product user guide
Contents
1. Access and Hard Standing Areas These include i Suitable area to off load the lorry and assemble the walings and struts ii Suitable hard standing for the lifting appliance to operate from if it is intended to lift the walings struts into the excavation iii Ladders and possibly other provisions to provide safe access into the excavation to install restraint chains and connect pump hoses product user guide GlEREMLicS all the support you need title issue issue date June 2012 g h j k Supply of Equipment to Site Mabey Hire will normally supply the legs and bracing struts pre assembled to the size range required for immediate installation in the excavation 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 an 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 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 of 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 Return of Equipment off Hire Clients should ensure tha2. Female Connector SAFETY Extend Detail A position An intermediate extension can also be used in place of an end extension product user Quid Crowes econ CLEAR INSIDE DIMENSION mm 3 5 i o l Al i i Ai 7 Ee Ly ty LA tad i i Uh un BREE all the support you need Se oa os aac ae oi sean oe sa AB p ny Zz LA Call ra UA LA 1 455m mm 2 055m max Note If intermediate extensions are used in place of end extensions add 100mm to clear inside dimension 100mm to face of sheet dimension These legs only use intermediate extensions All legs use the SHBP 100 ram unit except SHBP 13 Leg lengths over 7 0m may require bracing struts Frame sizes for other combinations can be supplied by Mabey Hire Ltd on request c Fixed length rails are generally used in combination with Shaftbrace Typical frame dimensions for Type A Tankbrace rails in combination with Shaftbrace legs with end extensions are given below TANKBRACE STANDARD SIZES Clear Inside rs S product user guide Guan xii Typical Sequence Of Sheet And Frame Installation And Removal a METHOD Installati ion of 2 fre Ni ili lacing one 1 Fully excavate to first frame level NOTE Excavation depth is subject to assessment in accordance with the 1996 Construction Regs 2 Place each leg in excav
3. p s i close lock off valves and remove hydraulics 6 Dig through to next frame position 7 Place legs of second frame in excavation and assemble safe working must be maintained refer to dimensions shown 8 Attachrestraint chains between first and second frames 9 Connect hydraulics and individually pressurize all lower 1 2m Typical ram units to 2500 p s i close lock off valves and remove hydraulics 10 Complete dig NOTE This method requires operatives working in the excavation and the contractor must ensure safe working conditions at all times c 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 product user guide G EREMiicS all the support you need title issue issue date June 2012 xiii Use of Restraint Chains Restraint chains are provided as a back up support arrangement in the unlikely event of hydraulic failure of one of the Powerbrace system hyd
4. 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 Services 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 From Address Site Tel No Fax No Tel No Fax No 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 date s Signed Name Date
5. Mabey Hire s Depot Ensure struts are fully retracted before stacking Stack assembled struts side by side ONLY ONE layer high Strut components should be stacked in skips or bins c Strut Sizes and Strut to Waler F Clamp Plate M16x80lg bolt Gr 8 8 Connection Details JCBP 044 or Gr 8 nut JCBP 046 Connector Plate JCBP 035 Left or Right Hand Half Strut JCBP 009 ode No Overall Stru igt L eke eee MWS 00 q or JCBP 008 M16x60lg c sunk 254x254 UC A socket head setscrew or Gr 10 9 203x203 UC Gr 8 nut JCBP 043 _Use outer pair of holes for connection to 254x254 UC Use inner pair of holes for connection to 203x203 UC SECTION A A General Since our policy is one of continual improvement components may vary in detail from those given in this publication 12 GUESEMLic all the support you need 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 equipemnt required to undertake
