weight when performing the weight test.
Bounce TEST WEIGHT up and down. Observe ANCHORS at each end of the cable for excessive movement.
Allow TEST WEIGHT to settle at the lowest point of the cable.
CABLE SAG is measured from the lowest point on the cable to the attachment height on the cable on the ending anchor.
Detach test weight and inspect termination hardware and anchors for proper configuration and strength.
Check for any slippage of cable through cable clamps/wire rope clips to verify they are adequately tightened. Check
anchors for deformation.
WARNING!! Do not use zip line if any slippage, deformation, misconfiguration, inadequate cable sag or other potentially
hazardous condition is found when performing the above test. The clamps must be retightened, equipment replaced or
reconfigured, cable sage increased, anchors reinforced with guy cables or different anchors chosen, or further
professional advice sought as appropriate for the situation before a participant is allowed on the zip line.
Once you have tried this non-human rider test run and made sure that the heights and speed appear to correct and
there is not sign of cable slippage, it is time to put yourself in the seat. If you think the zip line might be too fast you will
want to wear very heavy leather gloves. This way you can grab onto the cable BEHIND the trolley to slow down the
speed you are travelling (only attempt this if you are sitting on a seat or strapped into a harness, NEVER attempt to hold
on to just the handle with only one hand!). This is your chance to gauge the speed of the ride and decide if you need
slow it down or speed it up.
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If your zip line ride as a whole is a bit slow, tightening the turnbuckle just might do the trick. If it’s running a little fast
and you have some room to adjust your turnbuckle, try giving it some slack. If this doesn’t do the trick you may have to
adjust the height of either the beginning or ending anchor point.
After you have completed the test run it is important to make sure the cable is still tight. Make sure that the cable didn’t
slip down the tree. You may have to add a few nails to the tree to prevent the cable from slipping down.
*******************************************************************************************************************
SECTION THREE:
IMPORTANT INFORMATION/CARE/WARNINGS AND DISCLAIMERS
READ THIS INFORMATION AND REVIEW WITH ALL

ZIP LINE USERS BEFORE INSTALLING OR USING ZIP
LINE
DISCLAIMER:
ALL INSTRUCTIONS IN THS MATERIAL ARE EXTREMELY IMPORTANT. OVERLOOKING OR IGNORING ANY OF THE
FOLLOWING INSTRUCTIONS COULD RESULT IN RIDER INJURY OR DEATH. PLEASE TAKE ALL THESE INSTRUCTIONS
SERIOUSLY.
ANYONE PURCHASING, INSTALLING OR USING ZIP LINE EQUIPMENT MUST:

 READ ALL INSTRUCTIONS REGARDING ITS CORRECT INSTALLATION AND SAFE USE;
 ENSURE PROPER OVERSIGHT, SUPERVISION AND INSTRUCTION (INCLUDING THE USE OF APPROPRIATE SAFETY
EQUIPMENT) FOR THEMSELVES AND OTHERS USING THE EQUIPMENT;
 ENSURE ALL EQUIPMENT IS PROPERLY MAINTAINED AND INSPECTED FOR DAMAGE OR WEAR PRIOR TO EACH
USE;
 ASSUME ALL RISKS AND ACCEPT FULL RESPONSIBILITY FOR ANY DAMAGE OR INJURY, INCLUDING DEATH THAT
MAY ARISE FROM ITS USE.
REMEMBER SAFETY FIRST AND ALWAYS

