product user guide - Mabey Hire International
Contents
1. repair and falls through the slot in the top plate New Drive Caps only 3 2 3 M6 M7 and M11 Driving Caps Ensure all four pegs are secure within the head and that the pegs are straight 3 2 4 Multisheet and Multilock Drive Cap Ensure all four pegs are secure within the head and that the pegs are straight Inspect periodically for cracks at welds Ensure the lifting ring is in good repair and falls through the slot in the top plate New drive caps only 3 3 Fitting See sketches below Attention is drawn to the weight of these products which are normally fitted at height Responsibility for a safe system of work for fitting and removal of these products remains with the Client JCBP 028 Connector chain Y New M8 M11 M12 SWL 11 2 Tonnes or M15 or Multisheet alternatively Chain and l Multilock Drive Cap hook from excavator K M6 M7 or M11 M6 M7 or M11 M8 M11 M12 M15 Trench Sheet Driving Cap Multisheet or Multilock Trench Sheet O O H Lifting Drive Cap into Position Typical View on Underside of Drive Cap M8 M11 M12 M15 New M8 M11 M12 Multisheet or Multisheet Multilock Drive jet l M15 or Multisheet Multilock Trench poe JN Multilock Drive Cap Sheet H Trench Sheet Typical View on Underside of Drive Cap Typical View on Underside of Drive Cap Page 2 of 6 4 Quick Release Shackle Details Code QRS Weight 18Kg S W L 40kN Check that the QRS has been supplied with a cu2. stack to enable the main body of shackle to be slid over the head of the sheet to be lifted With the plunger tube assembly uppermost slide the fork of the shackle over the head of the sheet with the sheet in the throat of the shackle 5 4 4 With the plunger over the sheet lifting hole firmly tap the indicator bar end If the plunger does not locate directly through the hole move the shackle body until the plunger goes through the pile hole and into the shackle body on the underside The indicator bar should be flush with the plunger barrel assembly Do not lift if the indicator bar protrudes from the plunger barrel assembly 5 4 5 Install the safety ring over the plunger tube assembly as shown below Indicator Bar Out Pin Retracted Indicator Bar Flush Safety Ring DO NOT Lift z Ready to Lift in Engaged Position Lifting Sling Fitting the EGRS to a single Trench sheet or light pile 5 4 6 With the plunger properly located and the safety ring engaged the sheet can be lifted into position Operatives should keep well clear until the sheet is secured 5 4 7 Ensure the rope does not become trapped or snagged during lifting Ensure the sheet is held securely after lifting into position in guides or similar 5 4 8 To release the shackle the safety ring must be first unhitched by flicking the release rope then simply pull on the release rope If there is a tendency to jam then take the weight of the shackle on the crane and pull agai
3. CT TRENCH SHEETS THICKER THAN 3 55mm e Code M8 M12 EXT winged Fixed Used on Mabey trench sheets between 4 amp 6mm thick i e M8 M12 M15 Multilock amp em Leg Multisheet up to 8m long S W L 7 Tonnes 70KN Pin dia 1 1 8 28 6mm Colour Blue paint finish Weight 12 Kg Check that the Extractor has been supplied with a current Report of Thorough Examination and check its expiry date 6 2 Usage The trench sheet extractors are designed solely for extracting trench sheets from excavations one at a time and should NOT be used for any other purpose The S W L which is stamped on the body of the clamp and also referred to on the documentation supplied with the extractor indicates the maximum safe vertical pulling load that the extractor is intended to sustain as the trench sheets are extracted from the ground The extractor is not intended to be used for lifting purposes other than lowering a single sheet to the ground immediately after it has been extracted from the excavation DO NOT use the extractor clamp for pitching trench sheets 6 3 Prior to use Check Trench Sheets to be extracted for suitability for use with clamp The lifting hole size in the trench sheets should be 25mm diameter for M6 M7 and M11 Sheets 30mm diameter for M8 M12 and M15 sheets and 40 or 45mm diameter for Multisheet and Multilock sheets The hole centre should not be less than 75mm from the top and not more than 150mm Ensure that there is enough metal above the hole in
4. Shackle Piling Extractor Code QRSH2T or Code 3T EXT or 9T EXT See separate user QRSH3T guide for further details See separate user guide for See separate user further details 3 General Guidance Notes guide for further details 3 1 Usage Correct usage of the trench sheeting drive caps will result in quicker easier installation of the sheets and can also significantly reduce damage charges 3 2 Checks Prior To and During Use 3 2 1 Certification All Euro Ground Release Shackles EGRS Trench Sheet Extractors T S EXT and M8 M12 EXT and Quick Release Shackles QRS hired to customers are supplied complete with a test certificate and if it is more than 6 months since the equipment was tested a Report of Thorough Examination is also supplied These certificates state the items serial number maximum S W L and the date of test examination Mabey Hire s depot staff will have checked certificates are valid before issue but users are requested to double check this before using the equipment on site and to return them to Mabey Hire for re examination before the expiry date of the certificates Certificates are only valid for a maximum of six months from the date of test or examination 3 2 2 New M8 M11 M12 M15 and Multisheet Multilock Driving Caps Ensure the driving cap fits over the profile of the Light Piling Sheet without hindrance Inspect periodically for cracks at welds Ensure the lifting ring is in good
5. Size 200 x 100 x 340 Weight 27 Kg New M11 Driving Cap Code M11 DC Size 180 x 140 x 330 Weight 21 3 Kg Colour Blue Size 175 x 200 x 400 Weight 23 Kg New M8 Driving Cap Code M8 DC Size 180 x 140 x 400 Weight 23 4 Kg Colour Orange Size 175 x 250 x 400 Weight 29 Kg New M12 Driving Cap Code M12 DC Size 180 x 160 x 400 Weight 26 6 Kg Colour Self Colour Colour Purple Euro Ground Release Shackle Code EGRS Weight 17 5 Kg SWL 40 kN Vertical 20 KN Horizontal See pages 4 5 for further details Rammer Stem Code USHANK RSTEM Weight 3 5 Kg M11 U Head Code M11UHEAD Weight 13 5 Kg New M15 Driving Cap Code M15 DC Size 180 x 175 x 350 Weight 25 4 Kg Colour Yellow Quick Release Shackle Code QRS Weight 18 Kg SWL 40 kN See page 3 for further details N Trench Sheet Extractor Code T S EXT Colour Grey or Code M8 M12 EXT Colour Blue Weight 12 Kg See page 6 for further details Page 1 of 6 M6 M7 Drive Cap Code T S DCAP Size 225 x 60 x 305 Weight 20 Kg product user guide cionca part of the m Title Trench Sheeting and Light Piling Accessories pate June 2015 2 Identification of Accessories Contd C gt Trench Sheet Extractor Qy D 0 c w Safety Chain IO Code T S EXT SC or SJ ae Q Kap Trenchsheet M8 M12 EXT SC See separate user guide Drive Cap for further details Code Q KAP4 or pala ian Trench Snoer and Q KAP6 elease
6. age the main S W L 4 tonne 40kN vertical plunger MUST be engaged and pushed fully forward 2 tonne 20kN horizontal Throat depth A 150mm e When handling the EGRS the operatives MUST NOT Throat width B 30mm place their hands in between the jaws of the extractor Pin Dia C 22mm Pull Release Wire Pull Ring for Attachment of Soft Rope Safety Ring to prevent y accidental release A Soft Rope 5 2 Health amp Safety Key Features not in Mabey 5 2 1 Indicator Bar The shackle pin extends through the back of the barrel assembly as an indicator bar If the indicator bar is flush with the barrel it is safe to lift If the indicator bar protrudes Do not lift 5 2 2 Safety ring to prevent accidental release A Safety ring is provided which should be placed over the barrel assembly during lifting This prevents accidental release of the shackle pin caused by poor working practices 5 3 Checks before use 5 3 1 Certification All E G R S hired to customers are supplied complete with a test certificate and if it is more than six months since the E G R S was tested a current certificate of examination is also supplied These certificates state The E G R S serial number which is also carried by the E G R S The E G R S max S W L which is also carried by the E G R S The date of test examination Mabey Hire s depot staff will have checked certificates are valid before issue but users are requested to do
7. gged 4 4 2 Before positioning the lifting shackles it is necessary to retract the main pin Pull the main pin rope until the trip mechanism holds the main pin in its retracted position 4 4 3 Separate the sheet piles on the stack to enable the main body of shackle to be slid over the pile head With the main plunger barrel uppermost slide the fork of the shackle over the pile head with the pile in the throat of the shackle 4 4 4 With the main plunger mechanism over the pile lifting hole release the trip wire If the main pin does not locate directly through the hole move the main shackle body until the pin goes through the pile hole and into the main shackle body on the underside 4 4 5 Take the weight of the pile with the crane and lift until the shackle is 750 1000mm above ground OPERATIVES SHOULD KEEP WELL CLEAR Block the pile up and lower onto the blocks which must be amply strong enough to take the weight of the pile With no load on the shackle check that the main pin has gone right through the lifting hole and into the body of the shackle on the underside It is not safe to lift unless the pin is right through 4 4 6 With the main pin properly located the pile can then be lifted into position in guides or similar OPERATIVES SHOULD KEEP WELL CLEAR UNTIL THE PILE IS SECURED It is advisable to tie the shackle ropes to the threader to prevent them being trapped snagged or getting blown out of reach in strong winds 4 4 7 To release the
8. ly unscrew the winged pin fully and withdraw the extractor 6 5 Important checks to be carried out during use 6 5 1 Before and regularly during use clean and examine the extractor for any faults or damage In particular check the winged pin is not bent and that when fitted through the hole in the sheet it engages securely with the extractor body 6 5 2 Regularly check the lifting hole in the sheets for signs of elongation If this is noted the extractor is being overloaded and an alternative method of extraction should be adopted DO NOT MODIFY THE CLAMP OR ATTEMPT TO REPLACE PARTS AS THIS INVALIDATES THE CERTIFICATION 7 General Since our policy is one of continual improvement components may vary in detail from the descriptions given in this publication Page 6 of 6 Capat 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 the 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 A risk 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 Ba
9. n 5 5 Check list Ensure that there is enough metal above the sling hole to prevent tear out e Check that the shackle pin is fully engaged the indicator bar should be flush e Always use the safety ring to prevent accidental release e Avoid snagging the release rope during lifting Ensure sheet is adequately supported before releasing the shackle 5 6 On Site Checks Maintenance During Use Regularly check that the shackle mechanism is working correctly and that the product has not been distorted due to overload Regular light application of oil to the moving parts is necessary If the product does not operate perfectly DO NOT use and contact Mabey Hire Ltd immediately DO NOT MODIFY THE SHACKLE OR ATTEMPT TO REPLACE PARTS AS THIS INVALIDATES THE CERTIFICATION KEEP THE BURNING TORCH WELL CLEAR Page 5 of 6 product user guide Mabey Title Trench Sheeting and Light Piling Accessories pate June 2015 6 Trench Sheet Extractor Identification and Usage Mabey Hire Ltd have two types of trench sheet extractor intended to be used as described below There are also two types of trench sheet extractor fitted with safety chains See separate user guide for details 6 1 Identification Code T S EXT Used on Mabey trench sheets up to 3 55mm thick i e M6 M7 amp M11 sheets up to 7m long D Shackle S W L 5 Tonnes 50kN Pin dia 7 8 22 2mm Hinged Colour Grey paint finish Weight 12 Kg Leg DO NOT USE A T S EXT TO EXTRA
10. nking 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 Name 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
11. product user guide Pmlalolely niren part of the mabey family Contents Issue Date 8 June 2015 Page 1 Introduction Identification of Accessories Page 2 Identification of Accessories Cont d General Guidance Notes Page 3 Quick Release Shackle Details Page 4 5 Euro Ground Release Shackle Identification and Usage Page 6 Trench Sheet Extractor Identification and Usage General Appendix A Provision of a Mabey Hire Site Demonstrator Trench Sheeting and Light Piling Accessories 1 Introduction This booklet is intended to provide basic information for users of the Mabey Trench Sheeting and Light Piling Accessories and to draw the client s attention to the practical aspects of using these accessories In particular the client s attention is drawn to the size and weights of the components and the need for planning the lifting operations involved It is assumed that clients are familiar with general safe practices applicable to this type of work This booklet should be read in conjunction with the User Information for Trench Sheeting and Light Piling Refer to Appendix A for details of our site demonstrator service 2 Identification of Accessories Muiltlock Multisheet Drive Cap Code MLOCK DCAP M11 Drive Cap Code M11 DCAP M8 Drive Cap Code M8 D CAP M12 Drive Cap Code M12 D CAP Size 200 x 100 x 380 Weight 20 Kg New Muiltlock Multisheet Driving Cap Code MLOCK DC Size 180 x 230 x 325 Weight 30 Kg
12. rrent Report of Thorough Examination and check its expiry date WARNING 4 1 Identification SAFETY NOTE e When not in use or in general storage the main plunger MUST be Trip Wire engaged and pushed fully forward 2 e When handling the QRS the operatives MUST NOT place their hands 6 Main Pin in between the Jaws of the extractor am 2 Pull Wire 4 2 Usage The Quick Release Shackle has been developed for lifting singular steel piles into position and when the pile is held securely the shackle can be released safely from the ground The Quick Release Shackle should NOT be used for any other purpose The S W L which is stamped on the body of the shackle and also referred to on the documenta tion supplied with the QRS indicates the maximum safe load the shackle is intended to sustain as the piles are lifted into position 4 3 Prior to use Check Trench Sheets for suitability for use with the Shackle The lifting hole size in the pile should be 25mm diameter or larger The hole centre should not be less than 75mm from the top and not more than 150mm Ensure that there is enough metal above the hole to prevent the metal tearing under the load and is not distorted to an extent that it will interfere with the safe operation of the shackle 4 4 Method of Operation 4 4 1 Tie a length of soft rope to the loop on the main pin pull wire The rope should be 1000mm longer than the pile length Do NOT use a continuous loop as this will become sna
