product user guide GQEDED Title Issue _ [Date 5.0m x 2.0m Maxi Dragbox ad Feb 2020 Contents Page 1 : Introduction, Design, Trench Reinstatement, Identification of Components Page 2 : Identification of Components Cont'd, Dimensions and Connection Details, Sizes and Quantities of Struts Required to make up particular sizes of Dragbox Page 3: Off loading, Site Handling and Assembly of Maxi Dragbox Page 4 : Use of Maxi Dragbox Page 5 : Use of Maxi Dragboxes in Stacked format, Summary - Do's and Don't's, References, General Introduction This booklet is intended to provide basic information for users of the Mabey Maxi Dragbox system and to draw the client's attention to the practical aspects of handling, assembly, installation and use 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 size and weights of the Maxi Dragbox components and the need for planning the lifting operations involved. All major components of the Maxi Dragbox system have lifting points for safe slinging. It is assumed that clients are familiar with general safe practices applicable to the use of dragboxes. The Maxi Dragbox is intended to act as a shield to provide a safe working area for ‘operatives working in a trench, Itis not intended to provide significant support to the trench sides, and is therefore intended for use only in dry stable ground which stands to the excavated depth. It can then be dragged along a predug trench. Users should ensure that the length and selected width of the box is sufficient for the work to be carried out. Dragboxes are not normally suitable for use in water bearing soils or in trenches crossed by frequent services. The Maxi Dragbox is not intended for other Purposes. Design card] 3) |x| uniform lateral earth pressure of 20 kN/m2. Users are advised to check that their “sve excavation arrangement will not impose greater working pressures than this. Conditions which will increase the likelihood of trench wall instability and lateral fe earth pressures are’ Earth Pressure Ef zonnine In the event of trench wall instability the Maxi Dragbox is designed to cary ag, > | 3 a) Close proximity of structures. b) Excavated or construction materials adjacent to the trench. an ) Close proximity of site roads. Level d) Close proximity of railways. v WWW) | 3. Trench Reinstatement Users should note that settlement of the reinstated ground and ground next to the Maxi Dragbox is likely to occur after backfiling, 4. Identification of Components “T Extension Panel Cost: MOBP-OT4 Woight S10 Kg Front Strut Mounting RearStrut Spacer Outer Rear Strut Spacer Inner ‘Code: MOBP.008 {850-750 Only) (Code: MDBP-008 ‘Size: 300 x 430 x 180 Code: MOBP.007 Size: 176 x 178 x310 Weight 26.0 kg Size: 176 x 176 x55 Weight: 8.0 kg Weight: 8.0 kg Front Strut Pin Rear Strut Pin Pin with Twin ‘R' Clips Code: MOBP-005 Code: MOBP.009 Code: MBP-005 Base Panel Size: 35 dia x 148 Size: 25 dia x 155 Size: 35 dia x 180 Code: MOBP-013 Weight: 2.0 kg Weight: 0.8 kg Weight 1.5 kg Weight: 1078 kg Page 1 of 5product user guide 5.0m x 2.0m Midi Dragbox 4. Identification of Components Cont'd Rear Strut Spacer Outer Length | internal wiath th | Intemal width | Weight mm) | tomm) (mm | 9) oeP-008 | 530 | 800-1150 MOBP-002 550-750 | 36 MoBp.ots | 920_| 1150-1500 MDBP-003 ‘00-1150 | 82 ‘moBP-020_ | _1270__| 1500-1850 MOBP.015 1150-1500 | 74 MDBP-021 | 1620 | 1850-2200 MOBP-016 1500-1850 | 95 ‘wosp.022 | 1970__| 2200-2550 MOBP-017 1850-2200 MOBP-018 72200-2550) Code 5. Dimensions and Connection Details 2040 "Top iitting points Edema Pail Rear strut to Panel connection - M16 x 45 long bolt (4 per panel) | aS 7 Rear strut Innerto Outer connection-Pin Rat Strut (MDBP-009) (1 per strut on MDB-01 & MDBE-01, 2 per strut on all other sizes), Bottom lifting points ‘op lifting points a Direction of drag—+ Base Panel || Front strut to mounting connection - _{1__ 4830 clear between struts Pin (MDBP-005) 1 per side. Mounting ‘on box centreline to panel connection - M16 x 45 long See Table Rear End Side Elevation Front End Elev: Plan Elevation x 7 bolts (8 per panel). Note: All bolts 8.8 Bottom iting points Grade. ‘+4850 clear between struts ~! 6. Sizes and Quantities of Struts Required to make up particular sizes of Dragbox Note: 1. Always allow sufficient clearance for excavator bucket to work comfortably within internal width of side panels when selecting a box size 2. Non-standard equipment may be available if other widths required ‘Assombly | Front Strut Code | Rear Strut Assembly (2No. per | _ Internal extemal Width Code No, | No. (1No. Req) | base, tNo per extension) | Width¢mm) | (mm) Base | WB-0T | MDBP-002 ‘MOBP-006 + MOBP-007 350-750_| 710-910 Base | MDB-02 | MDBP-003 | 2No. MOBP.005 + MDBP-o08 | 800-1150 | 960-1310, Base | MDB.03_| _MDBP-015 | _2No. MOBP-006 + MDBP-018 | 1150-1500 _| 1810-1660 Base | MOB-04 | _MDBP.016 | _2No.MOBP.006 + MDBP.020 | 1600-1850 | 1660-2010 Base | MOB-05 | MDBP-017 | _2No.MOBP-006+MDBP-021 | 1860-2200 | 2010-2360, Base | MOB-06 | MDBP.018 | 2No. MOBP.006 + MDBP.022 | 2200-2660 | 2360-2710 Extension | MOBE-OT | MOBP-002 ‘MDBP-006 + MDBP-007 ‘550-750 | 710-910, Extension | MDBE-02 | MDBP-003 | 2No. MDBP-006 + MDAP-008 | 200-1150 | 960-1310 Extension | MDBE-03 | MDEP-015 | 2No. MDBP-006 + MDAP-019 | 1150-1500 _| 1910-1660 Extension | MDBE-04 | MDBP-016 | _2No. MDBP-006 + MDAP-020 | 1500-1860 | 1860-2010 Extension | MDBE-05 | _MDP-017 | _2Ne. MDBP-006 + MDAP-021 | 1860-2200 | 2010-2360 Extension | MDBE-06 | MDBP-018 | 2No. MOBP.006 + MDBP-022 | 2200-2550 | 2360-2710 Box Type Page 2 of 5product user guide GQEDED Issue _ [Date 5.0m x 2.0m Maxi Dragbox ad Feb 2020 Title 7. Off Loading, Site Handling and Assembly of Maxi Dragbox 7.4 Manpower The Health and Safely legislation require that personnel deployed are suitably trained, experienced and supervised by a competent person. All liting operations are to be controlled by an appointed person in accordance with BS7121 and LOLER regulations. 7.2 Plant for Lifting A suitable appliance is required for off-loading and assembly if required. The machine lifting capacity and clearance under the lifting point should be checked against the sizes and weights of the dragbox to be lifted / assembled. 7.3 Tools and Lifting Chains (available from Mabey Hire Ltd) 7.3.1 Podgers / Spanners for making bolted connections (M16 bolts) 7.3.2 Lifting chains of suitable length and capacity complete with current certification. Typically a set of 4 leg 10mm chains with 4.0m leg length complete with shortening clutches and safety hooks. (Code SB-LSLG/SH, weight 47kg) Refer to Lifting Chain User Information for more details. 7.4 Access and Hard Standing Areas These include: 7.4.1 Suitable area to off-load the lorry and assemble the Backhoe box. 7.4.2 Suitable hard standing for the machine to operate to lift the box into the trench. 7.4.3 Suitable access equipment (ladder or staging) for attaching lifting chains. 7.4.4 Ladders and possibly other provisions to provide safe access into and out of the trench, 7.5 Supply of Equipment to Site Base Boxes: Mabey Hire will normally supply Maxi Dragboxes completely pre-assembled to the width required for immediate installation in the trench. ‘Top Extensions: These will normally be supplied pre-assembled. Clients need to allow for the top extension to be connected onto the base box on site, NOTE: Clients should not normally attempt to dismantle and assemble boxes themselves on site. 7.6 Return of Equipment Off-Hire Clients should ensure that on removal, the equipment is returned in sections as supplied, 7.7 Slinging of Maxi Dragbox (See pages 1, and 2 for weights) 7.7.1 Off Loading/Reloading Lorry 7.7.2 Standing Pre-assembled (Pre-assembled in Depot) A Boxes Upright Use 4 leg chain sling x Use 4 No lifting points (SB-LSLGISH) connected provided. Lift from both to lifting points as shown. Z panels. 7.7.3 Lifting Pre-assembled Boxes When in Upright Position Use the 4 No. lifting points provided Page 3 of 5product user guide GQEDED Title Issue _ [Date 5.0m x 2.0m Maxi Dragbox ad Feb 2020 8. Use of Maxi Dragbox 8.1 Preliminaries. 8.1.4. Check all bolts are fitted and tight before lifting box into trench. 8.1.2 Check all pins chw ‘R' clips are fitted before lifting box into trench. 8.1.3 Asultable excavator is required - as a guide the manufacturer's quoted "digging force" should be at least 5 x the weight of the dragbox equipment in use. 8.2 Installation 8.2.1 Excavate initial section of trench slightly wider than the external box dimension. Lift dragbox into trench using excavator or crane, 8.2.2 The Maxi Dragbox must NOT be pushed down into the trench using a ‘dig and drive’ method. 8.2.3 Always maintain a safe balter of the unsupported parts of the trench in front of and behind the box. 8.2.4 Fill any large voids on outside of panels so that the box cannot be pushed sideways by any soil movement. Ensure the box is installed vertically. 8.2.5 Allow for at least 100mm of projection of top of box above ground level - to prevent debris rolling into excavation. 