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THE
TECHNICA
FILE
Excavation Support Systems
Excavation
for Temporary
SupportWorks
Systems for Temporary W
Technical Services
i.i
Foreword
Welcome to issue 3 of the Groundforce Technical File. Groundforce Shorco offer for rent, what we believe to be the largest and
most comprehensive range of temporary works shoring equipment anywhere in Europe.
Our products include linear shoring such as trench boxes and waler frames, four-way hydraulic bracing - including long span, high
load capacity modular systems – and hydraulic and mechanical modular struts capable of resisting loads in excess of 5000 kN. In
addition, we can provide an extensive range of ancillary equipment and products to cater for all your safety and shoring
associated needs.
Based in Morley, near Leeds, the ISO 9001 accredited Technical Services Department has extensive knowledge and experience in
the design of temporary works solutions for excavation support. Whether it is simply a matter of providing advice over the
telephone, or a fully validated temporary works design, we can prescribe innovative solutions to the most demanding of
projects. This is underwritten by professional indemnity insurance cover.
Our industry-renowned Major Projects team manage large or complex temporary works contacts ranging from complex
basement structures to intricate station boxes and tunnel portals. This team can offer a unique personal service from concept
through to construction, with emphasis on safety, buildability and cost effectiveness.
Our qualified designers and project team have vast experience within the specialist ground support sector and actively seek to
add value to your project by engineering unique, bespoke solutions, saving you time, effort and of course money.
Summary of Services
Clear concise calculations using either limit equilibrium of soil interaction software as appropriate.
Method statements.
Site visits.
Always up to date:
Advice on installation methods and techniques. Sign up to our Technical Website
www.gftech.co.uk
Supply and instruction of our bespoke GFsafe design software package.
Design engineers will be familiar with both “Permissible Stress” and “Limit State” design concepts. At the time of writing, it remains current
practice within the UK temporary works community, to continue to adopt permissible stress concepts for small scale temporary works.
With the adoption of Eurocodes and the consequential eventual replacement of the traditional design methodology, loads or actions on
support systems will be need to be calculated and presented in terms of limit state design values. Obviously, when designing around
proprietary equipment these design loads will need to be equated to limit state resistance values for the equipment being considered.
It is vitally important therefore in the transition period between permissible and limit state philosophy to fully understand the various design
terms to ensure that load factors are applied correctly, thus ensuring that equipment is correctly specified to operate safely within its
capacity.
Evidence of safety was traditionally recognised by quoting values for load capacity (or resistance) for shoring equipment in terms of (safe)
working load capacity. That is, the ultimate values for resistance parameters (calculated by recognised standards) are reduced by a lumped
(safety) factor, typically between 1.5 and 2.0 to generate working values and subsequently quoting these in standard load charts.
These charts are then used to equate with actual or unfactored working values of load for the member being designed.
It is more difficult to specify the equivalent level of “safety” as such with a limit state approach as partial factors are applied to both the loads
(or actions) and resistances as depicted on the diagram below.
Where:
γF: Partial Factor for Load. γM: Partial Factor for Resistance.
To gain an approximate comparison between allowable and limit state designs, the safety margin can be approximately recognised by the
product of γF multiplied by γM.
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
Technical Services
i.iii
C) Basis of design
This edition of the technical file retains the concept of permissible state philosophy and consequently all load charts shown within
give values of working load (WL) in accordance with the relationship below.
The ultimate values of resistance are generally calculated using the principals contained within BS 5950: 2000.
When considering the structural resistance of a hydraulic member whether it is a flexural bracing member or a strut designed for
predominantly axial load, two checks are carried out: (a) hydraulic capacity of the ram unit and (b) the structural capacity of the member
itself. The limiting factor at the span being considered dictates the overall capacity of the system. Generally at short spans it is the hydraulic
resistance that governs load capacity; at longer spans it is usually the members resistance to buckling that dictates.
D) Load Effects
Flexural members. When calculating the working load charts in this document, the load effects considered are:
Note that:
That self weight is generally ignored as it is assumed that waling members are adequately supported along their length.
The compression is assumed to be fully restrained for calculation lateral torsional buckling.
The effective span is taken to be the distance between end pin joints.
The span for calculating the axial load is the overall length of the member.
Struts. Verification of strut capacity is somewhat more complicated due to the various load effects that need to be considered. These include:
An allowance for accidental load – generally applied as a point load applied vertically at mid-span for the most onerous effect.
Eccentricity of applied load equal to 10% of the strut diameter plus serviceability mid-span deflection; applied as a uniform moment
(P-δ effect).
Note that:
Temperature change induced load effects, are not applied in the load charts but may need to be considered on a job specific basis,
particularly in the case of MP500 struts where monitoring has indicated that these loads can be very significant.
The effective length factor used for calculating lateral buckling effects is taken as 1.0 between end swivel pivot points.
The load effects acting on a typical cross strut are represented in the diagram below:
i) Flexural members (bracing frames) - The lines on the working load graphs in this document are expressed in terms of working load
limit (formerly known as SWL). Values are calculated based on the structural bending capacity available (divided by a global factor for
live load of 1.6 to express it in WLL terms) after axial stress due to coincident axial load has been subtracted. All member resistance
calculations are in accordance with BS5950: 2000. Note that a minimum global factor of safety of 2.0 has been applied to all hydraulic
components in order to determine the working axial capacity of the integral hydraulic ram.
ii) Struts (designed to resist predominantly axial load) - The lines on the working load graphs for the Groundforce range of struts are
expressed in terms of working load limit (formerly known as SWL - see below for definition of terms) This value is calculated based on
the remaining structural capacity available (divided by a partial factor for live load of 1.6) to express it in WLL terms after deducting
bending capacity required to resist self weight, accidental loading and secondary moment effects (see diagram on i.iii). All strut
resistance calculations are in accordance with BS5950: 2000. Note that a minimum global factor of safety of 2.0 has been applied to all
hydraulic components in order to determine the working axial capacity of the integral hydraulic ram.
Definition of Terms
Characteristic Load - The load (or action) that has a specific probability (usually 5%) of not being exceeded.
