Shaftbrace User Guide page 1 red
Contents
1. ARRANGEMENT THE LOAD MAY SEVERELY TWIST THE MASTER RING RESULTING IN DAMAGE OR FAILURE All lifting accessories attached to the excavator lifting point must hang freely and be free to move at all times TILTING THE HEAD OF THE DIPPER ARM QUICK HITCH UPWARDS MAY PREVENT FREEDOM OF MOVEMENT AND SO TWIST DAMAGE OR FAIL THE LIFTING EQUIPMENT CORRECT INCORRECT Page 4 of 12 product user guide p mialblely ines Title Issue Date Shaftbrace February 2013 7 Identification of Components Male Ram Unit Female Male Intermediate Extension 203 x 203 U C Female L Pin to Pin L mm Code Min Max Pin to Pin L mm Weight Kg SHBP 170 500 SHBP 110 1455 2055 270 SHBP 100 1855 2855 355 Male End Extension 203 x 203 U C Female SHBP 161 4500 T SHBP 177 5000 SHBP 162 7000 Pin to Pin L mm Weight Kg SHBP 193 550 SHBP 150 135 Degree Corner Unit SHBP 151 SHBP 174 SHBP 152 SHBP 153 Male Female Male End Extension 203 x 203 U C Male Female Nel Code Dimension L mm weight Ko ol SHBP 201 790 111 Pin to Pin L mm Weight Kg SHBP 195 450 50 Heavy Duty Intermediate Male Extension 254 x 254 U C Female Pin to Pin L mm Weight Kg Pin to Pin L mm Weight Kg SHBP 187 SHBP 178 5000 SHBP 182 SHBP 192 SHBP 171 SHBP 183 SHBP 168 SHBP 167 SHBP 172 SHBP 184 SHBP 169 SHBP 163 SHBP 186 SHBP 12. product user guide Title Issue Date Shaftbrace February 2013 Contents Page 1 Introduction Design Frame Dimensions Hydraulic Adjustments Page 2 4 General Guidance Notes Page 5 Identification of Components Page 6 Typical Waling Assembly and Site Connection Details Page 7 8 Typical Sequence of Sheet and Frame Installation Page 9 Removal of Frames Use of Restraint Chains SHBP 189 Capacity 2 0T Page 10 Frame Dimensions and Leg Weights Page 11 Mechanical Pump Details and Procedures for Extending Retracting Walings Page 12 Do s and Don ts General Appendix A Provision of a Mabey Hire Site Demonstrator 1 Introduction Mabey Hire s Shaftbrace system is intended to be used as a temporary waling system to sheeted excavations It is not intended for other purposes The product is frequently used in combination with e Super Shaftbrace waling system e Hydraulic bracing strut e Mechanical bracing strut e Double Acting Manhole Brace For details of these waling systems and bracing struts within Mabey Hire s range refer to the appropriate set of user information This booklet provides basic information for users of Shaftbrace to assist them in their preparation of a safe system of work on site Shaftbrace should NOT be used in seawater applications without prior consultation with Mabey Hire Refer to Appendix A for details of our site demonstrator service 2 Design No information on design is included
3. fluid leakage Keep plant spoil heaps and stored materials well clear from the edge of the excavation 5 8 Return of Equipment off Hire Clients should ensure that on removal the equipment is returned clean in lengths as supplied 5 9 Transportation Ensure all equipment is loaded to the satisfaction of the lorry driver and is securely chained strapped to the lorry 5 10 References 5 10 1 Legislation The Health amp Safety at Work Act 1974 The Management of Health and Safety at Work Regs M H S W 1999 The Construction Design and Management Regulations 2007 The Control of Substances Hazardous to Health COSHH Regulations 1994 The Lifting Operations and Lifting Equipment Regulations LOLER 1998 The Provision and Use of Work Equipment Regulations PUWER 1998 Work at Height Regulations 2005 Noise Manual Handling 5 10 2 HSE Guidance Health and Safety in Construction HSG150 rev A Guide to Managing Health and Safety in Construction ISBN 0 7176 0755 0 Health and Safety in Excavations Be Safe and Shore HSG185 Safe Work in Confined Spaces Regulations Approved Code of Practice and Guidance L101 Five Steps to Risk Assessment INDG 163 Excavators Used as Cranes Guidance Note PM42 5 10 3 Other Guidance CPA Guidance Safety in Shoring The Proprietary Shoring and Piling Equipment Manual CPA STIG Guidance STIG 0201 Selection of Proprietary Shoring Equipment CPA STIG Guidance TIN 203 The Use of Restraining