6. ation 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 drive with excavator bucket as far as possible 4 Connect restraint chains 5 Connect hydraulics and individually pressurize all frame ram units to 2500 p s i close lock off valves and remove hydraulics 6 Dig through to next frame position and push sheets down 7 Reposition restraint chains as necessary 8 Place legs of second frame in excavation and assemble safe working must be maintained 9 Attach restraint chains between st and 2nd frames 10 Connect hydraulics and individually pressurize 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 This method requires operatives working in the excavation and the contractor must ensure safe working conditions at all times product user guide G EREMiicS all the support you need title issue issue date June 2012 b METHOD 2 Installation of 2 frames by fully driving sheets piling with piling hammer Fully drive sheets piling using a piling guide 2 Remove piling guide and excavate to first frame level 3 Place each leg in excavation and assemble the frame 4 Connect restraint chains 5 Connect hydraulics and individually pressurize all ram units to 2500
7. clockwise no more than 2 turns 4 Pump to required size If the ram does not move refer to fault finding overleaf 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 5 Close lock off valve with tool provided hand pressure is sufficient 6 Move extend retract lever on pump from side to side a few times This relieves pressure on the couplers and allows easy removal and replacement of the hoses 7 Remove hoses Position 2 Position 3 MHB 100 Extend MHB 100 Neutral MHB 100 Retract PSP 101 Retract PSP 101 Neutral PSP 101 Extend Both hoses MUST be connected NOTE Return lever to Neutral for short period before Retract 10 product user guide G EEEMLicS all the support you need title issue issue date June 2012 d Fault Finding In the event of the frames not extending or retracting when pumped check the following points 1 Pump is adequately filled with fluid 2 Lever is in the correct position for required operation 3 Both hoses are connected double check connections to the couplers on the ram 4 Safety lock off valve is open rotated anti clockwise max 2 turns 5 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 1 To purge pump Disco
8. eneral Assembly and Site Connections The legs of all of the braces in the Powerbrace system are made to the correct length range prior to delivery so that only the corners need to be connected In all cases this is by using Bailey pins and spring retention clips supplied The lugs at the corner connections are a close fit so it is only possible to assemble them with the frames level Typical Site Connections Shaftbrace extensions are normally fixed prior to delivery but to suit fJ 4 Dia Pin gt site conditions the extensions can be changed by unbolting 2 bolts EFL i and removing the pin lt _ Spring Clip gt 2 No M20 Gr 8 8 Bolts 75mm Long Only the corners usually require For 48 Dia Pin site assembly Corner Connection Extension Connection a Double Acting Manhole Brace DOUBLE ACTING MANHOLE BRACE STANDARD FRAME SIZES Frame Clear Inside mm Over Frame mm F Code Cn ue n e MDAMBF 1405 2005 1765 2065 ea MDamBe 1740 2040 2100 270 o MDaMB D 2140 3140 2500 3500 1060 Moama 2985 3985 sss sas 1200 Mamee 3660 4660 s0 soo no b Shaftbrace Typical Leg Arrangement 100 Ram Section Intermediate Extension End Extension 100 S Two sizes Various Lengths Various Lengths See Page See Page 4 See Page 4 pe 4 AL Box Section T 2030030C 1 1 ah Hinged Cover See Detail A Below
9. ination e g Double Acting Manhole Brace with Shaftbrace consult Mabey Hire staff for frame dimensions Super Shaftbrace and Bracing Struts Shaftbrace and fixed length rails are often used in combination with Super Shaftbrace Mechanical Bracing Struts and Hydraulic Bracing Struts There are separate sets of User Information for these products See page 12 for use of Shaftbrace and Fixed Length Rails with JC40 Bracing Stnuts Hydraulic Adjustment The Powerbrace 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 Contents Introduction and General Guidance Notes Pages 1 3 Identification of Components and Stacking and Handling Pages 4 5 Connection Details and Standard Frame Sizes Pages 6 7 Typical Sequence of Sheet and Frame Installation and Removal Pages 8 9 Use of Restraint Chains and Pump and Hydraulic Fluid details Pages 10 11 Do s and Dont s Page 11 JC40 Bracing Struts Page 12 Provision of a Mabey Hire site demonstrater Appendix A product user guide GlEREMLicS all the support you need ti
10. ly referred to as Tank Brace Rail SHBP 187 SHBP 182 at ien toeo 10 SHBP 168 Section Size Pin Pin Weight SHBP I72 200 20 UC ke Cameo o o tert SE o Bo 254x254 10800 a si5P 166 product user guide G EREMiicS all the support you need title issue issue date June 2012 d Accessories 1 Restraint Chain Code SHBP 189 Length 2 0 m Weight 5 8 Kg Capacity 2000 Kg Note When used in combination with M11 sheets capacity reduces to 1500 Kg When used with M6 M7 sheets capacity reduces to 1000 Kg 2 Lifting Chain Code SB LSLG Weight 47 Kg 10mm Grade 80 4 leg chain sling 4m E L L c w 4 No C hooks and 4 No shortening clutches Refer to Lifting Chain User Information for further details 3 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 4 Optional Extras Supplied On Request 30 mm A F Podger Spanner Code POD SPANNER 24 30 mm A F Open Ended Spanner Code JCBP 026 30 36 mm A F Open Ended Spanner Code 3 39 ix 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 a