Characteristic Resistance - The value of resistance / strength of a supporting member that has a specific probability (usually 95%) of
being achieved.
Design Load - The characteristic load (or action) multiplied by a partial load factor.
Design Resistance - The characteristic resistance of a member divided by the partial safety factor relating to the material.
Safe Working Load - The maximum weight or load that a piece of equipment is designed to withstand in service (or unfactored)
conditions. Note this has been replaced the term “Working Load Limit” or WLL in many publications.
Lumped or Global Factor of Safety - used in permissible load methodology and is the ratio between the failure or ultimate load and
the working load (typically between 1.5 and 2 for ground support equipment).
Partial Load Factor(s) – used in limit state design and is a factor applied to a characteristic load or material property to produce the
design load or resistance.
Ultimate Load – the maximum load that the member can carry without collapse.
Useful Reading
The following documents are recommended reading being related specifically to the temporary works design of excavations:
CPA: Safety in Shoring – The proprietary shoring and piling equipment manual.
CPA: Managing Health and Safety Risk in Excavations - Be Safe and Shore, Temporary works guidance.
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
Technical Services - engineer support
i.v
GFsafe is an easy to use and innovative in-house developed program for the design of temporary works excavation support systems.
GFdraw
GFdraw is an add-on to GFsafe which provides accurate drawings of Groundforce frames either
designed within GFsafe or specified by alternative methods.
Export function to allow frame drawings to be inserted and edited within an AutoCAD
environment for ease of further editing and annotation.
GFsafe Import function to allows frames designed within GFsafe to be drawn automatically.
Manual frame creation, allowing the drawings of frames without the need of GFsafe.
Struts and knee braces can also be added to the frame layout.
We have created an online Design Hub that contains downloadable component drawings in
industry standard formats such as 2D & 3D AutoCAD blocks and also BIM Level 2 compliant Revit
families. These components can then be inserted into your design drawing to give an accurate
representation of the Groundforce equipment that will be delivered to your site.
The Design Hub also contains links to other relevant sites where you can view technical
tutorials, read technical documents or download the latest software trials and file viewers.
To ensure you’re always fully up to date easy access to User Guides, AutoCAD Blocks, Design Notes, Technical Files, Videos and much more
are available at www.gftech.co.uk. Sign up today.
Notes:
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
BRACING SYSTEMS
LIGHT DUTY
LIGHT DUTY
BRACING SYSTEMS
1
1.1 Mechshore Double Acting Manhole Brace
1.2 GF Double Acting Manhole Brace
1.3 Single Acting Manhole Brace
Mechshore Double Acting Brace
1.1.1
Features / benefits
Single 32mm diameter corner pin connection for rapid assembly on site.
Excellent structural performance makes them ideal for higher load design
applications in deeper excavations.
Double acting hydraulics enable the legs to be both expanded and retracted
hydraulically by a suitable installation pump unit.
Integral hydraulic lock of valve enables the pump hoses to be easily released
and reconnected without fluid loss.
690, 900M and 900S legs have a rough adjustment facility for greater on site
adjustment.
Compatibility
Can be used in conjunction with Maxi Brace legs with the appropriate adaptor
shoes. See Section 3.3 (Brace Ancillaries) for more details on frame
combinations.
Technical Specification
Controlling section size: for structural assessment: 200x200x8 SHS, Grade S355 (50C) steel
690 Legs
c/w 12mm thk front and rear doubler plates.
Controlling section size: for structural assessment: 203x203x60 UC, Grade S355 (50C) steel.
900M Legs
Working Moment capacity# 155.0 kNm (reduced due to proximity of joints).
Controlling section size: for structural assessment: 203x203x60 UC, Grade S355 (50C) steel.
Steel construction, double acting 63mm bore x 43mm dia piston rod bore area 31.2cm², working pressure 413 bar (6000 psi) combined
with integral lock-off valve. Hydraulic stroke is 1m on 490 & 900 legs, 0.9m on 690 legs and 0.75m on 290 legs. Thrust to Pressure ratio ~
22kN per 1000 psi (69bar).
Operating Data
The Mechshore Double Acting Manhole Brace range comprises five leg types as shown in the table below. In addition to hydraulic adjustment,
the 690 and 900 legs have a rough adjuster unit. The effective beam width on all leg types is 220mm (i.e. clear opening is the sheet-to-sheet
dimension less 440mm less leg deflection). The deflections stated in the table are worst case i.e. at maximum load and span.
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
Mechshore Double Acting Brace
1.1.3
Manhole brace legs act primarily as flexural members designed to resist inward bending due to lateral earth pressures. As the
assembled braces support load on 4-sides, coincident axial load is also taken into account, although this has only a relatively minor effect
as axial capacity of individual legs is limited by the rated capacity of the integral hydraulic ram. Refer to the introduction section for more
explanation and a summary of load effects included within the design curves presented below.
The lines on the graph below indicate the working load limit expressed as a UDL for any particular brace leg working within its operating
range. The area directly below the lines represents the envelope for determining a safe solution. Generally, the limiting factor for all brace
configurations, apart from the 290 leg, is the bending capacity of the steelwork. Ultimate values of resistance have been calculated in
accordance with BS 5950: 2000 and these have been reduced by a lumped factor (of safety) of 1.5 to produce working load values. At
very short spans, the load capacity may be restricted by the limiting or rated axial capacity of the integral hydraulic ram unit.
As the operating range of the 290 leg is relatively small, the working load has been artificially capped at 115.0kN/m throughout its range.
General arrangement of the rough adjustment mechanism (not for 290 & 490 legs)
The GF Double Acting Manhole Brace range consists of a series of hydraulically adjustable
legs which, when assembled together, form a mid-range bracing system to support
square or rectangular excavation sizes from 2.0m to 6.0m in length.
Features / Benefits
Single 50mm diameter corner pin connection for rapid assembly on site.
The legs can to be both expanded and retracted hydraulically by a hand pump
to aid installation and removal.
Double acting legs incorporate a lock-off valve for greater security and allow
the pump hoses to be easily released and reconnected without fluid loss.
Compatibility
Can be used in conjunction with the MAXI Brace system with suitable adapter
shoes. See Section 3.3 (Brace Ancillaries) for more details on frame
combinations.