INSPECTING YOUR ZIP LINE AND GEAR
INSPECT OFTEN!
Check your cable to make sure there is no fraying or excessive rusting.
Check your hardware (wire rope clips, turnbuckle) on a regular basis to ensure that nothing is loosening and adjust
accordingly.
Check your tree anchoring points to make sure the trees are healthy and the bark has not abraided (rubbed off).
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Check below your zip line run to make sure no trees have begun to grow under the cable, and that the area is clear of
all rocks and hard surface items.
Inspect all your gear often. Look for improper configuration, damage, fraying, bending, tearing, cracking, slipping or
anything that would indicate that the equipment’s performance or strength has been comprised. DO NOT USE THE ZIP
LINE IF THERE IS DAMAGE TO ANY OF THE GEAR. REPLACE ITEMS IMMEDIATELY.
Check your trolley. Do the wheels spin smoothly? Does your trolley sit straight and upright on the cable and are the
wheels centered on the cable? Look for excessive roughness, loose hardware and check inside the sheathing for
excessive wear from cable abrasion. The side plates sit centered on the cable and should not rub against the cable or
wheels. Replace your trolley if you see excessive friction marks from the cable or wheels.
Check the handlebar grips are they tight? If they move or slip it is time to replace.
Check your harness and lanyard. Carefully look at all the straps, tie in points and seams – make sure there is no
loose stitching, unravelling of materials or abrasion. Ensure that the metal buckles are solid and have no cracks, bends
or sharp spots/edges. Replace if you see any wear and tear.
Check the seat. Carefully inspect the rope to make sure the knots have not loosened and that the rope has not frayed.
If you are using a sling swing make sure that the seat does not show any cracking and that the straps are solid with no
fraying or loose stitching.
Check your Bungee Brake. Make sure it is not cracked or damaged and that the bolts remain solidly in place. Ensure
the bungee cord is not frayed or that the elastic along the length of the bungee cord is not exposed (if you notice an
increase or decrease in part of the diameter of the bungee this could indicate that there is internal damage to the cord).
Check to make sure the bungee still has stretchability, if it doesn’t stretch it is time to replace your bungee. Also check
the spring clips to ensure that they are solid and closing completely.
WARNINGS
Never allow children to use the zip line without adult supervision.
We recommend wearing a helmet when riding the zip line. Children must wear a helmet.
Keep hair away from the cable. Long hair should secured with an elastic and tucked into your collar or under a
helmet for safety. Catching your hair in the trolley or on the cable can have serious life threatening consequences.
Riders must never spin while connected with a harness or seat.
If you are using more than one trolley, never attach a rider to the zip line until the previous rider has
dismounted and provides clearance. A second person may be required to hold participant in place to prevent them
from descending down the zip line before their turn to ride.
DO NOT ATTEMPT to switch riding gear between riders or put riding gear on while standing on an elevated launch
platform where a fall could result in injury.
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Never jump from a ladder or platform onto the zip line. If no hazards are seen along the cable run and if your riding
gear securely and safely holds the weight of the rider, the rider may slowly push away from the platform and allow
gravity to propel them down the zip line.
NEVER, EVER place hands in front of trolley, we recommend using handlebars at all times. DO NOT touch the cable
with your bare hands.
If braking with leather gloves, grab BEHIND the trolley, NEVER in front of the trolley.
At the end of the run:
Riders must wait until they have come to a complete stop before dismounting from the zip line. Riders must
dismount by transferring their weight off the cable and onto the platform, ramp or ground. Children must be assisted
by an adult.
BE AWARE the zip line cable may spring upwards when rider dismounts, be sure any equipment attached (trolley,
separate handlebar, seat/harness) is removed or raised up slowly to avoid injuring the rider.
If trolley remains attached to zip line cable a tow line can be attached to the trolley AFTER COMPLETING THE RIDE. Do
not ride with the tow line attached to the trolley, harness or rider. DO NOT coil or loop the tow rope during the ride, it
may become entangled or cause strangulation. DO NOT allow the tow line to drag behind the participant during zip line
ride as it may become entangled with the rider or with objects along the zip line run causing serious injuries.
Never place more than 350 lbs on the zip line.
ACTIVITIES INVOLVING THE INSTALLATION AND USE OF ZIP LINES, TROLLEY, HARNESSES,
BRAKING SYTEMS AND OTHER RELATED GEAR ARE POTENTIALLY HAZARDOUS BY THEIR VERY
NATURE. EXTREME CAUTION AND CARE AT ALL TIMES ARE IMPORTANT FOR THE SAFETY OF
YOUR RIDERS.
SECTION FOUR - COMPONENTS
TYPES OF TROLLEYS
Fusion Tesa Speed Fusion Advent Fusion Z-Max ZLP Goliath