4. in this booklet Clients are strongly advised to ensure that a competent engineer is employed to provide a suitable design for excavation schemes requiring the use of Shaftbrace products Mabey Hire Ltd offer a design service and can on request also provide information on the strength capacities of Shaft brace products for clients undertaking their own designs 3 Frame Dimensions This booklet gives information for frame dimensions for Shaftbrace Walings When Shaftbrace is used in combination with Super Shaftbrace or Double Acting Manhole Brace consult Mabey Hire staff for frame dimensions 4 Hydraulic Adjustments The Shaftbrace system incorporates a hydraulic system of adjustment which is designed to extend or retract the frames under conditions of no or low loading e g as when first installed or as they become redundant after backfilling the excava tion Once they are sustaining significant ground loads hydraulic extension or retraction of the frames is inadvisable and is unlikely to be possible Methods of working should therefore avoid the need for frame adjustment removal whilst the walings are heavily loaded Page 1 of 12 product user guide Title Issue Date Shaftbrace February 2013 5 General Guidance Notes 5 1 Safe System of Work and Method Statement Assuming that the location plan size and depth of an excavation together with an arrangement of sheets and frames has already been determined the Health and S
5. 66 7 1 Accessories e Installation Kit Double Acting Pump Code MHB 100 or PSP 101 Weight 18 Kg empty 43 Kg full Hose Extensions Code PSP 275 Lock off valve spanner e Lifting Chain Code SB LSLG SH Weight 47 Kg 10mm 4 leg chain sling 4m E L L c w 4 No Safety Hooks and 4 No shortening Clutches Refer to Lifting Chain User Information for further details e Restraint Chain Code SHBP 189 Weight 5 8Kg 2m E L L Capacity 3200Kg Note When used in combination with Mabey Hire M11 sheets capacity reduces to 1500Kg See also Page 9 Page 5 of 12 product user guide p mialblely ines Title Issue Date Shaftbrace February 2012 8 Typical Waling Assembly and Site Connection Details Ram section Intermediate 2 Sizes Extension Various lengths See page 5 Various lengths See page 5 Box Section See Page 5 203x203 UC va iF fF ff rw Rie O JAA 2 No 20mm bolts x 5mm long 1 No Bailey pin 48mm c w spring retention clip 8 1 Assembly The legs of the brace are made to the correct length range where possible prior to delivery so that only the corners need be connected using a Bailey pin complete with spring retention clip as supplied The lug is a close fit in the clevis so that the legs should be as level as possible during assembly to make it easier to assemble the joint It is worth spending some time on levelling the ground on which the frame is to
6. Chains to Support Shoring Equipment CPA STIG Guidance TIN 204 The Correct Use of Lifting and Other Attachment Points for Shoring Equipment CPA Safety Guidance Risk Assessment SG 003 CPA Guide Ref No SG001 3 Guidance on Lifting Operations in Construction When Using Excavators CIRIA Report R166 CDM Regulations Work Sector Guidance for Designers CIRIA Report 97 Trenching Practice CIRIA Special Publication 131 Crane Stability on Site CIRIA Special Publication 95 The Design and Construction of Sheet Piled Cofferdams 5 10 4 British and European Standards BS 6031 2009 Code of Practice for Earthworks BS EN 996 1996 Piling Equipment Safety Requirements BS EN 1997 1 2004 Code of Practice for Foundations BS 5228 1 2009 Code of Practice for Noise and Vibration Control on Construction and Open Sites Noise BS 5228 2 2009 Code of Practice for Noise and Vibration Control on Construction and Open Sites Vibration Page 3 of 12 product user guide p mialblely ines Title Issue Date Shaftbrace February 2013 6 Sling Warning WARNING IF YOU ARE USING A SLING ON AN EXCAVATOR BEWARE THE FOLLOWING It is very important that a means of allowing the sling to swivel be introduced above the master top ring This will allow the sling and in particular the master ring to Attachment turn and align with the load rr Code SSBA 007 WITHOUT A SWIVEL N Refer to product user guide for further details