Technical Specification
Hydraulic Ram Specification: Double acting, steel construction 83mm bore x 1000mm
stroke rated axial load capacity = 150kN (FOS 2:1).
The GF Double Acting Manhole Brace range comprises four leg sizes, each with 1.0m of hydraulic adjustment facilitated by an integral
hydraulic ram. The beam width is 180mm. The clearance inside the frame is equal to the sheet-to-sheet dimension less 360mm less an
allowance for inward deflection. The deflections stated in the table are worst case i.e. at maximum load and span.
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
Single Acting Manhole Brace
1.3.1
Note: these legs are relatively light duty in terms of load capacity and the
single acting hydraulics necessitate manual retraction after pressure release.
Features / benefits
540 Legs, being constructed from high strength aluminium alloy, weigh only
35kg making them ideal for use with utility companies.
Compatibility
Technical Specification
a) 540 Legs
Controlling section size for structural assessment: approx 120mm square bespoke extruded Aluminium Section (6082TF material)
Ram Details: 50.8mm dia x 915mm stroke all alloy construction, single acting operation c/w
hydraulic lock off valve on most models. Rated ram capacity / axial load = 55kN
with a factor of safety of over 2 proven by test. Thrust to Pressure ratio ~ 14kN per
1000 psi (69 bar).
b) A and B Legs
Controlling section size for structural assessment: 120x120x10 SHS, Grade S275 (43C) steel
Ram Details: 63mm dia x 700/800mm (Leg A/B respectively) stroke all alloy construction, single
acting operation. (no lock off valve). Rated ram capacity / axial load = 100kN with
a factor of safety of 2 proven by test. Thrust to Pressure ratio ~ 22kN per
1000 psi (69 bar).
Controlling section size for structural assessment: 120x120x6.3, Grade S355 (50C) steel
Ram Details: 50.8mm dia x 460/915mm (400S/400M respectively) stroke all alloy construction,
single acting operation (no lock off valve. Rated ram capacity / axial load = 80kN
with a factor of safety of 2 proven by test. Thrust to Pressure ratio ~ 14kN per
1000 psi (69 bar).
Operating Data
Notes:
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
Single Acting Manhole Brace
1.3.3
Manhole brace legs act primarily as flexural members designed to resist inward bending due to lateral earth pressures.
As the assembled braces support load on 4-sides, coincident axial load is also generated within the supporting legs. However in the case of
single acting legs, 100% of the coincident axial load is resisted solely by the integral hydraulic ram. Therefore no axial load is transferred
into the structural casing (except at the very ends). Consequently, only bending effects are considered when calculating the working load
lines presented on the chart below.
The lines on the graph below indicate the working load limit (or safe working load), expressed as a UDL, for any particular brace leg work-
ing within its operating range. Ultimate values of resistance have been calculated in accordance with BS 5950 :2000 and these have been
reduced by a lumped factor (of safety) of 1.5 to produce working load values. At very short spans, the load capacity may be restricted by
the limiting or rated axial capacity of the integral hydraulic ram unit.
2
2.1 Maxi Brace
Maxi Brace
2.1.1
The MAXI Brace is a mid-range, heavy duty, hydraulically adjustable bracing system
suitable for supporting clear span square or rectangular excavations ranging from
3m to 12m in size. Higher load capacity and/or longer spans can be achieved by
incorporating either cross strutting of knee bracing. Modular extensions are
available to further extend beam lengths, however cross strutting is required with
these leg configurations.
Each standard leg type incorporates a hydraulic ram unit that provides 1.1m of
on-site adjustment. In addition there are three further legs which also incorporates
a pinned rough adjuster unit which provides further on-site adjustment (ie
additional 1.0m for the Type 8R, 2.0m for the Type 10R and 3.0m for the Type 12R).
Typical Applications
Features / Benefits
MAXI Legs 4 & 5 can also be adapted to be used as a medium duty hydraulic strut
with a maximum axial load of 245kN (FOS 2:1) for spans of 2.6m to 4.7m between
bearing surfaces.
The legs can be articulated (with adaptor brackets) to accommodate multi-sided i.e.
non-rectangular excavations.
Type R legs have a rough adjustment facility for greater scope for on site adjustment.
Compatibility
All Maxi Brace legs can be used in conjunction with Mega Brace, Mechshore Double Acting and GF Double Acting Manhole
Brace legs. See Section 3.3 (Brace Ancillaries) for more details on frame combinations. Modular extensions must be with cross
struts. Maxi legs and beams can also be used as the waling in raking strut systems, see section 5.5 (Strut Ancillaries).
Maxi Brace legs are available in three different configurations as illustrated in the diagrams below.
Standard Leg 4 and 5 configuration (Note these legs do not have a rough adjustment facility)
Each individual leg consists of a telescopic hydraulic ram section, and two choices of length for the outer section to achieve the overall leg
length stated in the range chart on 2.1.4. These legs cover a range of 2.9m to 5.0m when combined with any other Maxi Leg.
Standard Leg 6 to 10 configuration (Note these legs do not have a rough adjustment facility)
Each individual leg consists of a telescopic hydraulic ram section and five choices of beam length to achieve the overall leg length stated in
the range chart on 2.1.4. These legs cover an operating range of 4.9m to 10.0m when combined with any other Maxi Leg.
Each frame leg consists of a telescopic hydraulic ram section and three choices of rough adjustment unit to achieve the overall leg length
stated in the range chart on 2.1.4. These legs cover a range of 5.9m to 12.0m when combined with any other Maxi Leg.
Any Maxi leg except legs 4 & 5 can be used in conjunction with any number of fixed length modular extension
beams to create a desired leg length. Please note cross struts must be introduced as appropriate to support
each internal joint as shown above.