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The above trolleys by Fusion & ZLP sit on the cable, with the “V-shaped end” or opening end facing down.
A carabiner attaches the seat/harness and handle bar (except for Z-Max, which has the handle integrated into the
trolley). First attach the accessories to a carabiner which should come as part of the hardware in your kit then place the
trolley over the zip line and clip the carabiner through the hole in the bottom of the trolley all the way from one side of
the trolley to the other. Make sure the carabiner is not looped around the cable and that the trolley rolls smoothly
along the zip line. Tighten the carabiner safety catch. NOTE: If you intend to drop off your zip line into a body of
water – the Z-Max is not recommended, it is spring loaded and the cable can end up catching between the roller and
the outside sheaving as the trolley springs up when the rider drops off.
Petzl Trac Petzl Trac Plus
The Petzl trolley hooks onto the line by opening the carabiner opening and the trolley sits on top of our cable. A seat or
harness can then be attached to the carabiner before you clip it shut.
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TYPES OF SEATS AND HARNESSES
Sling Swing Seat LED Seat Heavy Duty Seat
Universal Harness Roar Seat Roar Deluxe Seat

Fusion or Black Diamond
Kid’s Warrior Plemistis Adult’s

Full Body Harness Full Body Harness
There are various types of seats based on your requirements. DO NOT ALLOW RIDERS TO SPIN WHILE RIDING THE ZIP
LINE.
The Sling Swing seat is for the more adventurous rider who simply sits in the seat like you would in a playground and
hang onto the straps or a rope instead of a handle bar to keep you in place. THIS IS NOT SUITABLE FOR CHILDREN.
The LED Seat is for shorter runs and is a hit with the children, weight limited to 200 lbs and under. The height can be
adjusted by changing the knot under the seat.
The Heavy Duty Seat comes in two sizes, Regular: 10” x 14” or Large: 13” x 17”, and offers a sturdy sitting platform that
is connected by a rope to your trolley by a carabiner, with a weight limit of 350 lbs. The height can be adjusted by
changing the knot under the seat. Thread the rope through the seat and twist into a figure eight. Thread the rope
through itself, pull upper half of rope while pushing down on knot to create a flat top for the seat to sit on. Do not use
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the seat if there is less and 12 inches of rope below the knot. Accessories such as handlebar or harness should never be
attached through the rope loop attachment. Accessories must always be clipped directly to trolley with a carabiner.
The Universal Harness is great for young children and adults who are faint of heart. Simply place each leg into the leg
hole and slide up to your waist and adjust the waist and leg buckles to a snug but comfortable fit. The harness is then
clipped via a carabiner to an adjustable lanyard or double lanyard (double lanyard will only work with Fusion Advent and
Z-Max trolleys that have a 2nd attachment opening at the back of the trolley). The other end of the lanyard will clip onto
the trolley using a 2nd carabiner. Before each ride, squeeze test the carabiners to make sure the locking gate is fully
engaged.
The rider can then hold onto the handle bars or onto the runner/lanyard. We suggest that when children are using a
harness that they also sit on the LED or heavy duty seat to enable them to hold onto the handlebar and this provides for
more safety and stability for the rider. A parent can also sit on the seat while having the child in the harness attached to
the trolley sitting on the parent’s lap.
Always use a harness for zip lines where a fall could result in injury.
DO NOT ALLOW riders to spin while connected to the zip line.

The Roar seat is designed for maximum comfort on long zip line ride with Contour foam padding, plus moisture wicking
material; multiple adjustment points to keep the rider balanced and quick release buckles to make it easier to put on.
The Roar Deluxe was originally designed for quadriplegics to go on zip lines, this harness is perfect for many adventurers
who have disabilities. Similar to the standard Roar Zip Line Seat but includes extra support for the head and neck. Has 4
loops for carabiner clip-ons. Legs and chest are both designed with easy to take on and off quick release buckle. Head
rest is made of water resistant PVC material with 2 permanently attached lanyards that can be adjusted up to 19″.
The Warrior is a full body children’s harness designed specifically for kids ages 3-8 to keep them safe and secure on the
zip line. Easy adjustment to accommodate many size children. Stitching is rated at 5,000 lbs.
Plemistis in Greek means “the warrior”. This harness was designed specifically for commercial zip line operation. This V-
style base model is light weight, offer’s three points of connection and is made of high strength hardware, webbing and
sewing patterns that meets and exceeds ANSI requirements.
.
TYPES OF BRAKING SYSTEMS
BUNGEE BRAKE BLOCK