7. Place each leg in excavation and assemble the frame Connect hydraulics and pump frame out to correct dimension Remove hydraulics 3 Using the frame and excavated face as a guide place sheets and using the relevant drive cap drive with excavator bucket as far as possible Connect restraint chains as per scheme drawing 5 Connect hydraulics and individually pressurise all frame ram units to 2500 p s i close lock off valves and remove hydraulics Dig through to next frame position and push sheets down 7 Reposition restraint chains as necessary Place legs of second frame in excavation and assemble safe working must be maintained 9 Attach restraint chains between second frame and the top of the sheets piling 10 Connect hydraulics and individually pressurise all lower frame ram units to 2500 p s i close lock off valves and remove hydraulics 11 Push sheets down to give toe in required and complete dig NOTE 1 This method requires operatives working in the excavation and the contractor must ensure safe working conditions at all times 2 See Page 9 for notes on use of restraint chains Page 7 of 12 product user guide p mialblely ines Title Issue Date Shaftbrace February 2013 9 2 Method 2 Installation of 2 frames by crane and excavator fully driving sheets piling with piling hammer Use the crane for lifting and driving operations and the excavator for digging operations Fu
8. afety at Work Act requires that a safe system of work is adopted to carry out the work on site These guidance notes are intended to draw the client s attention to practical aspects of Shaftbrace installation which need to be considered in compiling method statements for a safe system of work In particular the client s attention is drawn to the lengths and weights of the frame members and the need for planning the lifting operations involved All major components of the Shaftbrace system are fitted with lifting lugs for safe slinging Two methods of constructing a typical excavation using Shaftbrace are given on Pages 7 8 5 2 Manpower The Health and Safety legislation requires that personnel deployed are suitably trained experienced and supervised by a competent person All lifting operations are to be controlled by an appointed person in accordance with BS7121 and LOLER regulations The main activities associated with Shaftbrace installation are e Unloading the delivery vehicle e Bolting up and pinning steelwork together to form walings of the required length e Slinging and lifting walings into position in the excavation and connecting the corners to form frames e Connecting the pump to each waling in turn pressurizing the frames and fitting restraint chains 5 3 Plant and Lifting A suitable appliance is required for off loading and installation For off loading there needs to be sufficient clearance under the main hook to allow lifting
9. ame Site Address Tel No Fax No Re Provision of a Mabey Hire Demonstrator on site We confirm receipt of your User Information Appendix A and that we would like to request the services of your Demonstrator on the following date s Signed Name print Date
10. be assembled If the legs have to be altered to another range on site i e by adding or removing an extension section the intermediate connection detail is used This consists of 1 No Bailey pin and spring retention clip and two M20 x 75mm long bolts IMPORTANT Before lifting each leg into the excavation 1 Ensure that 1 No Bailey pin and 2 No M20 bolts are fitted at each intermediate connection 2 Ensure that the spring clips are fitted and that the bolts are fully tightened 8 2 Site Connections for Waling 1 No Bailey Pin 48mm 1 No Bailey Pin 48mm 2 No M20 Bolts x 75mm Intermediate Long e or End Extension End Ram Intermediate Extension Unit Extension 1 No Spring Retention Clip 1 No Spring Retention Clip Corner Connection Intermediate Connection Extensions are normally attached where possible prior to delivery but to suit site conditions the extensions can be changed by unbolting the 2 bolts and removing the Bailey pin Page 6 of 12 product user guide p mialblely ines Title Issue Date Shaftbrace February 2013 9 Typical Sequence of Sheet and Frame Installation 9 1 Method 1 Installation of 2 frames by excavator without piling hammer placing one leg at a time WARNING Refer to safety information on page 4 regarding excavators being used for lifting operations 1 Fully excavate to first frame level 1b Alternatively excavate slit trench only to first frame level 2
