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Product User Guide Issue: Date:
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Introduction to Light Duty Manhole Box 2.5m + 3.0m: Proshore’s User Guide aims to provide all the necessary information required to allow for safe, effective and well- informed use of Proshore’s Light Duty Manhole Box 2.5m + 3.0m. The guide will cover aspects of practical handling, assembly, installation and systems of best practice. Aspects of the guide will assume general competence within the field, however item specifics such as design components and planning for lifting operations will be comprehensively described.
The Light Duty Manhole Box is designed to enable the shoring of excavations for works with SMALL excavators, which do not have the lifting capacity to work with heavier trench box systems. A complete understanding of handling advice, lifting points and practice for safe slinging is advised before undertaking such works.
Although general competence is assumed, Operatives should ensure that the length and selected width of the box is sufficient for the intended works and should be aware that Light Duty Manhole Boxes are not suitable for use in water bearing soils or excavations containing frequent services. Proshore’s Manhole Box should only be used under the aforementioned circumstance and is not recommended for any other operative purpose.
User Guide Contents:
Light Duty Manhole Box 2.5m & 3.0m 1 Nov 16'
Design:
Please see diagram aside, which shows the typical pressures that Proshore’s Manhole Box can sustain. Although methods of estimating lateral earth pressures may vary, the present calculations should allow for the majority of working situations faced by the product. However, if you have any doubts, please speak to your company’s Proshore contact.
This item is designed to carry a lateral earth pressure of 20kN/m2. Users should check that their excavation arrangement will not impose a greater working pressure.
Actions, plans or conditions that may increase the likelihood of exceeding this pressure include; the close proximity of structures, excavated materials, construction materials, roads, services or railways. Users should also note that settlement of the reinstated ground and ground adjacent to the item is likely to occur after backfilling.
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Light Duty Manhole Box 2.5m & 3.0m:
• Page 1: Design• Page 2: Component Drawing• Page 3: Assembly & Site Handling• Page 7: Installation of Extension• Page 9: Operational Guidance• Page 11: User Summary
2900
100
Title:
Product User Guide Issue: Date:
Page:
Component Drawings:
1 Nov 16'Light Duty Manhole Box 2.5m & 3.0m:
Light Duty Manhole Box 2.5m & 3.0m:
Length
'L'
'W'
545
'S'
545
'E'
'C'
When closing off the endsof the box ensure side loadingsare taken on the 30mm pads.DO NOT allow the struts to carryside loadings
64
2000
Length
1000
Length
Dimensions of Manhole Boxes2.5 Manhole Backhoe Box is suitable for Manhole ring sizes of 1050, 1200 & 1350mm.
3.0 Manhole Backhoe Box is suitable for Manhole ring sizes of 1500, 1800 & 2100mm.
Note for Operatives, Planning & Design - The weights above are theoretical and therefore do not take into consideration Debris or Repairs: Add 5% for such effects.
1000
2000
1200mm
Clear
‘L’
Pin with ‘R’ Clip
Weight: 0.5kg
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Title:
Product User Guide Issue: Date:
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1 Nov 16'
Assembly & Site Handling:
• Operatives: MHSW legislation requires that all operatives that use this item are experienced,suitably trained and/or supervised by a competent person. All lifting operations required todeploy this item are to be controlled by and appointed person and all acts are to be inaccordance with British Standard: BS7121 and LOLER regulations.
• Plant required: Suitable appliances are required for offc loading and assembly of this item.Before lifting a comprehensive understanding of the size and weight of the item should bechecked against the item of plant’s lifting capacity and site clearance.
• Additional hire/tools required: Lifting chains of suitable length and capacity are requiredalongside proof of current certification. Speak to your company’s Proshore contact for furtheradvice or item hire.
• Access required: A suitable area to offload the lorry and to assemble the Box, suitable hardstanding ground required for the lift machine to operate, Ladders or staging suitable for accessto attach required chains and to provision safe access in and out of trench/excavation.
• Supply & Return of Equipment: Clients should ensure that the equipment is returned insections and state as supplied and should not be required to assemble or dismantle aspectswithout previous consent.
Light Duty Manhole Box 2.5m & 3.0m:
When NOT IN USE dismantle all extension boxes to store as per diagram. Boxes should not be stored on uneven or sloped ground, or exposed to extreme wind loading.
