product user guide GIEIEJEIIIE
Contents
1. 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 Single Acting Manhole Brace system are fitted with lifting lugs for safe slinging The method of constructing a typical excavation using Single Acting Manhole Brace is given in Section 10 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 Single Acting Manhole Brace installation are e Unloading the delivery vehicle e Slinging and lifting walings into position in the excavation carrying out mechanical adjustment of the waling if required 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 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 book2. and pressurize until the gauge reads 1500 p s i Close the ram lock off valve and connect the restraint chains between frames release the pressure at the pump end and disconnect hoses and sling NOTE If second frame cannot be passed through first frame the individual legs of second frame will have to be placed in position and assembled In excavation Safe working must be maintained at all times 10 7 Push the sheets down to give toe in required and complete the 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 8 for notes on use of restraint chains 11 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 4 way chain sling Connect bridle and pressurize system to 1500 p s i Open lock off valves Pressure may now be gradually released using the pump valve Remove restraint chains and lift frame from trench 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 Page 7 of 9 product user guide QIBESM ic a Single Acting Manhole Brace mn April 2014 12 Use of Restraint Chains TB 07 Capacity 500 kg Restraint chains are provided as a back up support arrangement in th
3. 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 9 product user guide corea 6 Sling Warning WARNING IF YOU ARE USING A SLING ON AN EXCAVATOR BEWARE THE FOLLOWING Iit 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 4 Attachment turn and align with the load Code SSBA 007 WITHOUT A SWIVEL N Refer to product user guide for further details ARRANGEMENT THE LOAD MAY SEVERELY TWIST THE MASTER RING RESULTING IN DAMAGE OR FAILURE e i 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 9 Single Acting Manhole Brace April 2014 7 Identification of Components Single Acting Manhole Brace Leg Hydraulic Pause en S Female ical
4. or depress the nipple in the hose end and in both cases pump until fluid flows freely through the hose THEN e PURGE AIR FROM THE RAM Attach the purged hose to the ram and fully extend Stand the ram on end with the valve block at the top Release the pressure at the pump valve and push the ram closed All air should now be purged 15 Do s and Don ts DO make sure lifting equipment and plant of adequate capacity are available for assembly and installation DO ensure that two coarse adjustment pins are fitted to each leg DO ensure that all pin retaining clips are in position before the frame is installed DO pump from outside the excavation use extension hoses for lower frames DO ensure that pressure is being held in rams before closing lock off valves DO ensure that restraint chains are used between each frame as well as onto the top of the sheets Where frames are doubled for deeper excavations it will be necessary to wrap the chains around the lower frame rather than using the lifting eye DO allow sufficient working space around a manhole for a man to get down and re connect the hoses to remove the lower frames DO ensure that all lock off valves are open max 2 turns prior to pumping and that all hose ram connections are clean DO NOT attempt to remove any pins while the frame is under pressure DO NOT release pressure by depressing or tapping the connector nipple DO NOT leave a gap between
5. the sheets at the corners DO NOT enter the excavation until pressure is held in the rams DO NOT lift a frame until the pressure has been released 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 use restraint chains as a means of suspension during frame installation or removal or for any other purposes other than described above In particular DO NOT use for lifting purposes 16 General Since our policy is one of continual improvement components may vary in detail from the descriptions given in this publication Page 9 of 9 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 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 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 Demonstr