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
Maxi Brace
2.1.3
Technical Specification - all data refers to lateral bending about the vertical plane for
the controlling section. Cross Section through controlling
beam sections at mid-span
a) Legs 4 and 5
Outersleeve - Fabricated Steel Section - see figure opposite - Grade S355 steel
b) Legs 6 to 10
Standard Steel Section: 305x305x118 UC - Grade S355 steel Maxi Legs 4 & 5 - Outersleeve
Classification - compact
Classification - compact
d) Other factors which influence the overall working load capacity of the leg assembly
60mm Ø Rough Adj’ Pin Shear Capacity = 330kN (limited by the bearing
stress on the inner sleeve)
Maxi Legs with Rough Adjuster
Note: all pin material is 605M36T (EN16T) alloy steel (8R, 10R and 12R)
The standard Maxi Brace range consists of seven individual leg sizes; Legs 4 to 10 and have 1.1m of length adjustment via an inbuilt
hydraulic ram. Legs 8R, 10R and 12R have an additional sliding/pinned rough adjustment facility which gives 1.0m, 2.0m and 3.0m of
additional adjustment respectively (see 2.1.2). The maximum beam widths are 260mm (Maxi 4 and 5) and 350mm (Maxi 6 to 12).
Therefore the clear opening inside the frame equals the sheet-to-sheet dimensions less twice the beam width, less twice the allowance for
beam deflection - refer to graph overleaf.
Articulation
Plates
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
Maxi Brace
2.1.5
Maxi Brace Performance Chart - refer to section ’i’ for definition of terms
Maxi brace legs act primarily as flexural members designed to resist inward bending due to lateral earth pressures. As the assembled
frames support load on 4-sides, coincident axial load generated by perpendicular connecting legs is also taken into account; although this
has only a minor effect since axial capacity of individual legs is limited by the hydraulic ram. Refer to the introduction section for more
explanation and a summary of load effects included within the design curve presented below.
The Red Line on the graph below indicates the working load limit on a non-cross strutted leg expressed as a UDL throughout its span
range. The area directly below the lines (shaded grey) represents the envelope for determining a safe solution. Generally, the limiting
factor for all brace configurations is the bending capacity of the steelwork. Ultimate values of resistance have been calculated in
accordance with BS 5950 and these have been reduced by a lumped load factor of 1.5 to produce working load values. At very short spans,
the load capacity is restricted by the axial capacity of the integral hydraulic ram unit. A coincident axial load equal to the hydraulic ram
capacity, induced by the secondary legs in square or rectangular frame configurations, has been taken into account. The chart below
indicates the load and deflection performance of clear span non-modular MAXI Brace equipment across its full span range. The dark shaded
area under the red line represents the envelope in which any given MAXI Brace leg will perform safely.
The Blue Line indicates (worst case) mid-span deflection at working load limits; assuming the beam to be simply supported between the
end pinned connections
Note: This graph does not apply to modular maxi configurations. Due to need for cross struts to support the joints, the working load
capacity of modular maxi configurations is produced on a scheme specific basis. For further information contact the Technical Services
Department.
Modular Maxi beams can be linked together to produce a continuous waling beam (in a similar manner to mega brace). Increased
versatility can be achieved by linking them to Maxi legs 6 to 10 or legs 8R to 12R to provide a hydraulic length adjustment facility (see
2.1.2). Due to the limited strength in bending of the joint between modular sections, cross struts must be introduced as appropriate.
Modular Maxi configurations must therefore be designed by a qualified engineer or the GF Technical Services Department.
Typical Applications
Features / Benefits
Modular construction with simple pin connections for quick assembly on site.
Note: The joint capacity is limited by the bearing strength of the connecting leaves.
2 No. 60mm Ø Connecting Pins The Maximum length of any unsupported cantilever
must not exceed 2m.
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
BRACING SYSTEMS
HEAVY DUTY
HEAVY DUTY
BRACING SYSTEMS
3
3.1 Mega Brace
3.2 Super Mega Brace
3.3 Brace Ancillaries
Mega Brace
3.1.1
The MEGA Brace is a high load capacity modular hydraulic bracing system
designed to support square, rectangular or multi-sided excavations ranging from
3.0m to 20.0m in plan. It comprises hydraulic unit for fine length adjustment
connected to a series of modular fixed length extension pieces for course length
adjustment, connected via a simple double pinned splice. The fixed length
extensions can be connected together to form a continuous heavy-duty
waling beam when used as part of an internally strutted frame.
Typical Applications
Features / Benefits
Ideal for long excavations, where large clear spans are required.
Double acting hydraulics with integral mechanical lock off valve for ease of Product Link
installation and removal with zero fluid loss. Brace Ancillaries - Section 3.3
Strut Ancillaries - Section 5.4
Full mechanical lock off system available on special order.
Compatibility
Mega brace legs are fully compatible with Maxi Brace legs. In addition the Mega Brace can be used with proprietary mechanical or
hydraulic struts, subject to detailed design checks, to increase the overall load capacity of the waling beam. The Mega beam can also
be used as the waling in raking strut systems, see section 5.5.
The beam section width is 370mm and the overall section width, inclusive of the joint connection cleats, is 530mm. Therefore:
Note: An additional allowance for the inward deflection of the brace should be taken into account when provision of a minimum clear
opening is critical, such as in the case of an excavation required to install a prefabricated tank (see graph on 3.1.5).
Joint details.
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
Mega Brace
3.1.3
1m
1m 1m
3m Ext
3m Ext 1m
5m Extension
5m Extension 1m
5m Extension 1m 1m
5m Extension 3m Ext
5m Extension 3m Ext 1m
7m Extension 3m Ext
7m Extension 3m Ext 1m
7m Extension 5m Extension
MEGA Brace legs comprise a double acting hydraulic ram unit (with a stroke of 1m) and a series of fixed
length extension sections which are connected together to obtain the desired brace length. The above chart
provides information relating to the individual configurations of brace legs. The list is not exhaustive as
certain legs can be made up with alternative combinations of extension units.
Note: Individual clear spanning MEGA Brace legs should not contain more than three extension units unless
part of an internally strutted frame for which a detailed scheme must be provided by a qualified engineer.
Please contact Groundforce Technical Services for more advice.
Bearing: All Groundforce struts up to 250 tonnes capacity can be safely applied to the
front flange of the mega brace beam without risk of web buckling, irrespective of the
strut location in relation to the web stiffeners.