8.2.6 DO NOT leave the base of the box ‘fying’ above the excavation level. Correct Incorrect SSUES Aways maintain a sate When the required excavation Ensure that thore are no largo voids between tho box batter ofthe unsupported _levelis reached and the box panel and the trench sides as this may cause the box to parts ofthe trench, in front sunk to the required depth, move sideways, of and behind the box. ensure that the box is vertical 8.3 Entering the Supported Excavation 8.3.1 Use a ladder to enter the working space between the struts of the Maxi Dragbox. Do not climb up or down the struts 8.3.2 Do not use any unsupported part of the trench for access. 8.3.3 Do not move the box when personnel are inside. 8.3.4 Wear a safety helmet to minimise risk of head injury. 8.3.5 Ensure that the excavator operator is aware of your intentions. 8.4 Operation 8.4.1 Before entering the working space within the Maxi Dragbox :- + Prepare the pipe bedding material + Lifta section of pipe into the trench, 8.4.2 Enter the working space and complete installation of the pipe section by joining onto previously laid sections Restrain the pipe section to prevent displacement whilst dragging the Maxi Dragbox along the trench. 8.4.3 Exit from the working space. 8.4.4 Drag the box forward by hooking the bucket round the front strut of the box. Use the hydraulics of the excavator for this rather then moving the machine on its wheels J tracks. 8.4.5 Backiil the trench behind the Dragbox. 8.5 Extraction 8.5.1 Lift the Maxi Dragbox from the trench with excavator or suitable craneage, using 4 leg chain (SB-LSLG/SH) connected to lifting points. 8.6 Site Storage (Stability Considerations) 8.6.1 Maxi Dragboxes should be stored laid on their side when not in use. Uneven or sloping ground andior wind loading can result in inadequate stability if left standing upright. 8.7 Maintenance 8.7.4 Keep all nuts and bolts tight 8.7.2 Damaged struts must not be used. 8.7.3 We regret that we are unable to provide staff to change boxes from one size to another on site. Page 4 of 5product user guide Title 9. Use of Maxi Extension Boxes 5.0m x 2.0m Maxi Dragbox The height of the Maxi Dragbox can be increased to 3m by adding an extension box as follows: The base box should be stood in it's normal upright mode in a partly dug trench approximately 1m deep and the extension box lowered onto the base using the lifting points provided. Connect the two boxes together using 1 No. MBP-005 pin per comer. It may be necessary to loosen all the strut connecting bolts in order to fit all the MBP-005 pins. Re-tighten the bolts after assembly. Lift the complete assembly from the trench, excavate to full depth and lit the assembled box back into the trench. This assembly will give an overall height of 3.0m, General Points:- 9.1.1 Always drag the pair of boxes by the front strut of the BASE box. 9.1.2 Do not use the excavator bucket to push down on the edges of the top box. 9.1.3 Check that the lateral earth pressure on the box assembly will not exceed 20 kN/m?. 10. Summary - DO'S AND DONT'S DO - Ensure that all operatives are familiar with the User Guide, DO - Take care not to overstress the boxes (watch for bowing of the panels). DO - Check that all nuts and bolts are tight but not over tightened. DO - Check all pins and 'R’ clips are fitted DO - Follow the basic maintenance instructions. DO - Use a ladder to enter the box. DO - Wear a safety helmet. DO - Use suitable 4 leg slings and lifting equipment, DO - Provide a landing below the top of the box. This will prevent debris rolling down onto personnel inside the box. DO - Always maintain a safe batter of the unsupported parts of the trench in front of and behind the Maxi Dragbox. DO - Store boxes on their side. DON'T - Move the box with personnel inside DON'T - Hammer the box with the bucket. DON'T - Use lifting lugs for other than loading Junloading or assembly purposes, DON'T - Use damaged struts. DON'T - Use spacer combinations other than those recommended by Mabey Hire Ltd, DON'T - Use unsafe lifting equipment. DON'T - Enter unsupported parts of the excavation, DON'T - Sit astride the box struts, IF IN DOUBT CONSULT MABEY HIRE LTD. WARNING - Trenches and excavations may be confined spaces, in which case extra precautions and equipment will be required. ALWAYS - Consult a qualified person if there is any doubt about ground pressures. 11. References CIRIA Report 97 : Trenching Practice CPA (STIG) : Safely In Shoring Manual 12. General Since our policy is one of continual improvement, components may vary in detail from the descriptions given in this publication. Page 5 of 5