• Stacking, Handling & Transportation: Baseand extension panels should be stacked as shownwith suitable timber dunnage. Panels should bepacked with in a maximum stack of 4 and all components and pins should be kept in separate skips/containers. During any form of transportation all stacks should be securely restrained to the vehicle.
Light Duty Manhole Box 2.5m & 3.0m:
Plywood Strips
Firm LevelDry Ground
1000
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Product User Guide Issue: Date:
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1 Nov 16'Light Duty Manhole Box 2.5m & 3.0m:
Light Duty Manhole Box 2.5m & 3.0m:
Attach hooksto top liftingeyes
Attach hooksto top liftingeyes
Attach hooksto slinging holes
Lie the first base panel flat on the ground with its wings pointing upwards
Pin 4 No. fixed length Strut to the base panel using pins and ‘R’ clips
Turn the other base panel over using 2 legs of the four leg sling
Re-‐sling this panel with the wings downwards (use all 4 legs of the lifting chain)
Complete assembly of the base box on its side by pinning the stuts to the upper panel before removing the 4 leg sling.
Site Assembly
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After standing upright, ensure that all pins and safety clips are checked to be in place. Next lift the box using the four leg chain sling, attached to the lifting points at the top of each panel.
1 Nov 16'Light Duty Manhole Box 2.5m & 3.0m:
Light Duty Manhole Box 2.5m & 3.0m:
Trench Width
Attach two chains of the sling to the upper lifting eyes of the uppermost panel and two chains of the sling to the upper lifting eyes on the lower panel. Next stand the box on its cutting edges (operatives note: take care to not damage the struts during movement). Ensure that the weights and radius are within the lifting capacity of the machine, to allow for impact and effects of lurching, as the box is turned upright.
Site Assembly
Installation of Base
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1 Nov 16'Light Duty Manhole Box 2.5m & 3.0m:
Light Duty Manhole Box 2.5m & 3.0m:
Dig the manhole approximately 600-‐1000mm deep to the correct width, and using the four leg sling, place the box into the excavation. The box can now be installed to the correct depth, by digging between the box panels and pushing down on the ends of the panels. (Operative note: Always dig below the panels before pushing down -‐ Push only on the corners of each panel and
never in the middle.)
When pushing the box panels down, always push down in the sequence shown and never diagonally across corners.
Example Sequence – A then B – Followed by C then D.
DO NOT complete in a sequence – A then C or B then D.
During the ‘dig and push’ operation, restrict the advance of one panel over the other to a maximum of 6% of the box width.
When the required excavation level is reached and the box has reached its full depth, operatives must ensure that the struts are horizontal at right angles to the panels before entering the excavation.
DO NOT use any unsupported part of the excavation for access. Leave the top of the box 100mm above the surrounding ground level.
Push in thesecorners
D C
B A
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+ 6%
of
Exc
avat
ion
Wid
th
Excavation Width
100
90°
Title:
Product User Guide Issue: Date:
Page:
1 Nov 16'Light Duty Manhole Box 2.5m & 3.0m:
Light Duty Manhole Box 2.5m & 3.0m:
300
mm
100
mm
90°
Dig and push the base box to stay within approximately 300mm from the top of the base box
Lift one extension panel upright using two of the 4-‐leg chain sling and pin two No. fixed length struts to the panel using pins
and R clips.
Lift the second extension panel upright using 2 of the 4-leg chain sling and lower on the other base panel. Whilst doing this, operatives should locate the two number struts into the panel. Secure the panel to the base box using pins and R clips.
DO NOT use any unsupported part of the excavation for access. Leave the top of the box 100mm above the surrounding ground
level.
Lift the extension panel, complete with struts, to lower onto one side of the base box. Secure the panel onto the base box using
pins and R Clips.
Continue the dig and push operation until the required excavation level is reached. Ensure all the struts are horizontal
and at right angles with the panels before entering the excavation.
Installation of Extension
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Product User Guide Issue: Date:
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1 Nov 16'Light Duty Manhole Box 2.5m & 3.0m:
Light Duty Manhole Box 2.5m & 3.0m:
Ensure that there are NO gaps between the box panel and the trench sides as this may cause the box to move sideways
DO NOT leave the base of the box ‘flying’ above the trench level.
When stopping off the end of the trench, steel walers should be used to support the sheets off the end of the panels.