Other factors which influence the overall working load capacity of the leg assembly
Design verification of clear spanning mega legs can be undertaken by either carrying out
individual checks on the capacity of the beam, the capacity of the joint(s) in the leg’s
assembled configuration and the capacity of the hydraulic ram. Alternatively by simply
using the load chart on page 3.1.5 which takes these factors into account for standard
assembly configurations.
Where cross strutting is required, struts must be carefully located so as not to induce reverse
bending across a joint. Consideration also needs to be given to the differing hogging and
sagging moment capacities of the beam as stated above.
The bending moment capacities specified above have been calculated using the following
assumptions.
The flange of the beam in contact with the piled face is assumed to be fully restrained against lateral torsional buckling effects.
Bending due to self weight and accidental loading are ignored as it is assumed that the mega brace is supported with chain hangers
or brackets at regular intervals along its length in accordance with the recommendations stated within the user guide.
Coincident axial loading can have a significant effect on the bending capacity of the mega beam. This is particularly significant in
knee braced frame configurations where welded shear stops or clamps (see photo above) attached to the waling restrain the strut
against longitudinal movement. It is recommended that a first principal assessment of beam capacity is made where coincident axial
load exceeds 500kN. Contact the technical department for more advice.
The reverse bending or hogging moment value for the beam quoted above considers potential buckling of the inner compression
flange taking into account load application is “destabilizing”. Web stiffeners are assumed to provide a degree of lateral and torsional
restraint to this flange.
Bearing loads applied to the inner flange between stiffener locations (in cross strut applications) are limited by web strength in relation
to the “stiff bearing length“. First principal checks are recommended where strut loads exceed 2500kN. Contact the Technical
Department for more advice.
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
Mega Brace
3.1.5
Mega Brace Performance Chart for 40T ram units - refer to section ’i’ for definition of terms
Mega brace legs act primarily as flexural members designed to resist inward bending due to lateral earth pressures. As the assembled
frames support load on 4-sides, coincident axial load generated by perpendicular connecting legs is also taken into account; although this
has only a relatively minor effect since axial capacity of individual legs is limited by the hydraulic ram. Refer to the introduction section for
more explanation and a summary of load effects included within the design curve presented below.
The chart below indicates the load and deflection performance of clear span i.e. non-strutted MEGA Brace waling beams across its full span
range. The darker shaded area represents the envelope in which any given MEGA Brace leg will perform safely. Ultimate values of
resistance have been calculated in accordance with BS 5950 and these have been reduced by a lumped load factor of 1.5 to produce
working load values. At shorter spans, the load capacity is restricted by the axial capacity of the integral hydraulic ram unit.
The Three Red Lines indicate the working load limit of MEGA Brace legs with coincident axial loads of zero, 200kN and 400kN induced in
them by the secondary legs. These lines govern the WLL of the MEGA Brace legs between spans of approximately 11.0m to 20.0m. The
Green Line is the WLL governed by the 400kN axial load capacity of the secondary legs as limited by the hydraulic ram. This line governs
the WLL of the MEGA Brace between spans of approximately 3.0m and 11.0m. The Blue Line indicates the approximate worst case
(inward) deflection of a MEGA beam calculated at mid-span under working load limit conditions. Note: This graph does not apply to cross
strutted configurations. The working load capacity of these is produced on a scheme specific basis. See notes on P4. For further
information contact the Technical Services Department.
Mega Brace Performance Chart for 50T ram units - refer to section ‘i’ for definition of terms
The latest Mega brace rams incorporate a 500kN or 50T hydraulic ram to improve performance,
particularly at shorter spans where axial compression is a limiting feature. All other leg details remain
the same and 40T and 50T units are interchangeable.
The performance chart for legs incorporating 50T rams is shown below, this is also represented by a
matrix chart which explains potential modes of failure at various spans and configurations.
Note: The two hydraulic units appear virtually identical except for a “MEGA 50T” stencil on the 50T
ram units.
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
Mega Brace
3.1.7
As a special order option only, the hydraulic unit on 500kN mega rams can be fitted with
locking rods to effectively isolate the hydraulic ram after installation and pressurisation.
The system has been designed to give ultimate peace of mind in highly sensitive situations
where it is considered not acceptable to rely on hydraulic pressure alone to support load.
A pair of high tensile 36mm diameter threaded rods are inserted through anchor plates
welded to both the sliding inner and outersleeves on the hydraulic unit. After insertion, the
rods are secured with locking nuts either side of the thrust plates. Heavy duty rubber
washers are inserted on the compression thrust faces to introduce a small amount of
flexibility into the system so the rods do not immediately attract all the load (being more
rigid than the hydraulic ram)
Note: this system is designed as an emergency failsafe feature to come into play in the
extremely unlikely event of hydraulic ram failure. The design (in compression) of the locking
rods includes for a reduced factor of safety of 1.2 to reflect this. Note that this feature is not available on all ram units and is therefore
subject to special order only and at additional cost.
Mega ram
sliding
innersleeve
Mega ram sliding outersleeve
Standard corner
pin detail
Integral anchorage points
on sliding sleeves
rubber the unlikely event of ram failure. Hard rubber washers are inserted
washers under steel washers on the thrust side of the rods as shown opposite.
These washers allow a small amount of axial movement within the
locking system so as to permit any subsequent (geotechnical) load
increase after installation to be distributed back into the hydraulic
ram; which is the main load bearing component.
LOLER defines lifting equipment as “work equipment for lifting or lowering loads”.
Restraining chains are not (and must not be) used for lifting or lowering a load and
therefore fall outside the scope of LOLER. Consequently the regime specified by
LOLER for regular thorough examination is therefore NOT applicable to these chains.
The Provision and Use of Work Equipment Regulations 1998 (PUWER) however,
require that all work equipment is maintained (Regulation 5) and inspected
(Regulation 6) at suitable intervals and it is standard practice to inspect each
restraining chain assembly before it is sent out on hire. This forms part of the
supplier’s in-house equipment maintenance procedures.
Chains are typically hooked onto the tops of the sheets or piles and attached to
dedicated attachment points on the equipment. The chains are also used to link
together lower frames to form continuous support. The amount and location of
restraining chains will always be indicated on the scheme specific drawings.