11. nd other components are given on Pages 4 7 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 advice on stacking layers is given below a Double Acting Manhole Brace Ensure rams are fully retracted Stack on 3 x 4 timbers in rows of 4 N Max Height 3 rows Hydraulic connectors facing upwards b Shaftbrace Legs Ensure rams are fully retracted Stack on 3 x 4 timbers in rows of 4 N Max Height 3 rows Hydraulic connectors facing sidewards Tir L i ThT i eo Rs aar a l LE 1 ao pH e bT 34 fi EE c Fixed Rails Stack on 3 x 4 timbers in rows of 4 N Max Height 3 rows product user guide GiEREMLicS all the support you need title issue issue date June 2012 x Connection Details and Standard Frame Sizes Frame size ranges possible with each product used alone are given Frame sizes for the products used in combination can be supplied by Mabey Hire staff on request In determining frame sizes the following must be taking into consideration a Allowance must be made for the depth of sheeting to arrive at the excavation size b A deflection allowance should be added to the clearance dimensions given Clearance dimensions snould be revised by Rail length mm 30 e g for a 7000mm long rail the clearance dimension should be reduced by 7000 233mm 30 xi G
12. nnect 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 2 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 function properly refer to your nearest depot xv DO S amp DON TS DLP scenes ensure that all lock off valves are open prior to pumping DD asia ensure that pressure is being held in the rams before closing the lock off valves it scii use restraint chains between each frame as well as to the top of the sheets a install frames as level as possible a pan release the pump pressure after closing the lock off valves to ease removal of the hoses DO sri keep the pump couplers dirt free by clipping male and female ends together after use DO NOT enter the excavation until pressure is held in the rams DO NOT lift a frame until pressure has been released DO NOT overpressurize the system as this can result in damage to the rails 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 pressurize a frame with a large gap between the rails at the ram position A packer must be inserted to fill the gap first DO NOT release ram pressure by depressing or striking the coupler nipple DO NOT use the restraint chains as a mea
13. ns of suspension during installation or removal of the frames 11 product user guide G EREMiicS all the support you need title i issue date June 2012 xvi Use of Bracing Struts with Powerbrace There are three types of bracing strut commonly used with Shaftbrace and Fixed Length Rails JC40 struts from the JC40 Trenchbox system Mechanical Bracing Struts Hydraulic Bracing Struts There are separate sets of user information available for the Mechanical Bracing Strut and the Hydraulic Bracing Struts Information on the JC40 struts appears below a Identification of Components i Left Hand Strut 800mm Extension 400mm Extension Right Hand Strut JCBP 009 JCBP 007 JCBP 006 JCBP 008 Weight 25Kg Weight 40Kg Weight 21Kg Weight 25Kg Clamp Plate ny Clamp Plate Connector Piiie e250 JCBP 044 Ik as ICBP 046 JCBP 035 o A Jof Use with Heavy CoL Use with Shaftbrace Weight I3Kg ____ Duty Intermediate lif eea le Extensions Extensions K e Weight 5Kg Weight 5Kg b 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 struts and components are given on this page Retum pre assembled struts as supplied from
14. product user guide G EREMiicS all the support you need title issue issue date June 2012 iii iv v vi Introduction The Powerbrace System is a range of products intended to be used as temporary waling systems to sheeted excavations The range of products comprises i Double Acting Manhole Brace ii Shaftbrace ili Fixed Length Rails These products are also frequently used in combination This booklet is intended to provide basic information for users of Powerbrace equipment and to draw the clients attention to the practical aspects of handling assembly installation and use which need to be considered in drawing up method statements for a safe system of work Powerbrace equipment should NOT be used in seawater applications without prior consultation with Mabey Hire Engineering Department Refer to Appendix A for details of our site demonstrator service Design No information on design is included 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 Powerbrace products Mabey Hire Ltd offer a design service and can on request also provide information on the strength capacities of Powerbrace products for clients undertaking their own designs Frame Dimensions This booklet gives information for frame dimensions for each of the Powerbrace products used separately When the products are used in comb
