product user guide GEEEHIIE
Contents
1. aanssoad wsexog wore wo g xog Wo Buryiom xogaseg uorsuayxg xog seg uosuaxg xogaseg uorsuaxg xogaseg uoisuayxg purdg Joam joson 8 joom Jom 8 002 X 86 SUIS S E O E OST 004 X 86 123546 xog 10 3489 29 AQEL NSS Ax LI8X86 Page 12 of 122. In heavy or wet ground it may be necessary to pull one corner of the box at a time to start it moving Connect the single leg chain to each top lifting point in turn and pull vertically to free the box Once the box is free attach 2 legs of the chain sling to the upper lifting points of one panel a Pull this panel up amp then repeat the operation on the other panel NOTE The advance of one panel over the other should not exceed 10 of the trench width as per installation in section ix The box can not be lifted from the trench using the 4 leg chain attached to all the lifting points b xiv Precautions During Use amp Maintenance 1 Regularly check that all pins amp R clips are fitted 2 Avoid laterally loading the spindles either by hanging or propping from them or by accidentally striking them General Since our policy is one of continual improvement components may vary in detail from the descriptions given in this publication Page 11 of 12 product user gu April 2014 2 5 3 0 3 5 and 4 0m Manhole Box Using 98 x 700 Spindles 009 4 00 004 86 004 86 ews 004 86 mwN S O 0 1 0 1 O I 0 I S 0 0 1 01 0 TIE LIE 34 8 8 H N
3. 1 After following the Assembly procedure the box width x will already have been set with a toe out at the cutting edge of 50mm Check all pins and safety clips are in 10 of Trench Width 5 place 1 d 2 Lift the box using the 4 leg chain sling attached to the lifting eyes at the top of each Manhole Box panel Max weight 3111kg approx 3 Dig the manhole excavation approx 600 1000mm deep to the correct width and using the 4 leg chain sling place the box in the trench by digging between the box panels amp pushing down on the ends of the panels the box can be installed to the correct depth Always dig below the panels before pushing down Push only on the corners of each panel and never in middle When pushing the box 4 During the Dig amp Push operation 3 panels down always push down on each panel restrict the advance of one panel over the in sequence and never diagonally across oo other to 10 of the box width corners ie push A amp B followed by amp D amp never A amp C or B amp D 5 When the required excavation level is reached amp the box sunk to full depth ensure that the struts are horizontal amp at right angles to the panels before entering the trench DO NOT use any unsupported part of the excavation for access Leave the top of the box 100mm min above the surrounding ground level Correct Incorrect Page 7 o
4. Clip KRINCLIP Spindle Assembly and Adjustment The spindles are mechanically adjustable by inserting a tommy bar into the locating hole in the female spring spindle holder and screwing the spindle either in or out as required It is easier to adjust the spindles if each one is wound in or out a little at a time The box should be set to the correct width with the cutting edge 50mm wider than the top of the box before the box is placed in the ground Page 4 of 12 product user guide all the support you need Title Issue Date 2 5 3 0 3 5 and 4 0m Manhole Box Using 98 x 700 Spindles April 2014 v Stacking Handling and Transportation Firm level dry ground 3 4 Thick plywood Base and top panels should be stacked as shown with suitable timber dunnage Max 4 panels per stack Strut components pins and bolts stacked in skips bins During transportation stacks should be securely restrained to the vehicle bed a In dismantled form and in Transit In assembled form on site If not in use separate base boxes from top boxes Store top boxes upright Lie base boxes on their side or leave them temporarily dug in Im WY bf X ZXIXT PORE 7 RIZZI K X Y ON re Off Loading amp Site Handling of Manhole Box General Guidance Notes a Manpower Health amp Safety Regulations require that personnel deployed are suitably tr
5. are well within the lifting capacity of the machine to allow for impact and lurching effect as the box is turned Lower Spindle upright The completed base box can now be lifted on 4 chain legs and the spindles extended to their required dimension Allow for 50mm of toe out at the cutting edges by extending the lower spindle See section v for guidance on safe storage Page 6 of 12 2 Stand the first top panel upright and securely prop eg between two kentledge blocks Ensure that the 1 Lie first panel on ground with spindle connector points upwards Pin into position 2 No spring spindle holders using 43mm dia pins panel is stable before KRINM43P and clips removing the chains KRINCLIP Repeat for the Mae weight 801kg second panel weight 871kg Approx 3 Sling the second panel and im lift upright Insert spindles extension bars into the holders and pin into position from ts 5 22 above using KRINM20P pins DOM YOY and KRINCLIP clips Ensure spindles extension bars are 4 Complete assembly of the top box by pinning the spindles staggered see page 6 into the holders in the first panel using KRINM20P pins and Max weight 1025kg approx KRINCLIP clips The top box is now ready to mount onto the base box See section vii for guidance on safe storage vii Installation of Manhole Box Base Box Box Width X
6. on its cutting edges with great to avoid damaging the spindles It is important that the weights and radius well within the lifting capacity of the machine to allow for impact and z z lurching effect as the box is turned Lower upright The completed base box can now be lifted on 4 chain legs and the as spindles extended to their required eg dimension Allow for 50mm of toe DIY yy WO WO py Ww out at the cutting edges by extending the lower spindle See section v for guidance on safe storage Page 8 of 12 1 Lie first panel on ground with 2 Stand the first top spindle connector points panel upright and upwards Pin into position 2 No securely prop e g SYP NI YN male spindle holders using between two kentledge Max Weight 871kg 43mm dia pins KRINM43P blocks Ensure that the and clips KRINCLIP panel is stable before Repeat for the second panel removing the chains Max weight 871kg Approx Max weight 801kg Approx ISP NI IINY 3 Sling the second panel and lift upright Insert female spindles extension bars into the holders and pin into a position from above using E KRINM20P pins and rep KRINCLIP clips 4 Complete assembly of the top box by pinning the spindles SKS Max weight 1025kg approx into the holders in the firs
7. NY SSS ARE Correct DO NOT leave the base of the box flying above the excavation level x When stopping off the end of a trench Walings and Trench Sheets steel walers should be used to support or alternatively End Panels the sheets off the ends of the panels Never use the spindles as supports for the trench sheets FA WA Spindles A Maintain a NOTE Mabey Hire can also supply End Panels to close off the trench Page 10 of 12 product user guide II the sup yo Title Issue Date 2 5 3 0 3 5 and 4 0m Manhole Box Using 98 x 700 Spindles April 2014 Extraction of Manhole Boxes Normal Methods Note No personnel should be in the manhole whilst extraction is in progress After initial back filling amp compaction lift the base box complete with top box chain attached to all 4 upper lifting points 7 Continue back filling as removal of the box proceeds Alternatively if the top box is to be Lt removed from the base box lift as per Unsupported 1 until the top of the base box is above around G L approx 300mm Remove the 4 No corner connecting pins amp lift the top box off the base box Continue backfilling as removal of the base box proceeds DO NOT remove the top box before the top of the base box is above G L Correct i Extraction of Manhole Boxes in Wet Ground
8. able by inserting a tommy bar into the locating hole in the spindle and screwing the spindle either in or out as required It is easier to adjust the spindles if each one is wound in or out a little at a time The box should be set to the correct width with the cutting edge 50mm wider than the top of the box before the box is placed in the ground Page 3 of 12 product user guide Ba aang Title Issue Date 2 5 3 0 3 5 and 4 0m Manhole Box Using 98 x 700 Spindles April 2014 c Spindle Components 98 x 817 Spindles Hole For Male Spring Spindle Tommy Bar Code KSPINNEWM Female Spring Spindle Weight 32 5 Kg Code KSPINNEWF Weight 32 5 Kg Length Extension Bar Connector Top to Base Length Code KRINCONN mm Code Weight 5 5 Kg 500 KBOSNEW 1000 KB100NEW 140 mm Pin Code KRINM43P Pin Weight 2 5 Kg Code KRINM20P Weight 0 4 Kg Accessories Standard Trenchbox Q 19mm x 1 5m E L L 13mm x 4 5m E L L x Single Leg Chain 4 Leg Chain Sling Code CHAIN___ Code CHAIN_ Weight 86 Kg Weight 25 Kg REFER TO LIFTING CHAIN REFER TO LIFTING CHAIN USER USER INFORMATION FOR INFORMATION FOR FURTHER FURTHER DETAILS DETAILS Connection Details Extension Bar to Spring Spindle Holder 1 No 20 dia pin KRINM20P R Clip KRINCLIP Spring Spindle Holder to Panel 1 No 43 dia pin KRINM43P R Clip KRINCLIP Connector Top to Base 2 No 43 dia pin KRINM43P R