Note: The angle between the chain and the sheet must not be greater that 30° (2:1)
The individual components which constitute the restraining chain assembly are
shown below.
Product Link
For further advice on restraining chains visit:
www.cpa.uk.net/p/Shoring-Technology-Interest-Group/
Where different bracing leg types are not directly interchangeable, a range of
adapter shoes have been developed to enable certain bracing frame legs types to
be connected together. This enables more economic design solutions to be
achieved in certain situations. For example, a lighter duty frame could be used on
the shorter side of an excavation with a heavier duty item on the longer side. Thus
achieving a more cost effective solution and lighter overall frame.
When combining frame types together however, care must be taken to ensure that
the smaller legs are not overloaded axially.
The inclusion of adapter shoes will in most cases affect the operating range of the
legs, in some cases very significantly - see table below.
Compatibility Tables
Not Not
Mega Compatible Compatible
Compatible Compatible
Compatible Compatible
Maxi Brace Compatible Compatible
Adapters Adapters
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Brace Ancillaries - Shear Clamps
3.3.3
Shear stops are required to transmit lateral or non-perpendicular strut forces into
waling members as in the case of knee braces. The re-usable “Shear Clamp” has
been developed as an economic and practical alternative to the traditional welded
shear stop.
The clamp is attached to the front face of the Mega Brace beam and comprises six,
rotating, high tensile, toothed, eccentric cams that grip onto the upper and lower
edges of the flange. They are pre-set onto the beam flanges using a special tool
and once in place, any load applied through the prop and into the clamp induces
self tightening of the cams.
When specified, the Shear Clamps will be either installed prior to delivery or onsite
by trained Groundforce personnel.
Advantages
Shear Clamps are fitted prior to the waling beam prior to delivery to site and are
consequently ready to go into service straight away.
Speeds up the strut installation process as they act as a guide for strut positioning, no
additional drilling, bolting or welding is required. The strut can simply be pumped out
and pressurised as per the user guide of specific instructions until it pushes up against
the shear clamp block.
Environmentally friendly as its reuse capability eliminates the need to weld and
subsequently remove disposable steel restraint blocks to/from the waling beam.
Compatibility
Can be used in conjunction with all Groundforce strut types – up to and including the
MP150 subject to design checks.
Load Capacity
Single shear clamp load capacity = 570 kN in direct shear - Factor of safety of 2
proven by test.
Two or more clamps can be used together where greater shear restraint is required
MECHANICAL
STRUTS
4
4.1 MP30 - 30 Tonne Mechanical Strut
4.2 MP60 - 60 Tonne Mechanical Strut
4.1
MP30
The Technical Information for this product
is currently in development.
The MP60 is a modular format medium-duty mechanically adjustable strut, combining the compressive
strength of steel tube with the convenience of mechanical length adjustment. MP60’s are used where single or
multi-directional support is required to excavations or cofferdams and mechanical, as opposed to hydraulic
adjustment is preferred . MP60’s use 350mm diameter tubular sections as the main structural member. At shorter
spans, the local capacity of the screw unit limits the axial load and at longer spans the potential for lateral
buckling of the extension sections dictate overall axial capacity.
The MP60’s can be configured to work within an operating range of 1.6m to 16.0m
without the need for intermediate support and can withstand working axial loads up to
60tonnes at shorter spans.
Typical Applications
Features / benefits
To aid removal under residual load, the locking nut incorporates a Strut Ancillaries - Section 5.4
self lubricating nylon washer on the thrust face and knocking bars
positioned around the circumference.
Mechanical screw specification : single 160mm Ø x 19mm wall thickness screws and 100mm long nuts (all of Grade ST52 steel).
Axial capacity of screw unit: 600kN (working load) at max length which includes a “global” safety factor of 2.0 (proven by test).
Limiting parameters: 1.56m (Minimum span), 16.0m (Maximum span un-supported), 8.5m (Maximum span at maximum load).
Global FOS on steelwork design = 1.5 calculated in accordance with BS 5950: 2000.
Extension bar specification: 355.6 x 8 CHS grade S355 with 460mm Ø flanges.
4m Extension
4m Extension 4m Extension
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MP60 Mechanical Strut
4.2.3
MP60 Mechanical Strut - Working Load Chart - see section ’i’ for definition of terms
The lines on the chart below indicate the maximum working axial strut loading at various spans and includes an allowance for either 0kN,
10kN or 20kN accidental load applied at mid-span (see load effect diagram below). The area under the lines indicate the envelope for a
safe solution. It is not considered necessary to account for thermal effects in MP60 struts when used in the UK and therefore this is not
included in this chart. Please refer to section ’i’ for more information on load effects on struts.
Explanation: The horizontal Green portion of the lines on the chart indicates the working axial capacity of the strut assembly as limited by
the local capacity of the mechanical screw unit i.e. 570kN. The sloping lines indicate a load reduction from this value due to the potential for
buckling of the steel tubular extension members. The sloping Green Line represents the working load after taking into account a 20kN mid
-span accidental load. The Red Line represents the working load after taking into account a 10kN accidental load. The Blue Line represents
the working load without allowing for any accidental loading effects. The blue line must be used with caution and after a full risk analysis.
The lines on the graph below are expressed in terms of working load limit. These values represent the remaining structural capacity or
resistance once allowances have been made for the bending effects induced by self weight, accidental loading, eccentricity and secondary
moments (see diagram below and also notes in section ‘i’). All steelwork structural resistances have been calculated in accordance with
BS5950: 2000. A global factor of 1.6 has been applied to ULS values to reduce them to working values. In addition the adjustable screw unit
has been subjected to load tests. Its maximum working local capacity of 570kN represent a global safety factor in excess of 2.
Ancillary Components
End Bearing Plate: The bearing plate has been designed to efficiently
distribute load internally into the waling beam or structure up to a maximum
inclined angle of thrust of +/- 45° to the normal.
The effective strength of the strut is also dependant on the local strength of
the supported member and/or the shear capacity of the web if a UC section
waling beam is used for example. The bearing strength of any waling should
be checked as a matter of course.