15. raulic legs They are not intended as a means of suspension to be relied upon during installation removal of frames Always ensure all the restraint chains are fitted and that as much slack as possible is removed with the chain shorteners or D shackles Users must ensure that frames are securely supported by means other than the restraint chains prior to depressurizing the frames xiiii Use of Pump and Hydraulic Fluid It is important to maintain an adequate level of fluid in the tank to avoid pumping air into the rams The fluid level in the pump should be checked after each ram has been pressurized a Mabey Hire Shoring Fluid Only Mabey Hire Shoring Fluid should be used with Powerbrace 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 temperature conditions Protective gloves should always be worn when handling shoring fluid ie Above 0 C 1 No 5 litre fluid to 20 litres water 6 C to0 C 2 No 5 litre fluid to 20 litres water 10 C to 7 C 3 No 5 litre fluid to 15 litres water 10 C and below Neat fluid only Alternatively one end pumped independant of the other end 1 Connect both hoses as per the diagram 2 Position the pump lever to the required position 3 Ensure that safety lock off valve on the ram is open by turning anti
16. t on removal the equipment is returned clean in lengths as supplied Tr ion Ensure equipment is loaded to the satisfaction of the driver and is securely chained strapped to the lorry References Health amp Safety at Work Act 1974 Management of Health and Safety at Work Regs M H S W 1992 Construction Design and Management Regs CDM 1994 The Construction Regulations BS 6031 1981 Code of Practice for Earthworks BS 8004 1986 Code of Practice for Foundations formerly CP2004 BS 7121 1989 Safe Use of Cranes 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 H amp S E Guidance Note PM42 Excavators used as Cranes product user guide G EREMiicS all the support you need title issue issue date June 2012 viii Identification of Components a Double Acting Manhole Brace Pin PinDim mm Min Max mr e le Mammie 1920 2520 232 Pomaro aa so s om ee fate Wee 2035 a 1855 SA E paraba wema SEDO a mo amr o o 1500 SHBP 193 550 f 8 SHBP 158 000 SHBP 150 SHBP 154 1500 SHBP 151 150 128 SHBP 155 SHBP 174 __SHBP 188 SHBP 152 2500 183 SHBP 156 3000 200 SHBP 153 ___SHBP 177 7000 420 Type B commonly referred to as Heavy Duty Intermediate Extension 254 x 254 U C Type A common
17. tle issue issue date June 2012 vii General Guidance Notes a b c d e 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 amp 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 Powerbrace installation which need to be considered in drawing up 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 Powerbrace system are fitted with lifting lugs for safe slinging Two methods of constructing a typical excavation using Powerbrace are given on Pages 8 amp 9 Manpower The Construction Regulations require that personnel deployed are suitably trained and experienced and supervised by a competent person The main activities associated with Powerbrace installation are i Unloading the delivery vehicle ii Bolting up and pinning steelwork together to form walings or struts of the required length iii Slinging and lifting walings into the excavation and connecting the corners to form frames iv Connecting the pump to each waling in tum pressurizing the frames and fitting res
18. traint chains v Slinging and lifting bracing struts into position and fixing them between walings 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 struts 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 excavation For smaller excavations say using Double Acting Manhole Brace it is quite common to lift complete frames into the excavation Tools and Lifting Chains available from Mabey Hire i Sledgehammers for making pinned connections Not in Mabey Hire supply ii Podgers spanners for making bolted connections M20 for walings M16 for struts iii Lifting chains of suitable length and capacity complete with current certification The walings have lifting lugs designed to take size 10 C hooks 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 10mm chains with 4 0m leg length complete with shortening clutches and C hooks Code SB LSLG weight 47Kg S W L 9 0 Tons 90
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