product user guide - Mabey Hire International
Contents
1. Multibrace System poe February 2015 14 Mechanical Pump Details and Procedures for Extending Retracting Walings 14 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 gauge hose connections and safety lock off valve referred to in the procedures Fluid Pressure 2 Female Safety Lock Off Valve manual H Male Hose W Air Supply Control Valve 1 2 B S P Claw Connector Extend Filler Cap 14 2 Preliminaries Check there is sufficient of the correct Mabey Hire shoring fluid in the tank Only Mabey Hire shoring fluid should be used Set the pump control valve to Neutral Connect the pump to a suitable air supply 100 p s i at 14 cu ft min and open air supply control valve on pump Purge the hoses of air To do this connect the hoses together and run the pump for a few seconds with the control valve set to Extend When satisfied that any air has been expelled set the pump control valve to Neutral At no time must the pump be left operating whilst unattended 14 3 Mabey Hire shoring fluid Temp Range Shoring Fluid Water C litres litres The pump is normally supplied with a full tank of pre mixed fluid Ata he T If the fluid is separately supplied neat in 5 litre orange coloured 10 to 7 15 15 containers it should be poured into the pump and cold clean 10 and below Neat fl2. prior to delivery but to suit site conditions the extensions can be changed by unbolting the 2 bolts and removing the 2 Bailey Pins The leg building process is substantially eased if the components are laid with the connecting lugs upward 2 x M24 Bolts 2 x M24 Bolts 2 No a Spring Clip Bailey Pins Bailey Pan for Bailey Pin Spring Clips gt Spring Clips T Bailey Pins lt for Bailey Pins Intermediate Extension to Intermediate Extension or Ram to Extension Connection Corner Connection End Extension Connection Page 6 of 12 product user guide t mja b e y hiren part of the mabey family i Multibrace System eae February 2015 9 Typical Sequence of Sheets and Frame Installation Note Multibrace equipment is not intended to be installed or removed in complete frames but only as described below i e one leg at a time 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 Fully excavate to first frame level Alternatively excavate slit trench only to first frame level Place each leg in excavation and assemble the frame Connect hydraulics and pump frame out to correct dimension Remove hydraulics 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 c
3. 010 MBRACEL 08 MBRACE 001 MBRACE 014 MBRACE 010 MBRACEL 09 MBRACE 001 MBRACE 014 MBRACE 011 MBRACEL 10 MBRACE 001 MBRACE 014 MBRACE 012 MBRACEL 10 MBRACE 001 MBRACE 016 Note The clear internal dimensions tabulated do not include any allowance for deflection of the walings under load A deflection allowance should be added to the clear internal dimensions given Clear internal dimensions should be reduced by rail length mm 30 e g Fora 7000 mm pin to pin long rail the clear internal dimension should be reduced by 7000 30 233 mmi e 117 mm per rail Allowance should also be made for the depth of sheeting to arrive at the excavation size n a Not Applicable 13 Stacking and Handling Suitable firm level dry areas should be made available on site for stacking and pre assembly work Suitable lifting equipment of adequate capacity should be provided for off loading pre assembly work installation and dismantling Slinging should always be carried out by suitably experienced and competent personnel Weight of legs and other components are given on Page 5 and in the table above Return pre assembled legs and struts as supplied from Mabey Hire s Depot Always stack all items in single layers wherever possible If space does not permit this walings should be stacked on 3 x 4 timbers in rows of 4 No max height 3 rows Page 10 of 12 product user guide mialblely hire part of the mabey family ee
4. 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 5m approx of waling and that as much slack as possible is removed by repositioning the D Shackle Users must ensure that frames are securely supported by means other than the restraint chains prior to depressurising the frames Forged hook for hanging over top of sheets not required if restraint chain is being used between frames Chain D Shackle for connecting to D Shackle lifting lug on waling Note When used with Mabey M11 sheets Restraint Chains capacity reduces to 1500 Kg When used with Mabey M6 M7 sheets Restraint Chain capacity reduces to 1000 Kg Page 9 of 12 product user guide QiEBEV iD part of the mabey family ie Multibrace System ce February 2015 12 Frame Dimensions and Leg Weights Clear Internal Dimensions Leg Code Leg Arrangement mm Dimensions Between Between to Face of Walings Waling Sheet Flanges Joints MBRACEL 01 MBRACE 001 MBRACEL 01A MBRACE 001 MBRACE 015 MBRACEL 02 MBRACE 001 MBRACE 010 MBRACEL 03 MBRACE 001 MBRACE 011 MBRACEL 04 MBRACE 001 MBRACE 012 MBRACEL 05 MBRACE 001 MBRACE 013 MBRACEL 06 MBRACE 001 MBRACE 014 MBRACEL 07 MBRACE 001 MBRACE 013 MBRACE
5. 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 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 GDS art of the mabey family ie Multibrace System eae February 2015 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 particu
6. aling Open the safety lock off valve by rotating anti clockwise Set the pump control valve to Extend Watch the waling extend until the pump gauge starts rising indicating that the frame is beginning to push against the sheets Allow the pressure to build up to 1000 p s i corresponding to a waling load of about 6 tonnes Shut down the pump by closing off the air supply valve Check that the hydraulic pressure is being maintained on the gauge NOTE DO NOT MOVE THE PUMP CONTROL VALVE TO NEUTRAL AT THIS STAGE AS THIS WILL SIMPLY RELEASE THE PRESSURE Close the safety lock off valve by rotating clockwise Set the pump control valve to Neutral Disconnect the pump hoses from the ram Repeat the above steps for each waling of the frame in turn Procedure for releasing walings and retraction Ensure the waling is secured against dropping before setting about releasing Set the pump control valve to Neutral and open the air supply valve 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 On completion of retraction close off the air supply valve and set the pump control valve to Neutral Close lock off valve in ram unit and disconnect pump hoses from the ram 15 Do s and Don