The bearing plate includes 22mm diameter pre-drilled holes (as shown
opposite) to enable bolted connections to waling flanges or capping beam
faces.
The bearing plate can be fitted with support cleats in a variety of positions to
facilitate the strut axis, once installed, aligning with the webs of various
Groundforce waling beams.
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HYDRAULIC
STRUTS
5
5.1 MP50 - 50 Tonne Hydraulic Strut
5.2 MP125/150 - 125/150 Tonne Hydraulic Struts
5.3 MP250 - 250 Tonne Hydraulic Strut
HYDRAULIC
STRUTS
5.4 Strut Ancillaries
MP50 Hydraulic Strut
5.1.1
The MP50 is a modular format medium-duty hydraulic strut combining the compressive strength of steel tube
with the convenience of hydraulic actuation for length adjustment and pre-loading potential. Swivel end
bearing units allow for various strutting alignments within an excavation, with or without waling beams.
MP50’s use 350mm diameter tubular sections as the main structural member. At shorter spans, the hydraulic
capacity of the integral ram limits the axial load and at longer spans, the potential for lateral buckling of the
extension sections dictate overall axial capacity.
MP50 struts can be configured to work within an operating range of 2.4m to 18.0m without the need for
intermediate support and are able to withstand working axial loads at shorter spans up to 53 tonnes.
Typical Applications
Features / benefits
Ram Construction: Steel, Double acting incorporating a mechanical lock-off valve on the full bore side.
Ram specification: Bore - 125mm, Piston rod diameter 90mm, stroke 1200mm, full bore area 123mm²,
annulus area 59.1cm², fluid volume required to achieve 50% stroke = 3.8 litres.
0.5m Extension 65
2m Ext 1m
1.0m Extension 100
4m Extension 2m Ext
4m Extension 2m Ext 1m
8m Extension
8m Extension 1m
8m Extension 2m Ext
8m Extension 2m Ext 1m
8m Extension 4m Extension
The MP50 Strut has a modular format comprising a hydraulic unit and a series of bolt together fixed length extension units to obtain the desired
length. The table above shows standard configurations of the strut. The list is not exhaustive as other permutations are possible and valid, how-
ever a strut assembly should not incorporate more than four joints in total.
It is possible to use additional mid-span vertical support such as king piles or plunge columns to extend the range of maximum performance. This
and requests for non-standard configurations other than those shown above must be verified by the Groundforce Technical Services Department.
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
MP50 Hydraulic Strut
5.1.3
MP50 Hydraulic Strut - Working Load Chart - see section ’i’ for definition of terms
The lines on the chart below indicate the maximum working axial strut loading at various spans and includes an allowance for either 0kN,
10kN or 20kN accidental load applied at mid-span (see load effect diagram below). The area under the lines indicate the envelope for a
safe solution. It is not considered necessary to account for thermal effects in MP50 struts when used in the UK and therefore this is not
included in this chart. Please refer to section ’i’ for more information on load effects on struts.
Explanation: The horizontal Green portion of the lines on the chart indicates the working axial capacity of the strut assembly as limited by
the capacity of the hydraulic unit i.e. 530kN. The sloping lines indicate a load reduction from this value due to the potential for buckling of
the steel tubular extension members. The sloping Green Line represents the working load after taking into account a 20kN mid-span
accidental load. The Red Line represents the working load after taking into account a 10kN accidental load. The Blue Line represents the
working load without allowing for any accidental loading effects. The blue line must be used with caution and after a full risk analysis.
The lines on the graph below are expressed in terms of working load limit. These values represent the remaining structural capacity or
resistance once allowances have been made for the bending effects induced by self weight, accidental loading, eccentricity and secondary
moments (see diagram below and also notes in section ‘i’). A minimum global factor of safety of 2.0 has been applied to all hydraulic
components in order to determine the overall working axial capacity of the hydraulic ram. Regarding steelwork, structural resistances have
been calculated in accordance with BS5950: 2000. A global factor of 1.6 has been applied to ULS values to reduce them to working values.
Ancillary Components
End Bearing Plate: The bearing plate has been designed to efficiently
distribute load internally into the waling beam or structure up to a maximum
inclined angle of thrust of +/- 45° to the normal.
The effective strength of the strut is also dependant on the local strength of
the supported member and/or the shear capacity of the web if a UC section
waling beam is used for example. This should be checked as a matter of
course.
The bearing plate includes 22mm diameter pre-drilled holes (as shown
opposite) to enable bolted connections to waling flanges or capping beams.
The bearing plate can be fitted with support cleats in a variety of positions
to enable the thrust to be transferred centrally into the webs of various
Groundforce waling beams.
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MP125 & 150 Hydraulic Struts
5.2.1
Product Note:
MP125 and MP150 struts are virtually identical
except for a higher capacity hydraulic ram in the
MP150 hydraulic units
Both MP125 and MP150 struts use nominally 500mm diameter tubular sections as the
main structural member. At shorter spans, the hydraulic capacity limits the axial load
and at longer spans, the potential for lateral buckling of the extension sections
dictates overall axial capacity.
Where greater axial capacity is required over longer spans the strut can
utilise heavy duty, thicker walled extension pieces - see design chart on
page 5.2.4.
Typical Applications
Swivel end bearing plates provide a zero moment end connection and
can articulate laterally up to 45° for knee brace and raking applications.
Two alternative swivel pin holes are provided to ensure the “line of
action” is carried through the back face of the end bearing plate at all
strut angles (see photo opposite).
Ram Construction: Steel, Double acting incorporating a mechanical lock-off valve on the full bore side.
Ram specification: Bore - 200mm, Piston rod diameter 140mm, stroke 1150mm, full bore area 314mm²,
annulus area 160.2cm², fluid volume required to achieve 50% stroke = 8.9 litres.
Pressure/load ratio - 21.6 tonnes per 1000psi (69 bar) induced pressure.
Extension Construction: 508Ø x 11.1mm thick (standard) or 14.3 mm thick (heavy duty) CHS grade S355 .
Extension lengths: 0.5m , 1.0m , 2.0m#, 4.0m# and 8.0m# - # available in heavy duty format.