11. e Customer should note the following A1 The Customers Responsibilities A safe system of work remains the Customers responsibility at all times It is his responsibility to prepare for organise and direct the operation including A1 1 Site induction for the demonstrator A1 2 Preparation of a method statement A1 3 Arisk assessment A1 4 Selection of lifting equipment and any other equipment required to undertake the work A1 5 Positioning of the crane or lifting appliance A1 6 Banking the crane A1 7 Slinging the components A1 8 Assembling the components and installing them A2 Activities which the Mabey Hire Demonstrator is authorised to carry out Mabey Hire Demonstrator is authorised to A2 1 Assist in indentification of Mabey Hire components A2 2 Explain how they fasten together A2 3 Point out slinging points and special methods of lifting as noted in the user information A2 4 Demonstrate how to attach hoses and use pumps to extend retract hydraulic braces A2 5 Draw attention to the content of the user information A2 6 Clarify queries with Mabey Hire scheme drawings The Demonstrator is NOT AUTHORISED to take over or direct the installation To Mabey Hire Limited Please return this completed form to the Mabey Hire depot supplying the equipment Contact details for all the Mabey Hire depots are available both on line at www mabeyhire co uk depot directions and within our brochures From Company N
12. et the pump control lever to Neutral Connect the pump hoses to the ram unit of the waling Slowly open the safety lock off valve to release the hydraulic fluid pressure and allow fluid to flow back through the pump To release frames it will be necessary to retract the walings in turn by setting the pump control valve to Retract and operating the pump until the ram is fully retracted On completion of retraction set the pump control valve to Neutral Close lock off valve in ram unit and disconnect pump hoses from the ram 13 6 Fault Finding In the event of the frames not extending or retracting when pumped check the following points Pump is adequately filled with fluid Pump Control Lever is in the correct position for required operation Both hoses are connected double check connections to the couplers on the ram Safety lock off valve is open rotated anti clockwise max 2 turns Frame is not heavily loaded If the ram still does not move there may be air in the system which may be indicated by the ram springing back and this must be purged as follows To purge pump disconnect hoses from ram and connect hose ends together Pump for several strokes until fluid can be heard returning to the tank Repeat with lever in opposite position To purge ram connect hoses and pump ram to full extension Reverse lever and pump until fully closed Repeat until there is no sign of ram springing back If the ram still does not f
13. et to Sheet Approx Max Dimensions Dimensions Leg mm mm per Waling Weight iN SHBP 100 SHBP 155 SHBL 10 SHBP 100 SHBP 151 105 4105 3605 D O O Ql O1 Ol O1 D O O Ql wwo AJ S oO gt amp OO O O1 O1 O1 1 1 483 1 Leg Code Leg Arrangement kg SHBL 11 SHBP 100 SHBP 150 2605 3605 3105 SHBP 100 SHBP 157 3455 2955 3955 1250 423 SHBP 100 SHBP 170 3205 2705 3705 411 SHBL 12 SHBP 100 1m stroke 1 855m to 2 855m 1705 2705 2205 3205 355 SHBL 13 SHBP 110 0 6m stroke 1 455m to 2 055m 1305 1905 1805 2405 270 D N Ql Ql NIN N O1 SHBL 05 SHBP 100 SHBP 156 SHBP 151 33 14 97 80 64 47 30 14 64 47 25 4 WN Cp a L T WW W WW eA E e a O na a D amp X NOTES These legs only use intermediate extensions e If intermediate extensions are used in place of end extensions add 100mm to Clear Inside dimension 100mm to Face of Sheet dimension e All legs use the SHBP 100 Ram Unit except SHBL 13 e Leg lengths over 7 0m may require bracing struts e Frame sizes for other combinations can be supplied by Mabey Hire Limited on request e The clear internal dimensions tabulated do not include any allowance for deflection of the walings under load e These waling deflections are listed separately above and generally it will be necessary to increase the clear internal dimensions by
14. h lifting sling to lifting eyes and lift each leg one at a time from excavation Follow the above procedure for the upper frame When the frames have been removed and the excavation backfilled the sheets can be removed one at a time using a trench sheet extractor 11 Use of Restraint Chains SHBP 189 Capacity 2 0T Restraint chains are provided as a back up support arrangement in the unlikely event of hydraulic failure of one of the Shaftbrace hydraulic legs They are NOT to be used for any other purpose and particularly are NOT to be used as lifting chains They are NOT intended as a means of suspension to be relied upon during installation or removal of the frames Always ensure all the restraint chains are fitted as per arrangement shown on the scheme drawing or if no scheme has been prepared 1 No chain every 2 5 m approx of waling Remove as much slack as possible from the chain by repositioning the lower D shackle Users must ensure that frames are securely supported by means other than the restraint chains prior to depressuriz ing the frames Forged hook for hanging over top of sheets D Shackle D Shackle NOTE When used with Mabey Hire M11 sheets Restraint Chain capacity reduces to 1 5T When used with M6 M7 sheets capacity reduces to 1000 Kg Page 9 of 12 product user guide Title Issue Date Shaftbrace February 2012 12 Frame Dimensions and Leg Weights Clear Internal She