N.B – NEVER use the struts as supports for the trench sheets.
Correct Incorrect
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Struts MaintainClearance
Waling and Trench Sheetsor alternatively, End Panels
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Product User Guide Issue: Date:
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300 300
1 Nov 16'Light Duty Manhole Box 2.5m & 3.0m:
Operating within a support excavation
• Use suitable access (Ladder) to enter the working space. At no point should an operative climbup and down the struts of the Manhole Box; additional access required at all times.
• DO NOT use unsupported parts of working area for access.• DO NOT move/lift the Manhole Box whilst operatives are inside.• Full PPE in accordance with clients working best practice to be worn and MUST include a
safety helmet.• Ensure that all works are effectively planned and that site operatives are made aware of said
planning
Extraction of Light Duty Manhole Box Due to the consolidation of the ground against the modules, operatives MUST BE AWARE that it’s more difficult to extract Manhole boxes, than to insert them. Operatives MUST take guidance from below, ensuring that all lifting operations use the recommended lifting points provided.
NO OPERATIVES CAN BE INSIDE THE MANHOLE BOX DURING EXTRACTION/LIFTING OPERATIONS.
Method for extraction in Normal Conditions
After the initial backfilling and compaction, lift the base box, complete with extension box (if fitted) from the manhole using the 4 leg lifting chain attached to ALL 4 upper lifting points. Continue backfilling as the removal of the box proceeds.
If the extension box is to be removed from the base box, lift as per previous description, until the top of the base is approximately 300mm above ground level. Then remove the corner pins used to secure one of the extension panels to the base and the other pins used to secure the other extension to the base. Then lift this whole panel, complete with struts, from the base. Finally remove the struts from the extension panel and stack the panels and struts, as per previous stacking guidance.
DO NOT – remove the extension panels before the top of the base is above ground level & DO NOT remove the extension box as a complete item from the base box.
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Light Duty Manhole Box 2.5m & 3.0m:
Title:
Product User Guide Issue: Date:
Page:
1 Nov 16'Light Duty Manhole Box 2.5m & 3.0m:
Light Duty Manhole Box 2.5m & 3.0m:
Method for extraction in Wet or Heavy Ground Conditions
In such conditions, it may be necessary to pull one corner of the box at a time, to initiate the lifting process. To do so, connect the single leg connector chain to the upper lifting points of each BASE panel, pull each panel vertically in turn in order to lift the box free.
ALWAYS fit the connector chain to the BASE panels of the Manhole Backhoe box and NEVER to the extension panels.
Once the box is free, attach two legs of the chain sling to the upper lifting points (as per diagram a) to pull this panel up. Repeat the operation on the remaining BASE panel.
DO NOT exceed the advancing of one panel over the other by 6% of the box width; this is as per installation guidance. Any advice required, speak to your company’s Proshore contact.
The box can now be lifted from the Manhole using the 4-‐leg chain, attached to all four lifting points on the base box (as per diagram b).
Maintenance Guidance:
Ensure regular checks on all pins and connections. Avoid laterally loading struts, this could be effected by handing or propping from them or by accidental striking by site plant operations.
N.B – Damaged struts should NEVER be operated with and all staff should be made aware of anydamage to items.
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Lifting Lug
Snatch Chain
a) b)
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Product User Guide Issue: Date:
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User Summary – Light Duty Manhole Box 2.5m + 3.0m:
✗ -‐ Move the item with Operatives inside
✗ -‐ Use the lifting points for uses other than loading/unloading or assembly
✗ -‐ Use unsafe lifting equipment
✗ -‐ Enter unsupported parts of the Working Area/Trench/Excavation
✓ - Ensure that all operatives have been briefed and have confirmed familiarity with the User
Guide.
✓ - Follow basic maintenance instructions.
✓ - Ensure all works are in accordance with design and do not overstress the boxes.
✓ - Ensure that all access is per recommendation e.g. Using a ladder to enter working area.
✓ - Ensure that all operatives have recommended PPE.
✓ - Ensure that when not in use – Manhole Box is stored on its side.
✓ - Ensure that a safe batter of the unsupported parts of the trench is maintained.
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1 Nov 16'Light Duty Manhole Box 2.5m & 3.0m:
Light Duty Manhole Box 2.5m & 3.0m:
