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1User Guide – Conquip Lightweight Manhole Box

Introduction

The Conquip Lightweight Manhole 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 Lightweight Manhole Box is available in approximately 3m length and is generally suitable for trench depths of up to 3m.

Conquip Lightweight Manhole Boxes are manufactured from Grade S275 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

Lightweight Manhole 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

User GuideUser Guide

Edge Support Trench Lining SystemConquip Lightweight Manhole Box


Lightweight Manhole Box Specification

Overall length 2989mm

Overall height 2012mm

Width Refer to pages 5-8

Weight 900kg (Excluding Struts)*

Limit state 30kN/m2

design load

Base Box (TL104-00013)

Base Box at minimum extension

Base Box at maximum extension

Overall length 3500mm

Overall height 1301mm

Width Refer to pages 5-8

Weight 660kg (Excluding Struts)*

Limit state 30kN/m2

design load

W

L

H

W

L

H

Extension Box (TL104-00014)

Base Box at minimum extension

Base Box at maximum extension

*For weights of Incremental Struts refer to page 8.

For weights of Variable Struts refer to page 10.

W

L

H

W

L

H


Base Box Parts Diagram


1

2

Item No. Part No. Description Quantity

1 TL900072 Manhole Side Panel 2

2

See Page 5 Incremental Strut

4

See Page 7 Variable Strut


Extension Box Parts Diagram


1

2

3


1 TL900073 Manhole Extension Side Panel 2

2

See Page 5 Incremental Strut

2

See Page 7 Variable Strut

3 TL900046 Connecting Bracket 4


Struts Specification

Incremental Struts to suit Lightweight Manhole Box

No. of Sections

Strut Length Strut Weight Trench Width (External)

Working Width (Internal)

Working Width between ‘C’ sections

Strut Resistance

1 780mm 9.6kg 1992mm 1865mm 865mm 164kN

2 880mm - 1480mm 18.4kg 2092mm - 2692mm 1965mm - 2565mm 965mm - 1565mm 164kN

3 1580mm - 2180mm 27.2kg 2792mm - 3392mm 2665mm - 3265mm 1665mm - 2265mm 164kN

IMPORTANT: The increments between each hole are 100mm.


Incremental Struts Parts Diagram


1

4

3

2

5

ITEM NO. PART NAME PART NO With Rockers/QTY. DESCRIPTION

1 TL900041 2 Rocker Assembly

2 TL900042 1120x120 x8mm Strut Section With

Adjustment Holes, Length 780mm

3 TL900043 2 40mm Pin assembly

4 TL900044 3 28mm Pin Assembly

5 TL900047 1100x100x10mm Strut Section

With Adjustment Holes, Length 780mm

C

E

D

FF

C

D

E

3 16 4 27 5

6 5

B

A

78 234 1

B

A

10/02/2017Drawn By: Checked By:

Strut Assembly without RockersDWG No:

Description:

Material: All dims in mm unless otherwise stated

All content belongs to Conquip Engineering Group

Tolerances: 1Unless otherwise stated

8

Date:Part Code:

Notes:

©


1 TL900041 Rocker 2

2 TL900042Strut with Adjustable Holes, Length 780mm

(120x120x8mm)1

3 TL900043 Pin 40mm Ø x 250mm Length 2

4 TL900044 Pin 28mm Ø x 150mm Length 3

5 TL900047Strut with Adjustable Holes, Length 780mm

(100x100x10mm)1



Variable Struts

Brace Extension Working Width (bi) Working Width (bc) Trench Width (b) Weight

Without 990mm - 1290mm 1990mm - 2290mm 2200mm - 2500mm 71kg

500mm 1490mm - 1790mm 2490mm - 2790mm 2700mm - 3000mm 91kg

1000mm 1990mm - 2290mm 2990mm - 3290mm 3200mm - 3500mm 102.1kg






Variable Struts Parts Diagram

2

6

3

1

5

4


1

TL900006 Strut Extension 500mm

1





2 TL900004 Standard Spring Plate/Strut Connector 2

3 TL900011 Standard Variable Length Strut 300mm Stroke 1

4 TL900010 Pin Ø40mm x 226mm 2

5 TL900009 Pin Ø20mm x 148mm 3

6 ZZ290006 Retaining R Clip 5mmØ 5


Original Working Instructions

1.

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)

4.

Connect the sling to the lifting points of the panel facing downwards and lift it into position above the struts.

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)

5.

Lower the plate carefully, guiding the runners onto the four upright strut assemblies.

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.

Assembly Instructions

3.

Then connect the four remaining rocker assemblies to the struts using the 40mm pins and R-clips supplied.

6.

Secure the struts to the panel with the remaining four pins and R-clips. (As shown in Diagram C)

Diagram A Diagram B Diagram C

C

E

D

FF

C

D

E

3 16 4 27 5

6 5

B

A

78 234 1

B

A


Trench Box Standard Kit Assembly InstructionsDWG No:

Description:




8

Date:Part Code:

Notes:

©

C

E

D

FF

C

D

E

3 16 4 27 5

6 5

B

A

78 234 1

B

A



Description:




8

Date:Part Code:

Notes:

©

C

E

D

FF

C

D

E

3 16 4 27 5

6 5

B

A

78 234 1

B

A



Description:




8

Date:Part Code:

Notes:

©

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 11).


This shows 1 Base Box with 1 Extension Box


Lightweight Manhole Box Assembly Diagrams

IMPORTANT: The Lightweight Manhole Box should only be used as one Base Box and one Extension Box.



Connector Bracket

The Base Box and extension box are connected via a connector bracket (as shown above Detail D)

The connector bracket will fit within the panel soldier of the base box and is secured using a 40mm pin and R-clip.

The extension box is then placed on top of the Base Box. The protruding connector bracket must lock into the top of the panel soldier of the extension box.

Once in place, insert a 40mm Ø pin through the panel soldier and connector bracket. Secure with an R-clip.

D

DETAIL DSCALE 1 : 8 C

E

D

FF

C

D

E

3 16 4 27 5

6 5

B

A

78 234 1

B

A


3.5m Manhole Box + ExtensionDWG No:

Description:




8

Date:Part Code:

Notes:

©

E

DETAIL ESCALE 1 : 8

C

E

D

FF

C

D

E

3 16 4 27 5

6 5

B

A

78 234 1

B

A



Description:




8

Date:Part Code:

Notes:

©



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

Components

BC

F

DETAIL BSCALE 1 : 8

PC

DETAIL CSCALE 1 : 5

L, H

DETAIL FSCALE 1 : 6

VC

C

E

D

FF

C

D

E

3 16 4 27 5

6 5

B

A

78 234 1

B

A



Description:




8

Date:Part Code:

Notes:

©



Installation Instructions

Extraction

IMPORTANT: Never enter an unsupported excavation.

IMPORTANT: This should be done when the top of the base is approximately. 200mm above ground level.

1. Excavate the ground to approximately 1m or deeper, as ground conditions permit.

2. Lower the box into the trench using a 4 leg chain sling of the correct capacity.

1. 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 top 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.

3. The excavator operator then digs progressively between the two faces of the box plates.

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: All personnel involved in installation must wear relevant personal protective equipment.



Diagram A

Diagram C

Diagram E

Diagram B

Diagram D

Diagram F

Installation Instructions


Safety Notes

Installation & Transportation

Personnel

Equipment Maintenance & Cleaning

• 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.

• 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.

• 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.


Disclaimer

Warranty

The products supplied by Conquip Engineering Group are all

guaranteed by a 12 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 12 months of

the date of sale, at no additional cost.

Exceptions include:

• 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

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.

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.

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