15. hortening clutches and safety hooks Code SB LSLG SH weight 47kg SWL 9 0 tons 90 though clients should check that the leg length is suitable to use with their lifting appliance 5 5 Edge Protection Access and Hard Standing Areas These include e Suitable area to off load the lorry and assemble the walings e Suitable hard standings for the lifting appliance to operate from if it is intended to lift the walings into the excavation e Ladders and possibly other provisions to provide safe access into the excavation to install restraint chains and connect pump hoses e Edge protection ladders and possibly other provisions to provide safe access into and out of the excavation Edge protection and ladder access platforms can be supplied by Mabey Hire Ltd Page 2 of 12 product user guide Title Issue Date Shaftbrace February 2013 5 6 During Excavation Works on Site If Mabey Hire Ltd have designed the sheeting and frame arrangement for the excavation they will have used ground data provided by the client If during the excavation it is noted that the actual ground conditions and or ground water levels differ from those provided at design stage it is advisable to have the scheme rechecked 5 7 After Excavation Works are Completed Plan for edge protection to be installed as early as possible Regularly inspect the excavation for signs of excessive movements of sheets or walings Check the hydraulic walings for signs of
16. lly drive sheets piling using a piling hammer 2 Remove piling guide and excavate to first frame level 3 Weld angle brackets to the piling if required to support the frame 4 Place each leg in excavation and assemble the frame 5 Connect restraint chains 6 Connect hydraulics and individually pressurise all ram units to 2500 p s i close lock off valve and remove hydraulics 7 Dig through to next frame position 8 Weld angle brackets to the piling if required to support the frame 9 Place legs of second frame in excavation and assemble safe working must be maintained 10 Attach restraint chains between second frame and the top of the sheets piling 11 Connect hydraulics and individually pressurise all lower ram units to 2500 p s i close lock off valve and remove hydraulics 12 Complete dig NOTE 1 This method requires operatives working in the excavation and the contractor must ensure safe working conditions at all times 2 See Page 9 for notes on use of restraint chains Page 8 of 12 product user guide p mialblely ines Title Issue Date Shaftbrace February 2013 10 Removal of Frames Backfill to the underside of the lowest frame and carry out any compaction required Ensure frame is securely packed or supported from below Connect hydraulics and individually open lock off valves max 2 turns and fully retract all lower frame ram units Remove restraint chains Remove corner pins attac
17. twice the appropriate waling deflection Page 10 of 12 Title Issue Date Shaftbrace February 2013 13 Mechanical Pump Details and Procedures for Extending Retracting Walings 13 1 Introduction It is advisable before commencing installation to read the notes below to become familiar with the procedures involved The diagram below shows the pump control lever gauge hose connections and safety lock off valve referred to in the procedures Female Connector P EXTEND wea Retract set to retract EXTEND Jt Shaftbrace Ram Unit Pump Control Sn Lever See detail to left Pump lever set to extend Male Connector Handle Extend PSP 101 Pump 13 2 Preliminaries e Check there is sufficient of the correct Mabey Hire shoring fluid in the tank Only Mabey shoring fluid should be used e Set the pump control lever to Neutral e Purge the hoses of air To do this connect the hoses together and pump for several strokes with the pump control lever set to Extend When satisfied that any air has been expelled set the pump control valve to Neutral 13 3 Mabey Hire Shoring Fluid The pump is normally supplied with a full tank of pre mixed fluid If the fluid is separately Temp Range Shoring Fluid Water supplied neat in 5 litre orange coloured containers it should be poured into the pump C litres litres and cold clean water added according to pre