There are 4 kits available:
Brake Block Kit #1 with 1/2″ bungee for zip lines under 300 feet
Brake Block Kit #2 with 5/8″ bungee for zip lines between 300 and 400 feet.
Brake Block Kit #3 with two 5/8″ bungees for zip lines between 400 feet and 500 feet for 350+ feet zip lines with faster
slope/runs to enable safe stoppage. The bungees would go to two different anchoring points 5-10 feet of the side of the
zip line.
Brake Block Kit #4 with two 3/4″ bungees for zip lines over 500 feet or for faster slope/runs to enable safe
stoppage. The bungees would go to two different anchoring points 5-10 feet off the side of the zip line.
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Step 1
UNBOLT the 4 bolts holding the Brake Block together and pull the Brake Block apart.
STEP 2
BOLT the Brake Block back together with the zip line cable running through the middle. Make sure the eye bolt is
closest to the start of the zip line and facing downwards. (see photo on next page) Tie one end of the bungee using a
double knot (review diagram on next page showing the proper way to tie your knot) leaving a loop at the end, hook a
spring clip into the look and connect onto the eye bolt on your brake block ensuring that the spring clip is securely
closed.
STEP 3
DETERMINING where to place your bungee anchoring point. Your bungee anchoring point can either be a tree or a
pole strongly embedded in the ground.
Kits 1 & 2 includes 20 feet of bungee cord. The bungee stretches approximately 175% of it’s length.
Kits 1 & 2
The formula for placement of your bungee anchor if your original bungee cord is 20 feet long:
20 feet minus 3 feet (accounts for knots) x 1.75 = distance from Bungee anchor to End Anchor Point
(20 - 3 = 17 x 1.75 = 29.5 ft).
This anchor must also be located at least 10 feet off to the side of the zip line run.
Screw the eye screw about 8 feet up from the bottom into a tree or pole. [Drilling a ¼” pilot hole can be helpful for
screwing the eye screw into your brake anchor tree or pole] Tie the other end of the bungee using a double knot
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(review diagram showing proper way to tie your knot) leaving a loop at the end, hook a spring clip into the loop and
connect onto the eye screw that you have placed on your bungee anchor, ensuring that the spring clip is securely closed.
***The eye screw can be replaced with an eye bolt which can be inserted right through the tree or pole and tightened
with a washer and nut.
**WARNING** Eye screw must embed to full depth in solid wood. Gently scrape away any bark that prevents the screw
from embedding fully into the wood.
Kits 3 & 4 utilizes a brake block with two eye bolts and includes two 20 ft bungee cords. As with Kits 1 & 2 you want to
find your bungee anchoring points, using the same formula place one bungee anchoring point on each side of your zip
line and continue with same directions as Kits 1 & 2 for securing your point. This will provide a safe stop for your rider.
Kit 3 & 4
DO NOT ALLOW THE BUNGEE TO SAG INTO THE RIDER’S WAY, IT CAN ENTANGLE THE RIDER.
STEP 4
Testing your Brake. DO NOT ATTEMPT TO RIDE YOUR ZIP LINE WITHOUT FIRST TESTING.
Make sure you test your Brake Block using your trolley with weights attached. Send a test weight from very beginning of
zip line to test bungee brake system.
Do not allow bungee to stretch to more than 175% of the bungee’s length, bungee may fail and injure zip line riders or
bystanders.
First measure to avoid overstretching of the bungee - have a helper stand near the end point of your zip line and have
them drop a bright object or marker on the ground below the test weight where the bungee stretches to its maximum
point. Measure from the object to the bungee anchor point. You should not have any impact with the ending anchor
point (final tree or pole).
Depending on the weight of the riders as well as the speed and distance of your zip line, you may need to adjust your
bungee anchoring point
If the bungee is overstretching or impacting with the ending anchor point with too much force, there are some things
you can do:
 unscrew the eye screw from the current bungee anchoring point and move it to a new location further away, or
 shorten your bungee, (do not shorten by more than 2 feet), or
 double up the bungee’s strength by adding a second bungee cord parallel to the original cord, or
 reduce the cable slope, or
 increase the cable sag to slow the rider’s speed down.
20
This is simply trial and error to get the correct safe stopping point if you have a speedier run. However, the general
calculations you used in Step 3 will work if your zip line does not exceed the 6% drop.
REMEMBER TO CHECK ALL YOUR EQUIPMENT AND CONNECTIONS OFTEN TO MAKE SURE THAT NOTHING HAS BEEN
DAMAGED, MOVED, STRETCHED OR FRAYED – REPLACE ALL WORN PARTS BEFORE USING YOUR ZIP LINE.
THE SPRING STOP BRAKE
The Spring Stop Brake operates much like a bungee brake, but without the need to anchor
off to the side of the zip line. The 3 foot 1-1/4” diameter stainless steel spring compresses,
absorbing the inertia of the rider, and then pushes the rider back out.
You will need to thread your cable through the Spring Stop Brake before completing the
installation of your zip line.
**Note the spring stop brake is not recommended for zip lines longer than 100 feet or for
zip lines that are more than 3% grade. Riders should have little to no momentum when
coming in contact with the Spring Stop Brake. For riding slopes greater than 3% we recommend using a Bungee
Brake.
GRAVITY BRAKE
This method works just the way it sounds, gravity is your friend. A zip line cable can be tuned so that the rider will not
have enough speed to carry them to the end of the zipline. This can be achieved through creating a large amount of sag
with the cable going uphill at the end, or reducing the overall drop of the cable from end-to-end.
LEATHER GLOVE
This requires proper training and practice for a rider to know how to safely bring themselves to a stop. A leather glove is
worn on the participants hand and used to push down on the zip line cable behind the trolley to create friction, slowing
the rider down. Although you may see this method used on You Tube videos we do not recommend this method as
damage to your hand can occur due to wear on the glove, inattention or loss of control. ONLY GRAB CABLE BEHIND THE
TROLLEY, NEVER IN FRONT. DO NOT TOUCH CABLE WITH BARE HANDS.
THE BRAKEHAWK
The Brakehawk is specially developed for the Petzl Trac & Trac Plus trolleys and the Fusion TESA speed trolley. This
active braking device keeps hands free of the cable and puts the power of braking firmly in the hand of the rider. The
rider engages the brake by pulling down on the BrakeHawk and creating friction between the zip line cable and the
BrakeHawk brake pad.
We advise the use of the optional tether that can be connected to the
Brakehawk, whereby the rider simply needs to pull down on the tether and it
will slow or stop the brake as needed and keeps the rider’s hands safely away
from the cable.
This system does require rubber or leather brake pads to be replaced if wear
shows. *see BrakeHawk Brake Pads
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How to Use with Fusion Tesa Speed Trolley: Remove provided clevis pin and install BrakeHawk on trolley. Lock
clevis pin back in place. Place BrakeHawk and attached trolley on zip line cable (brake travels behind trolley).
Attach carabiner and harness to trolley. Place dominate hand on hand grip to the back of the BrakeHawk. For
slowing down or stopping apply downward pressure as needed from brake to zip line cable.
How to Use With Petzl Trac/Trac Plus: First remove the black retaining
clip and carabiner from the Petzl Trac/Trac Plus. Install the BrakeHawk
onto the trolley and reinstall the carabiner and retaining clip. Place the
BrakeHawk and attached trolley on the zipline cable (the brake travels
behind the trolley). Attach the carabiner and harness or seat to the
trolley.
For braking, place your dominant hand on the hand grip at the back of the
BrakeHawk. To slow down or stop apply downward pressure as needed
from brake to zipline cable.
22
BrakeHawk Brake Pads: Brake Pads are an essential part of the Brake Hawk
Braking system. Please replace the pads when they begin to show wear.
Instructions for changing Brake Pad:
 Remove trolley and lay BrakeHawk on a solid surface.

