Edge Support Trench Lining System

Transcription

1 User Guide Conquip Trench Box Edge Support Trench Lining System Introduction The Conquip 3.5m Trench Box is a simple to assemble, two sided trench lining support system designed to be installed by an excavator using the dig and push technique, or by simply carrying out the excavation and then lowering each box into place. The Trench Box is normally selected for installing utility pipes where ground movement is not critical. The size of the system required depends on maximum trench depth requirements and the size of pipe sections. It is generally suitable for trench depths of up to 5.8m and trench widths of up to 4m. All Conquip Trench Boxes are manufactured from Grade S355 British and European steel. The equipment is manufactured at our fabrication facility in the UK to the highest manufacturing standards held in the construction industry. Conquip supply a full range of suitable lifting and extraction chains, edge protection and trench access accessories. Important Notes This User Guide is for the Conquip Trench Box System only. Non-standard applications should be approved by a suitably qualified engineer All excavation work must be thoroughly planned before work commences on site to identify potential hazards and assess risk All personnel involved in installation must be properly briefed and supervised by a competent person Any general or specific drawings that are relevant to the application of this unit must be read in conjunction with this User Guide

2 Trench Box Specification Base Box (TL ) Base Box at minimum extension Base Box at maximum extension Overall length 3500mm W L W L Overall height 2560mm H H Width Refer to pages 5-8 Weight (excluding struts)* 2500kg Limit state 84.33kN/m 2 design load Extension Box (TL ) Base Box at minimum extension Base Box at maximum extension L Overall length 3500mm W W Overall height 30mm L Width Refer to pages 5-8 H H Weight (excluding struts)* 372kg Limit state 84.33kN/m 2 design load *For weights of Incremental Struts refer to page 6. For weights of Variable Struts refer to page 8. 2

3 Trench Box Specification Base Box Parts Diagram Item No. Part No. Description Quantity TL Trench Box Base Panel 3500mm x 2560mm 2 2 TL90004 Rocker 8 3 See Page 5 See Page 7 Incremental Strut Variable Strut 4 4 TL Pin 40mm Ø x 250mm 8 3

4 Trench Box Specification Extension Box Parts Diagram Item No. Part No. Description Quantity TL Trench Box Extension Panel 3500mm x 30mm 2 2 TL90004 Rocker 4 3 See Page 5 See Page 7 Incremental Strut Variable Strut 2 4 TL Pin 40mm Ø x 250mm 2 5 TL Connecting Bracket 4 4

5 Struts Specification Incremental Struts IMPORTANT: The increments between each hole are 00mm. No. of Sections Strut Length Strut Weight Trench Width (External) Working Width (Internal) Strut Resistance 780mm 9.6kg 265mm 065mm 64kN 2 880mm - 480mm 8.4kg 365mm - 965mm 65mm - 765mm 64kN 3 580mm - 280mm 27.2kg 2065mm mm 865mm mm 64kN 5

6 Struts Specification Incremental Struts Parts Diagram Item No. Part No. Description Quantity TL90004 Rocker 2 2 TL Strut with adjustment holes, length 780mm (20x20x8mm) 3 TL Pin 40mm Ø x 250mm length 2 4 TL Pin 40mm Ø x 50mm length 3 5 TL Strut with adjustment holes, length 780mm (00x00x0mm) 6

7 Struts Specification Variable Struts Brace Extension Working Width (bc) Trench Width (b) Weight Without 990mm 290mm 200mm 500mm 7kg 500mm 490mm 790mm 700mm 2000mm 9kg 000mm 990mm 2290mm 2200mm 2500mm 02.kg 500mm 2490mm 2790mm 2700mm 3000mm 3.3kg 2000mm 2990mm 3290mm 3200mm 3500mm 24.4kg 2500mm 3490mm 3790mm 3700mm 4000mm 35.5kg 7

8 Struts Specification Variable Struts Parts Diagram Item No. Part No. Description Quantity TL Strut Extension 500mm TL Strut Extension 000mm TL Strut Extension 500mm TL Strut Extension 2000mm TL Strut Extension 2500mm 2 TL Standard Spring Plate/Strut Connector 2 3 TL9000 Standard Variable Length Strut 300mm Stroke 4 TL90000 Pin Ø40mm x 226mm 2 5 TL Pin Ø20mm x 48mm 3 6 ZZ Retaining R Clip 5mmØ 5 8

9 Original Working Instructions Assembly Instructions. Using a certified lifting sling connected to the four corner lifting points, lift the panel onto some bearers and using the pins provided connect the rocker assembly to the panel. (As shown in Diagram A) 2. Place all four struts onto the rockers protruding from the panel facing upwards and secure them using the pins and R-clips supplied. (As shown in Diagram B) 3. Then connect the four remaining rocker assemblies to the struts using the 40mm pins and R-clips supplied. 4. Connect the sling to the lifting points of the panel facing downwards and lift it into position above the struts. 5. Lower the plate carefully, guiding the runners onto the four upright strut assemblies. 6. Secure the struts to the panel with the remaining four pins and R-clips. (As shown in Diagram C) 7. Disconnect the lifting sling connection points from the two lower lifting points and lift the box to the upright working position. 8. Connect the two free legs of the lifting sling to the upper lifting points of the other panel before lifting the box into the trench. Diagram A Diagram B Diagram C IMPORTANT: Top extension boxes are to be assembled in the same way but only two struts should be fitted. Extension boxes are secured to the base boxes using connector brackets and pins (see page 2). 9

10 Original Working Instructions Components H Handling Point L Lifting Point VC Vertical Connecting Point for connecting base boxes to extension boxes PC Panel connector which is used to connect base boxes to extension boxes VC PC H, L DETAIL A SCALE : 8 A C DETAIL C SCALE : 0 B L DETAIL B SCALE : 5 0

11 Original Working Instructions Installation Instructions IMPORTANT: All personnel involved in installation must wear relevant personal protective equipment.. Excavate the ground to approximately m or deeper, as ground conditions permit. 2. Lower the box into the trench using a 4 leg chain sling of the correct capacity. IMPORTANT: Never enter an unsupported excavation. 3. The excavator operator then digs progressively between the two faces of the box panels. 4. The operator then uses the back of the bucket of the excavator to push down on the 4 corners of the box in turn. 5. Repeat steps 3 and 4 until the desired depth is reached. 6. When attaching a top extension, these should be attached to the Base Box at each corner, using connectors supplied. Each connector is secured using a pair of pins and R-clips. IMPORTANT: Stage 6 should be carried out when the top of the base is approximately 200mm above ground level. Extraction. Simply reverse the installation process, start by backfilling the trench. 2. Progressively pull the box upwards using a certified 4 leg lifting chain sling. 3. If extension boxes have been used, these should be disconnected as the joint becomes clear of the ground and then lifted clear before reconnecting the sling to the Base Box and continuing the extraction.

12 Original Working Instructions Trench Box Installation Diagrams This shows Base Box with Extension Box Diagram A Diagram B 2

13 Original Working Instructions Trench Box Installation Diagrams This shows Base Box with 2 Extension Boxes Diagram A Diagram B IMPORTANT: This is the maximum number of extension boxes permitted. 3

14 Safety Notes Installation & Transportation It is recommended that the box panels extend over the full height of the dig and are not flown above the base of an excavation unless the box is adequately supported and has been approved as a safe method of work by a risk assessment undertaken by a competent person. Ensure support is provided over the full height of the dig. Pins should face inwards and clips must be correctly fitted. It is essential that four panel connectors are used to attach extension boxes (top boxes). When moving the equipment make sure that only lifting points are used to attach the chains or lifting apparatus. When installing the box system push at the corners only. When moving or installing equipment always use a banksman. Before excavating locate underground services. Lay the box horizontal to the ground before excavating. When installing the box make sure that it is not excessively forced into the ground. Suitable edge protection must be set-up directly after box installation, for more details on edge protection and accessories contact a representative from Conquip Engineering Group. It is prohibited to stand within the pivoting range of the excavator or crane and beneath suspended loads. When handling and removing the shoring, pay attention for overhead contact lines and power cables. A load operator must stand to the front of the excavator and be in eye contact with the machine operator. Personnel Ensure personnel are not in the box during installation. Once installed, operatives must never exit the box into an unsupported area. Never climb on the struts, always use a secured ladder. Equipment Maintenance & Cleaning The end-user has a responsibility under LOLER to ensure that all lifting equipment is fit for use. When not in use is it essential that the boxes are stored on flat stable ground. There is a wind loading risk if in an exposed area. They can either be stacked on their side or dug into the ground by at least 0.5m. It is imperative that all components are inspected at the start of every shift. Assess the self-weight of equipment correctly and use appropriately certified lifting equipment to lift and move the panels and assembled boxes. Store assembled boxes on firm, level ground. If this is not the case, or there is tendency to adverse weather conditions, lay the boxes flat on their sides. Do not store materials on the struts as it could damage them. 4

15 Disclaimer Warranty The products supplied by Conquip Engineering Group are all guaranteed by a 2 month warranty. Apart from where exceptions apply, Conquip Engineering Group promises to repair or replace any fault which the Company considers to be due to defective material or workmanship within 2 months of the date of sale, at no additional cost. Exceptions include: Conquip Engineering Group will not cover or reimburse any transportation and/or shipment costs to and from their premises or their recognised agents, or any material and/or labour costs for repair, replacement or assessment against a warranty claim. Conquip Engineering Group and/or their directors, employees, insurers or recognised agents will not be held liable for consequential damages, losses or expenses relating to the inability to use the product correctly for its purpose. Faults arising from unauthorised alterations (see modifications section below for full details) Damage caused by abuse, neglect, misuse or falling Damage caused because of failure to follow transportation, storage, loading, cleaning or operating instructions Replacement or repair of components due to fair wear and tear Any consequential damage or wear arising from the use or fitting of additional or non-standard parts Modifications If any third-party modifications or alterations, involving drilling, welding, cutting or distortion of materials in any form, are to be carried out on the product, Conquip Engineering Group must provide full written approval prior to the work being carried out. Alterations, modifications, additions or repairs must be carried out by Conquip Engineering Group s recognised distributors, if they are not carrying out the work themselves. Conquip Engineering Group operate a continuous improvement policy and therefore reserve the right to alter technical specifications and user guide details at any point without notice. 5