6. Hydraulic Connectors este Thy amp Safety Valve Over Sleeve containing Pi Two pins must the Ram Unit Male always be in position Code MHB 04 Inner Pin Code MHB 04 size 20 dia x 220mm Long Weight 0 6 Kg a Ram Ram mm Ram Ram Ram fully pont Closed Extended Closed Extended extended M rn in Tex MHBL D Minimum 1270 1630 1340 1700 1550 1910 78 Maximum 1470 1830 1540 1900 1750 2110 Minimum 1470 1830 1540 1900 1750 2110 28 0 MHBL A Medium 1670 2030 1740 2100 1950 2310 101 Clear Internal Dimension SWL on Leg l Pin to Pin Le in KN m run Leg Leg Mechanical Minimum Maximum Dimension Minimum Maximum W i Type Code te a 2970 3330 3030 3390 3300 3660 1 2 MHBL C 3270 3630 3330 3690 3600 3960 178 3570 3930 3630 3990 3900 4260 7 1 Accessories e Installation Kit Code MHB IKIT consisting of Single Acting Pump Code PSP 100 Weight 18 kg empty 43 kg full Hose Extensions Code PSP 275 Mabey Shoring Fluid Code PSP 160 S e Lifting Chain Code PSP 155 SH or PSP 155 Weight 24 Kg 7mm 4 leg chain sling with 4m leg length Refer to Lifting Chain User Information for further details e Restraint Chain Code TB 07 Length 2m Weight 4 0 Kg Capacity 500Kg Page 5 of 9 product user guide U Single Acting Manhole Brace _ April 2014 8 Stacking and Handling e Suitable firm level dry areas should be made available on site for stacking and pre assembly wor
7. 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 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
8. ator 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
9. e unlikely event of hydraulic failure of one of the Single Acting Manhole Brace 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 depressurizing the frames 60mm wide hook for hanging over top of sheets 9mm long link galvanised chain D Shackle D Shackle 13 Mechanical Pump Connection and Use Restraint Chains 4 Way Manifold ht T AT Ly Pressurize all four rams to 1500 p s i Close lock off valves release pressure at the pump and disconnect the hoses Handle PSP 100 Pump Shorter sheets may be used at the corners to provide bucket access if the sheets require the dig and drive method 13 1 Mabey Hire Shoring Fluid The pump is normally supplied with a full tank of pre mixed fluid If the fluid is separately supplied neat in 5 litre orange coloured containers it should be poured into the pump and cold clean water added according to prevailing temperatu
10. ing Retention Clips gt Fig 2 Corner Connection Page 6 of 9 product user guide a Single Acting Manhole Brace oa April 2014 10 Typical Sequence of Sheet and Frame Installation WARNING Refer to safety information on page 4 regarding excavators being used for lifting operations 10 1 Assemble frame securing all pins setting the pins to suit the excavation size Two pins must always be in position on each leg in addition to the corner pin see fig 2 Set rail length to approx 150mm less than distance between sheets 10 2 Place the sheets and drive as far as possible 10 3 Dig to depth of first frame Attach 4 way sling to lifting eyes and lift in frame complete with linking chains and hose Chock the corners with timber wedges if required 10 4 Pump out the frame and pressurize until gauge reads 1500 p s i Close the ram lock off valve and connect the restraint chains to top of the sheets release the pressure at pump end and disconnect hoses and the slings 10 5 Excavate through the first frame to the second frame position keeping a min sheet toe in of 0 5m The sheets holding the restraint chains are to be left high until the other sheets are driven Re locate the restraint chains on to the driven sheets and drive the high sheets to the correct level 10 6 Lift the second frame complete with restraint chains and hoses and pass through the first frame to the second frame level Pump out the frame
11. k e Suitable lifting equipment of adequate capacity should be provided for off loading pre assembly of frames installation and dismantling e Slinging should always be carried out by suitably experienced and competent personnel Weights of legs can be obtained from section 7 Ram fully retracted d b J k L 4 legs per row Fig 1 Stacking Detail longest legs at bottom 3 x 4 Timbers 9 Typical Waling Assembly and Site Connection Details 9 1 Excavator Lifting Requirements X dimension from rear face of excavation to centre line of excavator crane when standing at a safe distance from the excavation Max Lift Frame weight weight of chains see page 5 Radius 2 width of frame x Radius Refer to excavator manufacturer for machine load capacity Corner Pin Coarse Adjustment Pins Code MHB 04 oag Code MHB 04 9 2 Frame Assembly Set the individual leg lengths to the required range by means of the two coarse adjustment pins see fig 2 The range should be chosen so that with the ram fully closed the leg is not more than 300mm less than the required excavation width inside the sheeting With all legs set in this way place the legs on firm level ground and connect the corners using the pins and clips supplied The frame is now ready for installation Make up as many frames as possible in advance of excavation to ensure that they are ready as required during digg