18. unction properly refer to your nearest depot 14 Do s and Don ts DO install the legs of each frame one at a time DO install frames as level as possible DO use restraint chains between each frame to the top of the sheets DO ensure the lock off valves are open prior to pumping DO ensure that the pressure is being held on the rams before closing the lock off valves DO release the pump pressure after closing the lock off valves to ease removal of hoses DO keep the couplers of the hoses dirt free by clipping male and female ends together after use DO NOT attempt to install or remove by lifting complete frames DO NOT over pressurise the system as this can damage the rails DO NOT pressurise a frame with a large gap between the rails and the sheets A packer must be inserted to fill the gap first DO NOT attempt to disconnect a hose until the lock off valve has been fully closed and pressure has been released at the pump DO NOT release ram pressure by depressing or striking the coupler nipple DO NOT use restraint chains as a means of suspension during installation or removal of the frames 15 General Since our policy is one of continual improvement components may vary in detail from the descriptions given in this publication Page 12 of 12 oee User Information Appendix A Provision of a Mabey Hire Site Demonstrator Mabey Hire can subject to availability offer the services of a Site Demonstrator However th
19. vailing temperature conditions See table En o a 0 tO right Protective gloves should always be worn when handling shoring fluid 10 to 7 15 15 10 and below Neat fluid only NOTE A Shoring Fluid safety data sheet is available from Mabey Hire Limited 13 4 Procedure for extending walings to predetermined lengths or pressurizing a frame e Ensure each waling is set up level and safely on packs just clear of the ground so that it will be free to extend Connect both hoses as per the diagram Set the pump control lever to Extend Ensure that safety lock off valve on the ram is open by turning anti clockwise no more than 2 turns Pump to required size If the ram does not move refer to fault finding section 13 6 If necessary the frame can also be pressurized by continuing to pump The pump will develop a pressure of 2500 p s i before cutting out corresponding to a load of about 6 tons Close safety lock off valve with tool provided hand pressure is sufficient Move pump control lever between extend and retract a few times This relieves pressure on the couplers and allows easy removal and replacement of the hoses Remove hoses Repeat the above steps for each waling of the frame in turn Page 11 of 12 product user guide Title Issue Date Shaftbrace February 2013 13 5 Procedure for releasing walings and retraction Ensure the waling is secured against dropping before setting about releasing S
20. with a safe angle between the lifting slings If the walings are to be lifted into the excavation then the appliance should be located a safe distance from the edge of the excavation and the lifts and radii checked against the safe lifting capacities of the appliance In this booklet it is assumed that the frames will be lifted into the excavation one leg at a time and assembled in the exca vation Likewise for removal it is assumed that the frame will be dismantled in the excavation and the legs removed one at a time WARNING If an excavator is being used for lifting operations refer to safety information on page 4 5 4 Small Plant Tools and Lifting Chains for Handling Essential equipment required is 5 4 1 Acompressor with 100 p s i output and sufficient length of air line to power the pump The pump is fitted with a standard 1 2 BSP air hose claw connector 5 4 2 Sledgehammers for making pinned connections Not in Mabey Hire Supply 5 4 3 Podgers spanners for making bolted connections Bolt sizes are M20 for walings and M16 for struts These are normally supplied with Mabey Hire s installation kit 5 4 4 Lifting chains of suitable length and capacity and with current certification The walings have lifting lugs designed to take 10mm safety hooks 5 4 5 In most cases the centre of gravity of the lifts involved will not be at mid length so shortening clutches are advisable Mabey Hire offer sets of 4 leg chains with 4 0m leg length c w s
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