9. ained and experienced and supervised by a competent person Plant for Lifting A suitable appliance is required for off loading and assembly The lifting capacity and clearance under the lifting point should be checked against the stages shown below For narrow boxes an excavator may be suitable For wider boxes a crane is likely to be required Lifting Chains Available from Mabey Hire Limited Lifting Chains of suitable length amp capacity complete with current certification Typically for Manhole Box a set of 4 leg 13mm chains with 4 5m leg lengths complete with C Hooks and shortening clutches Code _ _ _ Weight 86kg REFER TO LIFTING CHAIN USER INFORMATION FOR FURTHER DETAILS Access and Hard Standing Areas These include i Suitable area to off load the lorry and assemble the manhole box ii Suitable hard standing for the machine to operate from to lift the box into the excavation iii Suitable access equipment ladder or staging for connection removal of lifting chains and pinning panels together wider boxes only iv Ladders and possibly other provisions to provide safe access egress to the excavation Return of Equipment Off Hire Clients should ensure than on removal the equipment is returned in sections as supplied Page 5 of 12 product user guide cioccia all the support you need Title Issue Date 2 5 3 0 3 5 and 4 0m Manhole Box Using 98 x 700 Spindles 5 April 2014 vi Site Assembly
10. angles to the panels before entering the trench DO NOT use any unsupported part of the excavation for access Leave the top of the box 100mm min above the surrounding ground level Correct Incorrect Page 9 of 12 product user guide the suppi yo ed Title Issue Date 2 5 3 0 3 5 and 4 0m Manhole Box Using 98 x 700 Spindles A April 2014 x Installation of Manhole Box Top Boxes Dig amp Push Base Box into Excavation to within 300mm of top of base box Fit 1 No connector KRINCONN at each of the four top comers of the base box using KRINM43P Pins and KRINCLIP Clips Use 4 leg chain to sling top box into position over base box Max Weight 1824 kg Approx Lower one side of the top box into position first Ensure connectors locate in top panel end posts amp pin with KRINM43P pins and KRINCLIP clips Repeat for second top panel Repeat steps 1 5 if second top box is required Do not use boxes with more than 2 top boxes fitted Ensure that safe ground pressures are not exceeded N xi Before Entering Manhole Excavation All Boxes Ensure that there are no voids between the box panel and the excavation sides as this may allow the box to sway sideways 7 2s RR VA A VN y A xR 5 Z XIX KX SS SN N WR X lt lt lt YY
11. d Spindle Adiustable Spindle Length Weight Length mm Code K Mi KRINMISP ad o 165 KRINOSOO 16 ini Small KRINSMSP 515 700 265 KRINO600 20 Standard KRINSPIN 700 1030 Type Code Length Extension Bar Length Weight Spring Spindle Holder Connector Top to Base mm Code Kg Code KRINSPH RINCONN 500 500 19 Weight 13 0 Kg 1000 KBAR1000 30 140 mm Pin Code KRINM43P Weight 2 5 Kg Pin Code KRINM20P Weight 0 4 Kg S 9 13mm x 4 5m E L L x 0 19mm x 1 5m E L L 4 Leg Chain Sling Single Leg Chain Code CHAIN Code CHAIN _ Weight 86 Kg Weight 25 Kg REFER TO LIFTING REFER TO LIFTING CHAIN USER CHAIN USER INFORMATION FOR FURTHER INFORMATION FOR DETAILS FURTHER DETAILS Connection Details Spindle to Extension Bar 1 20 dia pin KRINM20P R Clip KRINCLIP Spindle to Spring Spindle Holder 1 20 dia pin KRINM20P R Clip KRINCLIP Spring Spindle Holder to Panel 1 No 43 dia pin KRINM43P R Clip KRINCLIP Connector Top to Base 2 43 dia KRINM43P R Clip KRINCLIP Spindle Assembly and Adjustment a When using 98 X 700 spindles only one extension bar per spindle should be used Should required box width be greater than 2565mm external dim use 98 x 817 spindle b The spindles are mechanically adjust
12. f 12 viii Site Assembly of Base and Extension Boxes 98 x 817 Spindles Dismantling is Reverse Procedure Max Weight 1243kg DPN IXY YY YOY 1 Z Case pan panel fat on ground with spindle connector points upward 2 Pin into position 4 No male spindles using 43mm dia pin KRINM43P clips KRINCLIP gt extension Extension Spindie Spindie 3 Insert the required extensions into the Spinde N spindles and pin in position from above using 20mm dia Pins KRINM20P clips KRINCLIP ib i 4 Complete assembly of the base box by pinning the spindles into the holders in the first panel using KRINM20P pins and KRINCLIP clips Max Weight 1383kg approx LAA MA AAAS YYOYOYY DY NY 5 Turn the other base panel over using 2 legs of the four leg sling 6 Re sling this panel with the spindle connector points downwards Use all for legs of the lifting chain Pin into position spring spindle holders as in 2 above 7 Complete assembly of the base box on its side by pinning the spindles to the upper panel using KRINM20P pins amp KRINCLIP clips Do not release the weight of the top panel until all of the pins amp clips are in place DOO yyw 8 Attach 2 chains of sling to Upper k Lifting points on UPPERMOST panel Trench Width and 2 chains of sling to UPPER lifting points on LOWER panel Stand box