12. let it is assumed that the frames will be lifted into the excavation fully assembled Likewise for removal it is assumed that the frame will be removed fully assembled 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 Sledgehammers for making pinned connections Not in Mabey Hire Supply 5 4 2 Lifting chains of suitable length and capacity and with current certification The walings have lifting lugs designed to take 10mm safety hooks 5 4 3 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 shortening clutches and safety hooks Code PSP 155 SH weight 24kg 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 protecti
13. on and ladder access platforms can be supplied by Mabey Hire Ltd Page 2 of 9 product user guide Single Acting Manhole Brace April 2014 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 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 that the Manhole Brace Rams are fully retracted prior to loading and that the legs are stacked on the lorry as figure 1 in section 8 Ensure all equipment is loaded to the satisfaction of the lorry driver and is securely restrained to the vehicle bed The installation kit is transported and stored in a stillage 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
14. petent engineer is employed to provide a suitable design for excavation schemes requiring the use of Single Acting Manhole Brace products Mabey Hire Ltd offer a design service for excavation schemes 3 Frame Dimensions This booklet gives information for frame dimensions for Single Acting Manhole Brace Walings See page 5 for details 4 Adjustments The Single Acting Manhole Brace system incorporates a mechanical and hydraulic system of adjustment which is designed to extend the frames under conditions of no or low loading e g as when first installed Once they are sustaining significant ground loads 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 9 product user guide a Single Acting Manhole Brace oa April 2014 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 Safety 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 Single Acting Manhole Brace installation which need to be considered in compiling method statements for a safe system of work In particular
15. product user guide a Single Acting Manhole Brace mn April 2014 Contents Page 1 Introduction Design Frame Dimensions Adjustments Page 2 4 General Guidance Notes Page 5 Identification of Components Page 6 Stacking and Handling Typical Waling Assembly and Site Connection Details Page 7 Typical Sequence of Sheet and Frame Installation Removal of Frames Page 8 Use of Restraint Chains SHBP 189 Capacity 2 0T Mechanical Pump Details and Use Page 9 Points to Watch Do s and Don ts General Appendix A Provision of a Mabey Hire Site Demonstrator 1 Introduction Mabey Hire s Single Acting Manhole Brace system is intended to be used as a temporary waling system to sheeted excavations The frames have 4 way adjustment part mechanical and part hydraulic It is not intended for other purposes Single Acting Manhole Brace CANNOT be used in conjunction with Mabey Hire s other frame systems Double Acting Manhole Brace Shaftbrace Tankbrace or Super Shaftbrace This booklet provides basic information for users of Single Acting Manhole Brace to assist them in their preparation of a safe system of work on site Single Acting Manhole Brace 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 Refer to the table on page 5 for information on allowable leg loads Clients are strongly advised to ensure that a com
16. re Temp Range Shoring Fluid Water C litres litres conditions See table right Protective gloves should always be worn when handling Above 0 5 20 shoring fluid 6 to 0 10 20 10 to 7 15 15 NOTE A Shoring Fluid safety data sheet is available from Mabey Hire Limited 10 and below Neat fluid only Page 8 of 9 product user guide a Single Acting Manhole Brace mn April 2014 14 Points to Watch 14 1 Over Extension of Rams If the maximum extension of the ram is passed fluid will discharge from a small safety vent and it will not be possible to achieve the working pressure To retract the ram into its correct working range release all pressure at the pump and close the rams down by hand 14 2 Air in the System Occasionally air may get into the system causing either springiness in the ram or a lack of prime in the pump If this occurs the following steps should be taken 14 2 1 To restore prime to the pump disconnect the handle from the piston rod by undoing the wing nuts and removing the pin open the pump valve fold the handle over the front of the pump and manually work the piston rod up and down as fast as possible When prime is restored a considerable increase in resistance will be felt The handle can now be reconnected and normal pumping continued 14 2 2 To ensure that the ram is air free e PURGE AIR FROM THE HOSES Either connect the hose end to the male coupler on the bucket top if it is of that type
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