Installation Instructions 

Installation Instructions

Carnie Cap™ Rebar Guard Warnings
And Installation Instructions

Read These Warnings Before Using The Carnie Cap™!

  • Before use of this system, read and understand all instructions, warnings, cautions and notes marked on the equipment and contained in these WARNINGS AND INSTRUCTIONS.

  • The CARNIE CAP™ is designed and tested only as a system. The System includes the CARNIE CAPS™ (Standard size Model #CC-100 for #4 to #9 Bar and Large size Model #CC-200 for #5 to #16 bar), pieces of lumber which are commonly found, Construction Grade Fir 2" x 4"s, 4" x 4"s (nominal) (for use with the Model #CC-100) and 2" x 6"s (nominal) (for use with Model #CC-200), lumber, nails, and common rebar. Other uses with different components should be tested if employers intend to rely on the device for safety of the employees. (Note: 2 pieces of the 2" lumber were tested nailed together to create a 4" nominal thickness.)

  • Use of components that have not been designed and/or tested for use with this system can be dangerous and lead to injury or death. Contact Carnie Cap Inc. if you are unsure about using an equivalent product.

  • The CARNIE CAP™ is not a fall protection device. It is used as part of a total system to prevent impalement on rebar when a worker falls. Additional fall protection or positioning devices should be used to prevent falls to the level of the rebar.

  • The CARNIE CAP™ System has been tested to resist a 250 pound sandbag dropped 10 feet directly onto the top of the lumber. The System should not be relied upon to protect a heavier worker falling from this height or any worker falling from a higher point. Note: CAL-OSHA does not allow falls greater than 7.5 feet. Consult your state or federal OSHA plan for other limitations.

  • Treat the CARNIE CAP™ System with respect. Your life is on the line! Use care when moving, shipping or storing CARNIE CAPS™. Use only CARNIE CAPS™ in good condition, and lumber and nails without defects or weaknesses. If damaged from use or rough handling—remove from service. If there is any doubt, remove from service and call for advice from Carnie Cap Inc.

  • Any CARNIE CAP™ System or component part of a system that is involved in a personal fall incident or is struck by a weight shall be removed from service immediately and discarded or returned to Carnie Cap Inc. for inspection.

  • Failure to install, use and/or remove CARNIE CAP™ equipment in a safe manner by skilled and trained craftsmen can result in serious injury or death. Until the CARNIE CAP™ is properly installed, use alternate fall protection means. Ask your supervisor for proper training.

  • CARNIE CAP™ allows spacing up to 8’ between caps. However, you should use additional CARNIE CAPS™ when needed to ensure that all rebar stays under the piece of lumber, or if the lumber gets displaced by workers moving about, grabbing it or leaning on it. If at any time any worker observes any rebar exposed, stop work above and next to the CARNIE CAP™ System, and readjust or reinstall the System.

  • The CARNIE CAP™ System is a single use item. If involved in arresting a fall or the System is struck with a weight (or a load), the units involved should be taken out of service and replaced. Contact Carnie Cap Inc. at 1-888-743-7725 or 1-309-752-9155 for assistance.

  • The CARNIE CAP™ Systems were tested on rigidly supported #4 rebar. The CARNIE CAP™ Model #CC-100 is designed to fit on rebar from #4 to #9 and Model #CC-200 is designed for rebar from #5 to #16. (Call for information on larger sizes.) Use on rebar that is smaller or unsupported could have different results. Use on larger rebar could cause permanent damage to the CARNIE CAP™. Some deformation to the rebar is possible when a fall occurs. Carnie Cap Inc. cannot be responsible for the stability or quality of the structure that the CARNIE CAP™ System is mounted on, or for consequential damages to the structure from the effects of the fall. Note: Destruction and/or deformation of the wood, the CARNIE CAPS™ and possibly the rebar is expected and is a natural consequence as part of the deflection and absorption of the impact forces.

  • This device does not guarantee your safety; Carnie Cap Inc. and its agents do not guarantee that no injury will occur if a person falls onto the CARNIE CAP™ System while working above or adjacent to this unit. Use of this device is only expected to reduce the likelihood of serious injury and limit the penetration of the rebar into a person’s body if a fall occurs. Other means should be considered to limit the likelihood of a fall as well, which may include but are not limited to fall arrest and fall positioning equipment, scaffolds, guardrails, nets, man lifts, ladders, ramps, aerial lifts, and others. Risks inherent to falling onto a 2" x 4", 4" x 4" or 2" x 6" lumber, plastic caps and to the ground from heights are assumed entirely by the user and the employer of the users. The employer has a non-delegatable duty to provide a safe workplace. The CARNIE CAP™ System and other methods may be considered to minimize the injury inherent in the construction trades and while around construction operations. This system meets the requirements of CAL OSHA and Federal OSHA for Rebar Protection at the time of this publication and sale. (CAL OSHA #C-1721-AG.)