13. hole Boxes should NOT be used in seawater applications without prior consultation with Mabey Hire Limited Engineering Department Design Methods of estimating lateral earth pressures vary Typical working pressures that the Manhole Box can sustain are as shown in the table on page 12 Please contact Mabey Hire Limited if further assistance is required Users are advised to check that their excavation will not impose greater working pressures than these Conditions that are likely to increase the lateral earth pressure include the close proximity of structures excavations or construction materials adjacent to the trench and close proximity of site roads and or railways is dependant on strut length see table on p12 for appropriate values Page 1 of 12 product user guide Title Issue Date 2 5 3 0 3 5 and 4 0m Manhole Box Using 98 x 700 Spindles April 2014 iv Identification of Components Dimensions and Weights og Base Panels Top Panels Code 2 5m 2502 Weight 940kg Code 2 5m MATO2501 Weight 512kg 3 0m MABO3002 Weight 1041kg 3 0m MATO3001 Weight 668kg 3 5m 502 Weight 1142kg 3 5m MATO3501 Weight 733kg 4 0m 4002 Weight 1243kg 4 0m MATO4001 Weight 801kg Page 2 of 12 product user guide Ba aang Title Issue Date 2 5 3 0 3 5 and 4 0m Manhole Box Using 98 x 700 Spindles April 2014 b Spindle Components 98 x 700 Spindles Length Fixe
14. of Base and Extension Boxes 98 x 700 Spindles Dismantling is Reverse Procedure Max Weight 1318kg OVANA ANNAN A RAVAN AN ANAN A 1 Lie base panel flat on ground with 2 Pin into position 4 No spring spindle spindle connector points upwards holders using 43mm dia pin KRINM43P R clips FRINCLIP Extension Spindle 3 Insert the required spindles into the holders and pin into position from above using 20mm dia pins KRINM20P and R Extension clips KRINCLIP 4 Complete assembly of the base box by pinning the spindles into the holders in the first panel using KRINM20P pins and KRINCLIP clips 5 Max Weight ISDH aw WD AID 1380kg approx 5 Turn the other base panel over using 2 legs of the four leg sling 6 Re sling this panel with the spindle connector points downwards Use all for legs of the lifting chain Pin into position spring spindle holders as in 2 above 7 Complete assembly of the base box on its side by pinning the spindles to the upper panel using KRINM20P pins amp KRINCLIP clips Do not release the weight of the top panel until all of pins amp clips are in place 8 Attach 2 chains of sling to UPPER Lifting points on UPPERMOST panel _ _Trench Width and 2 chains of sling to UPPER lifting wis ahi es points on LOWER panel Stand the box its cutting edges with great care to avoid damaging the spindles It is important that the weights and radius
15. product user guide Title Issue Date 2 5 3 0 3 5 and 4 0m Manhole Box Using 98 x 700 Spindles April 2014 Contents Page 1 Contents Introduction Design 2 4 Component Identification Dimensions amp Weights Page 5 H Stacking Handling and Transportation 6 9 Site Assembly and Dismantling Page 10 3 Base amp Extension Box Installation Page 11 Extraction of Boxes and Precautions during use Page 12 p Pressure Table amp Weights for Manhole Box System Introduction This booklet is intended to provide basic information for users of the Mabey Hire Limited 2 5 3 0 3 5 amp 4 0m Manhole Box System using 98 x 700 spindles and to draw the clients attention to the practical aspects of the manhole box assembly which need to be considered in drawing up method statements for a safe system of work In particular the clients attention is drawn to the size and weights of the Manhole Box components and the need for planning the lifting operations involved All panels of the Manhole Box System have lifting points for safe slinging when the box is assembled and standing on it s cutting edges Lifting operations during box assembly require slinging techniques as detailed on pages 6 9 It is assumed that clients are familiar with general safe practices applicable to this type of work The Manhole Box is a trench support system for support of trenches up to 5 40m deep It is not intended for other purposes Man
16. t panel using KRINM20P pins and KRINCLIP clips The top box is now ready to mount onto the base box See section v for guidance on safe storage ix Installation of Manhole Box Base Box Width X 1 After following 2 Lift the box using the 4 leg chain sling the Assembly attached to the lifting eyes at the top of procedure the box i each Manhole Box panel width x will Max weight 3111kg approx already have been set with toe out at the cutting edge of 50mm Check all Vi pins and safety clips 10 of Trench Width 5 are in place Le X 50mm 3 Dig the manhole excavation approx 600 1000mm deep to the correct width and using the 4 leg chain sling place the box in the trench by digging between the box panels amp pushing down on the ends of the panels the box can be installed to the correct depth Always dig below the panels before pushing down Push only on the corners of each panel and never in the 4 During the Dig amp Push operation 3 middle When pushing the box panels restrict the advance of one panel over the down always push down on each panel in other to 10 of the box width sequence and never diagonally across corners ie push A amp B followed by C amp D amp never A amp CorB amp D 5 When the required excavation level is reached amp the box sunk to full depth ensure that the struts are horizontal amp at right
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