7. 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 10mm chains with 4 0m leg length complete with shortening clutches and safety hooks Code SB LSLG SH weight 47Kg though clients should check that the leg length is suitable to use with their lifting appliance Page 2 of 12 product user guide cacani part of the mabey family ie Multibrace System eae February 2015 5 5 Edge Protection Access and Hard Standing Areas These include Suitable area to off load the lorry and assemble the walings Suitable hard standings for the lifting appliance to operate from if it is intended to lift the walings into the excavation Ladders and possibly other provisions to provide safe access into the excavation to install restraint chains and connect pump hoses 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 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 prot
8. ealth 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 Multibrace 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 Multibrace system are fitted with lifting lugs for safe slinging Regular users of Mabey Hire s Manhole Brace and Shaftbrace systems should note that the Multibrace system components are considerably heavier Two methods of constructing a typical excavation using Multibrace are given on Pages 7 amp 8 5 2 Manpower The Health and Safety legislation requires that personnel deployed are suitably trained and 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 Multibrace installation are Unloading the delivery vehicle Bolting up and pinning steelwork together to form walings of the required length Slinging and lifting walings into position in the excavation and connecting the corners to form frames Connecting the pump to each waling in turn pressurising the frames and fitting restraint chains 5 3 Plant and L
9. ection 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 all equipment is loaded to the satisfaction of the lorry driver and is securely restrained to the vehicle bed 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
10. f 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. hains as per scheme drawing Connect hydraulics and individually pressurise all frame ram units to 1000 p s i close lock off valves and remove hydraulics Dig through to next frame position and push sheets down Reposition restraint chains as necessary Place legs of second frame in excavation and assemble safe working must be maintained Attach restraint chains between first and second frames Connect hydraulics and individually pressurise all lower frame ram units to 1000 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 t mja b e y hiren part of the mabey family ee Multibrace System as February 2015 9 2 Method 2 Installation of 2 frames by fully driving sheets piling with piling hammer Use the crane for lifting and driving operations and the excavator for digging operations Fully drive sheets piling using a piling guide Remove piling guide and excavate to first frame level Place each leg in excavation and assemble the frame Connect restraint chains Connect hydraulics and individually pressurise all ram units to 1000 p s i close lock off valve and remove hydraulics Dig through to next frame position Place
12. ifting 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 sling legs WARNING If an excavator is being used for lifting operations refer to safety information on Page 4 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 A surcharge for the excavator must have been allowed for in the excavation brief design In this booklet it is assumed that the frames will be lifted into the excavation one leg at a time and assembled in the excavation Likewise for removal it is assumed that the frame will be dismantled in the excavation and the legs removed one at a time See pages 9 and 10 for further details 5 4 Small Plant Tools and Lifting Chains for Handling Essential equipment required is A compressor 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 Sledgehammers for making pinned connections Podgers spanners for making bolted connections Bolt sizes are M24 for walings Lifting chains of suitable length and capacity and with current certification The walings have lifting lugs designed to take size 10 C hooks In most cases the
13. lar the master ring to turn and align with the load Code SSBA 007 WITHOUT A SWIVEL Refer to product user guide for ARRANGEMENT THE LOAD further details 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 QESEM ic part of the mabey family os Multibrace System eae February 2015 7 Identification of Components 2000mm Min A 3000mm Max 50 y La l Female Male Lo H Female j E Neo ay Ram Unit Assembly End Extension Unit Code MBRACE 001 Octagonal Extension Unit Code MBRACE 015 Weight 640 Kg NOT CURRENTLY AVAILABLE Weight 144 Kg Intermediate Extension Unit Length L mm Weight kg MBRACE 010 MBRACE 011 Accessories Air Powered Hydraulic Pump Code SSBA 003 Weight 75 Kg full 4 Leg Chain Sling Code SB LSLG SH Weight 47 Kg 10mm chain 4m E L L c w safety hooks and chain shorteners Refer to Lifting Chain User Guide for further details Restraint Chain Code SHBP 189 Weight 9 Kg 10mm chain 2m E L L c w forged hook Capacity 2000 Kg Note When used in combination with Mabey M11 sheets capacity reduces to 1500 Kg When used in combinati