  • Do not use CARNIE CAPS™ until you have trained and fully understand the device, the warnings and the instructions. If you have any questions regarding the safe installation, use or removal of CARNIE CAPS™ or the CARNIE CAP™ System or need additional instructions, call Carnie Cap Inc. Call Carnie Cap Inc. for Spanish translation or assistance with other languages.

  • Carnie Cap Inc. is staffed with professional safety consultants, experienced in establishing fall protection programs, testing applications of fall protection products and conducting training for field employees. If you can benefit from these additional services, please call. (Consulting is offered through Miller Safety Consulting, Inc. 1-303-477-1044)


Safety First!


  • In order to use the CARNIE CAP™ properly, ensuring compliance with applicable OSHA and MSHA regulations, the Installer must follow these instructions and installation guidelines and ensure that competent staff understands and implements the following at a minimum.

  • It is the Installer’s responsibility to safely and properly install and maintain the CARNIE CAP™ System and to provide a work environment with limited hazards.

  • Do not use the CARNIE CAP™ alone. Model #CC-100 must be used with 2" x 4" lumber or 4" x 4" lumber and Model #CC-200 must be use with 2" x 6" lumber, nails and be securely mounted on rebar to form a complete system. Model #CC-100 may only be used on rebar size #4 through #9 and Model #CC-200 may only be used on rebar size #5 through #16. All component parts must be used, properly secured and in good condition before any work overhead or adjacent to the CARNIE CAP™ System is allowed to proceed. NOTE: In order to comply with CAL-OSHA standards as of 10/1/2000 double the thickness of 2" x 4" or 2" x 6" lumber (to 4" nominal thickness) by nailing two pieces together with at least 3 #8 common or 3 #8 coated nails and spaced no greater than 4’).

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  • Place the CARNIE CAPS™ female end over the rebar. Ensure that the CARNIE CAP™ is securely attached to the rebar by pressing it down all the way. On larger bars, you may have to twist the CARNIE CAP™ to get it on. (See #1 in diagram)

  • CARNIE CAP™ should be placed at no greater than 8’ spacing. If a longer piece of lumber is used, additional CARNIE CAPS™ should be near the ends of the piece of lumber. (See #2 in diagram.) Use additional CARNIE CAPS™ to ensure that all rebar stays under the piece of lumber, or if the lumber gets displaced by workers moving about, grabbing it or leaning on it. If bars are of irregular height, place CARNIE CAPS™ on the highest ones, without exceeding any other limitations herein. If at any time any worker observes any rebar exposed, stop work above and next to the CARNIE CAPS™ System and readjust or reinstall the System.

  • Set a proper sized, proper grade, proper quality piece of lumber in the top (saddle) of the CARNIE CAP™ and secure by nailing with #8 coated or #8 common nails approximately 1" deep through the holes provided. Bend the nails over.

  • Do not butt the ends of two lumber in a single CARNIE CAP™ saddle. Each piece of lumber must have at least 2 CARNIE CAPS™.

  • Do not use small pieces of lumber in a single CARNIE CAP™. The system must have at least two CARNIE CAPS™ and the piece of lumber must be at least as long as two adjacent rebars.

  • Do not butt the ends of two pieces of lumber over a rebar. The intersection of two pieces of lumber should be in-between two adjacent rebars.

  • Ensure that all rebar in the row are lined up underneath the piece of lumber, to eliminate the hazard of impalement. (See #4 in diagram.) Use additional Systems on adjacent lines of rebars. Use additional caps on rebar that tends to bend out from the center point of the piece of lumber to pull it into line and center it under the center of the piece of lumber. (See #5 in diagram.)

  • Vertical and inclined applications are also possible. The female end of the CARNIE CAP™ must be no higher than horizontal. Do not use overhead in an inverted application—the CARNIE CAP™ can be pulled off the overhead bars by gravity and may strike and injure someone.

Warranty Notice And Disclaimer

The product is only warranted to be free from material manufacturing defects at the time it is produced and shipped. Based on the variety of conditions and the variable for the use of this product, the Manufacturer, and its sellers, agents, successors and assigns make no warranties or guarantees expressed or implied, including but not limited to warranties for fitness for purpose, merchantability, marketability, or performance, or for level of protection offered.

These instructions and warnings are purely advisory and they and the product are intended for the purpose of assisting the client in loss control, safety and risk management procedures.

Implementation and use of the CARNIE CAP™ System as a part of the user’s total loss control and safety program, and/or compliance with suggestions and recommendations made or offered by Carnie Cap Inc. or its agents, and proper and lawful use of any information given by them, is the sole responsibility of the user. User, by using this product, agrees that it has the sole responsibility for the decision to use the product for protection and accepts the limitations of the product as described herein and in available test reports. If user does not agree, they are advised to not use the product, and return it postage paid for a prompt full refund.