 Place the tip of a flathead screwdriver in the back corner of the
BrakeHawk between the brake pad and the brake housing (see Figure
A).
 Pry screwdriver up and down while pushing forward until brake pad
pops up. Remove old brake pad.
 Before installing the new brake pad make sure the wide side of the
wedge is facing up.
 Place new brake pad on the brake ramp at an angle making sure brake
pad is even with the back of the brake housing.
 Put the tip of the flathead screwdriver into the cable channel and push
down on the high side of the brake pad while moving back and forth
until brake pad feels fully seated on brake ramp (see Figure B).
Visually inspect to confirm brake pad is fully seated on brake ramp by
looking the front and back of the brake pad.
 Reinstall BrakeHawk onto trolley.
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SECTION FIVE: PROFESSIONAL ZIP LINE INSTALLERS IN CANADA
Should you not want to install your zip line yourself, there are three professional zip line installation companies in
Canada. The average cost to install the cable begins at $1,500-$2,000 depending among other things on where you live
and how long a zip line you want. This usually includes: a site visit/consultation so they can advise you as to whether
your trees are healthy enough, what heights are best for your topography for safe zip lining and whether you will require
platforms.
If you are thinking of using your zip line for a commercial/money-making operation, you will require a
professional installer to do the cabling work to ensure that all the health and safety measures are followed
exactly and to code. A professional installer is trained, insured and knowledgeable about all the legalities
involved in installing and operating a commercial zip line. They can also arrange for your employees to receive
the proper training necessary to operate your zip line.
The contact information for three of Canada’s professional zip line installation companies are:
Ontario
1/ Elevation Aerial Design & Consulting http://elevationaerial.com 800-739-4992 **This is the company does
installations world-wide
2/ Challenges Unlimited https://challengesunlimited.com 705-385-4209
Alberta
3/ Rocky Mountain Lift Services & Supplies Inc www.riggingspecialties.com 403-678-8836
PLEASE REVIEW THIS GUIDELINE OFTEN TO ENSURE YOU KNOW ALL THE SAFETY ISSUES AND
IF YOU ARE IN DOUBT CONTACT YOUR ZIP LINE PROVIDER.
24