13. shackle once the pile is secure simply pull on the release ropes If there is a tendency to jam then take the weight of the shackle on the crane and pull again 4 5 Important checks to be carried out during use 4 5 1 Ensure that the main pin has gone through both sides of the shackle body 4 5 2 Ensure that there is enough metal above the sling hole to prevent tear out 4 5 3 Keep the plunger mechanism well lubricated 4 5 4 Care should be taken to avoid the pull ropes getting snagged 4 5 5 Do not use the shackle for pulling or extracting 4 5 6 Ensure the pile is adequately supported before releasing the shackle 4 5 7 If the product does not operate perfectly DO NOT use and contact Mabey Hire Ltd immediately THE QUICK RELEASE SHACKLE SHOULD NOT BE MODIFIED ALTERED AS THIS WILL INVALIDATE THE CERTIFICATION Page 3 of 6 product user guide Trench Sheeting and Light Piling Accessories eae June 2015 5 Euro Ground Release Shackle Identification and Usage The Euro Ground Release Shackle E G R S is intended to be used for lifting trench sheets or light piles into position one at a time After the sheet is held securely in temporary guides the shackle can be released quickly and safely from ground level The E G R S is not intended to be used for other purposes and should not be used for pulling or extracting trench sheets or piles 5 1 Identification Code EGRS Weight 17 5 kg SAFETY NOTE l l When not in use or in general stor
14. the trench sheet to prevent the metal tearing under the load and it is not distorted to an extent that prevents the extractor clamping properly onto the sheet as described below 6 4 Method of operation 6 4 1 Before positioning the extractor it is necessary to unscrew and withdraw the winged pin 6 4 2 Position the extractor vertically over the top of the trench sheet to be extracted with the fixed leg of the extractor on the excavation side of the trench sheet 6 4 3 Align the hole on the fixed leg of the extractor with the hole in the trench sheet and the hole in the hinged leg of the extractor 6 4 4 Screw the winged pin fully in through the hinged leg the trench sheet and the fixed leg Tap the winged pin with a hammer to ensure a tight fit 6 4 5 Check that the threaded portion of the winged pin is protruding through the nut on the fixed leg of the extractor and the clamp plates are tight against the trench sheet 6 4 6 Using a suitable lifting appliance attached to the D shackle on the trench sheet extractor pull vertically to extract the trench sheet from the excavation OPERATIVES MUST KEEP WELL CLEAR DO NOT try to loosen the sheets by pulling the extractor sideways DO NOT snatch or shock load the extractor 6 4 7 Once the sheet has been extracted lower the sheet to the ground OPERATIVES MUST KEEP WELL CLEAR UNTIL THE SHEET IS FLAT ON THE GROUND 6 4 8 To release the trench sheet extractor once the sheet is flat on the ground simp
15. uble check this before using the E G R S on site and return them to Mabey Hire for re examination before the expiry date of the certificates Certificates are only valid for a maximum of 6 months from the date of test or examination 5 3 2 Weight to be lifted Check that the weight to be lifted is within the S W L of the shackle i e less than 2 0 tonne if lifting sheets from a horizontal position 5 3 3 Slinging hole in sheets The sling hole should be 25mm diameter or larger For Mabey sheets the hole centre line position should not be less than 75mm from the top and no more than 150mm For all sheets ensure there is enough metal above the slinging hole to prevent tear out 5 3 4 Site Operatives Only operators with adequate training and experience in lifting and control of loads should be allowed to use the E G R S Ensure they are aware of how the shackle is intended to be used and its key safety features Page 4 of 6 product user guide ire Title Trench Sheeting and Light Piling Accessories pate June 2015 5 4 Method of operation 5 4 1 Tie a length of soft rope to the pull ring on the pull wire The rope should be 1 metre 3 feet longer than the pile length Do NOT use a continuous loop as this will become snagged 5 4 2 Before positioning the lifting shackle it is necessary to retract the plunger Pull the pull wire until the trip mechanism holds the main plunger in it s retracted position 5 4 3 Separate the sheets on the
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