14. legs of second frame in excavation and assemble safe working must be maintained Attach restraint chains between first and second frames Connect hydraulics and individually pressurise all lower ram units to 1000 p s i close lock off valve and remove hydraulics 10 Complete dig NOTE 1 This method requires operatives working in the excavations and the contractor must ensure safe working conditions at all times 2 See Page 9 for use of restraint chains Page 8 of 12 product user guide t mja b e y hiren part of the mabey family ee Multibrace System eae February 2015 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 attach 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 2000 Kg Restraint chains are provided as a back up support arrangement in the unlikely event of hydraulic failure of one of the Multibrace hydraulic legs They are NOT to be used for any other purpose and particularly are
15. on with M6 M7 sheets capacity reduces to 1000 Kg See also Page 9 8 Typical Waling Assembly and Site Connection Details Ram Unit Extension 267 1 No Bailey Pin E c w spring j retention ie s 2 No Bailey Pins 1 No Bailey Pin c w spring retention clips c w spring retention clip Page 5 of 12 product user guide t mja b e y hiren part of the mabey family ee Multibrace System eae February 2015 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 Bailey Pins and spring retention clips 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 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 2 No Bailing Pins and spring retention clips and two M24 bolts for which a 36mm A F spanner is required IMPORTANT NOTES Before lifting each leg into the excavation Ensure that 2 No Bailey pins are always fitted at each extension to extension and ram to extension connection Ensure that the correct bolt sizes are fitted and that bolts are fully tightened Site Connections for Waling Extensions are normally attached where possible
16. onsibilities 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 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 Name Site Address Tel No Fax No Re Provision o
17. product user guide cacani part of the mabey family ie Multibrace System eae February 2015 Contents Page 1 Introduction Design Frame Dimensions Hydraulic Adjustments Pages 2 4 General Guidance Notes Page 5 Component Identification Typical Waling Assembly and Site Connection Details Page 6 Assembly and Site Connections for Waling Pages 7 8 Typical Sequence of Sheet and Frame Installation Page 9 Removal of Frames Use of Restraint Chains Page 10 Frame Dimensions and Leg Weights Stacking and Handling Pages 11 12 Mechanical Pump Details and Procedures for Extracting Retracting Walings Page 12 Do s and Don ts Appendix A Provision of a Mabey Hire Demonstrator 1 Introduction The Multibrace 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 Shaftbrace waling system Super Shaftbrace waling system Supershaft Plus waling system Mechanical bracing strut Details of these products can be found in the relevant User Guide This booklet provides basic information for users of Multibrace to assist them in their preparation of a safe system of work on site Refer to Appendix A for details of our Site Demonstrator service Multibrace should NOT be used in seawater applications without prior consultation with Mabey Hire 2 Design No information on design is included in this bookle
18. t Clients are strongly advised to ensure that a competent engineer is employed to provide a suitable design for excavation schemes requiring the use of Multibrace products Mabey Hire offer a design service and can on request also provide information on the strength capacities of Multibrace products for clients undertaking their own designs 3 Frame Dimensions This booklet gives information for frame dimensions for Multibrace Walings When Multibrace is used in combination with Shaftbrace Super Shaftbrace or Supershaft Plus consult Mabey Hire staff for frame dimensions 4 Hydraulic Adjustments The Multibrace 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 excavation 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 QiEBE Gi part of the mabey family on Multibrace System eae February 2015 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 H
19. 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 16 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 f AT nil 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 Resp
20. uid only water added according to prevailing temperature conditions See table right Protective gloves should always be worn when handling shoring fluid NOTE A Shoring Fluid safety data sheet is available on request from Mabey Hire Limited 14 4 Procedure for extending walings to predetermined lengths either prior to assembly into frames or to set an assembled frame to a given size Ensure each waling is set up level and safely on packs just clear of the ground so that it will be free to extend Set the pump control valve to Neutral and ensure air supply valve is open Connect the pump hoses to the ram unit of the waling Open the safety lock off valve on the waling by rotating anti clockwise Set the pump control valve to Extend Watch the waling extend to the required length Shut down the pump by closing off the air supply valve Close the safety lock off valve on the ram unit by rotating clockwise Set the pump control valve to Neutral Disconnect the pump hoses from the ram Page 11 of 12 product user guide mialblely hire part of the mabey family ee Multibrace System ma February 2015 14 5 Procedure for extending and pressurising walings of a previously installed frame against the sheets of an excavation Ensure all restraint chains are in place and the frame is level Set the pump control valve to Neutral and ensure air supply valve is open Connect the pump hoses to the ram unit of the first w
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