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GENERAL INSTALLATION

AND SAFETY GUIDE

SECTION ONE – BEFORE YOU BEGIN

SECTION TWO – CABLE INSTALLATION 10

SECTION THREE: IMPORTANT INFORMATION/ CARE/WARNINGS & DISCLAIMERS 13

SECTION FOUR – COMPONENTS

SECTION FIVE – PROFESSIONAL ZIP LINE INSTALLERS IN CANADA 24

FREE STANDING POLES:

Installing a ground anchoring pin –

Sight Level or Laser Ladder

CABLE SLOPE & SAG

STEP 4 - ELEVATION CHANGE

Determine your SIGHTING HEIGHT and enter it in Box B.

________________ plus 7 feet = ________________

STEP 6 - STARTING ANCHOR POINT HEIGHT

Using his length of 180 from Step 1 he multiplies it by 0.02 4

Step 6 To calculate his starting anchor height he uses the Slope # +

Next fully extend the turnbuckle to it’s longest length – unscrew

Another option is to place a large eye bolt through

Now it’s time to do the CABLE WEIGHT TEST

WARNING!!! Never place more than 350 lbs on zip line

Allow TEST WEIGHT to settle at the lowest point of the cable.

READ THIS INFORMATION AND REVIEW WITH ALL

ANYONE PURCHASING, INSTALLING OR USING ZIP LINE EQUIPMENT MUST:

REMEMBER SAFETY FIRST AND ALWAYS

Check your cable to make sure there is no fraying or excessive rusting.

Riders must never spin while connected with a harness or seat.

At the end of the run:

Never place more than 350 lbs on the zip line.

SECTION FOUR - COMPONENTS

Fusion Tesa Speed Fusion Advent Fusion Z-Max ZLP Goliath

Petzl Trac Petzl Trac Plus

Sling Swing Seat LED Seat Heavy Duty Seat

Universal Harness Roar Seat Roar Deluxe Seat

Kid’s Warrior Plemistis Adult’s

DO NOT ALLOW riders to spin while connected to the zip line.

TYPES OF BRAKING SYSTEMS

BUNGEE BRAKE BLOCK

THE SPRING STOP BRAKE

 Remove trolley and lay BrakeHawk on a solid surface.

2/ Challenges Unlimited https://challengesunlimited.com 705-385-4209

3/ Rocky Mountain Lift Services & Supplies Inc www.riggingspecialties.com 403-678-8836

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plus 7 feet =