Flange details: 640mm Ø / 30mm thick; connected with 12No. M24 grade 8.8 bolts - min tightening torque 550Nm
Working bending moment capacity of flange under zero axial load = 240kNm.
Swivel Pin details: 108mm Ø (EN19T) - optional load pin can be used in lieu.
Bearing Plate Articulation: +/- 45° from the normal.
MP125 / 150 Operating Range/Weight Chart (Note : MP125 strut assemblies weigh 25kg less than weights shown in the chart below)
4m Extension 2m Ext 1m
8m Extension
8m Extension 1m
8m Extension 2m Ext
8m Extension 2m Ext 1m
8m Extension 4m Extension
8m Extension 4m Extension 1m
The MP 125 / 150 struts have a modular format comprising a hydraulic unit and a series of bolt together fixed length extension units to
obtain the desired length. The table above shows standard configurations of the strut. The list is not exhaustive as other permutations are
possible and valid, however the strut should not use more than three extension pieces in a single assembly.
Heavy duty extensions pieces or additional mid-span vertical support can be used to extend the range of maximum performance. This and
requests for non-standard configurations other than those shown above must be verified by the Groundforce Technical Services Department.
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
MP125 & 150 Hydraulic Struts
5.2.3
MP125 / 150 Hydraulic Strut - Working Load Chart - refer to section ‘i’ for more information
The lines on the chart below indicate the maximum working axial strut loading at various spans and includes an allowance for either 0kN,
10kN or 20kN accidental load applied at mid-span (see load effect diagram below). The area under the lines indicate the envelope for a
safe solution. It is not considered necessary to account for thermal effects in MP125 / 150 struts when used in the UK and therefore this is
not included in this chart. Please refer to section ’i’ for more information on load effects on struts.
Explanation: The horizontal Green portion of the lines on the chart indicates the working axial capacity of the strut assembly as limited by
the capacity of the hydraulic unit i.e. either 1250kN / 1500kN. The sloping lines indicate a load reduction from this value due to the
potential for buckling of the steel tubular extension members. The sloping Green Line represents the working load after taking into
account a 20kN mid-span accidental load. The Red Line represents the working load after taking into account a 10kN accidental load. The
Blue Line represents the working load without allowing for any accidental loading effects. The blue line must be used with caution and
after a full risk analysis.
The lines on the graph below are expressed in terms of working load limit. These values represent the remaining structural capacity or
resistance once allowances have been made for the bending effects induced by self weight, accidental loading, eccentricity and secondary
moments (see diagram below and also notes in section ‘i’). A minimum global factor of safety of 2.0 has been applied to all hydraulic
components in order to determine the overall working axial capacity of the hydraulic ram. Regarding steelwork, structural resistances have
been calculated in accordance with BS5950: 2000. A global factor of 1.6 has been applied to ULS values to reduce them to working values.
Ancillary Components
End Bearing Plate: The bearing plate has been designed to efficiently distribute load into the waling beam or structure over a stiff bearing
length of 600mm up to a maximum inclined thrust angle of 45° to the normal. Up to 25° the central pinhole can be used (depending on
direction of the angle) from 25°, up to 45° the offset pinhole is used to ensure that the line of action of the thrust remains through the
bearing plate.
The effective capacity of the strut is also dependant on the local bearing strength of the waling member and/or the shear capacity of the
web if a UC section waling beam is used for example. This should be checked as a matter of course. The bearing plate includes several
22mm diameter pre-drilled holes to enable bolted connections to waling members or to attach a cleat attachment plate.
Note: MP125 Bearing Plate has Ø102 holes for Swivel Pin
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MP250 Hydraulic Strut
5.3.1
Product Link
Strut Ancillaries - Section 5.4
MP500 - Section 6.1
The MP250 is a modular format high load capacity hydraulic strut combining the
compressive strength of steel tube with the convenience of hydraulic actuation for
length adjustment and pre-loading potential. Swivel end bearing units allow for
various strutting alignments within an excavation, with or without waling beams.
MP250 struts use 610mm diameter tubular sections as the main structural member.
At shorter spans, the hydraulic capacity limits the axial load and at longer spans,
the potential for lateral buckling of the extension sections dictates overall axial
capacity.
The MP250 has an practical operating range of 3.1m to 25.0m without intermediate
support and can withstand working loads up to 250 tonnes at shorter spans. For
higher load / longer span applications, it is possible to combine the MP250 hydraulic
unit with 1220mm (super tube) diameter extension pieces, using appropriate
adaptor pieces,
Typical Applications
The MP250 is designed to provide direct support between concrete capping beams in
basement type excavations. However it can be used to span steel section waler
beams with appropriate bearing checks.
MP250 struts combines the strength of steel tubes with the convenience of
hydraulic adjustment.
Hydraulic units can be used with super tube extensions to achieve clear spans up to
48.0m, depending on loading conditions.
Swivel end bearing plates provide a zero moment end connection and can
articulate laterally up to 45° for knee brace and raking applications.
Two alternative swivel pin holes are provided to ensure the “line of action” is
carried through the back face of the end bearing plate at all strut angles (see photo
opposite).
Provides 1m of double acting hydraulic adjustment with integral lock-off valve for
simple zero fluid loss installation and removal techniques.
Individual struts can be fitted with the Groundforce wireless, fully automated, load
monitoring system.*
The MP250 hydraulic units can be fitted with a mechanical lock-off system. - special
order only.*
Technical Specification
Ram Construction: Steel, double acting incorporating a mechanical lock-off valve on the full bore side.
Ram specification: Bore - 250mm, Piston rod diameter 180mm, stroke 1050mm, full bore area 491mm²,
annulus area 236cm², fluid volume required to achieve 50% stroke = 14 litres.
Pressure/load ratio - 33.8 tonnes per 1000psi (69 bar) induced pressure.
Standard Extensions Fabricated from 610 x 12.7 grade S355 CHS; available in 0.5m, 1.0m, 2.0m, 4.0m, 8.0m & 12.0m long.
Standard lengths - see weight chart on 5.3.2. - also compatible with 1220 x 16 super tube extensions.
Connection Flanges 810mm Ø / 30mm thick; connected with 8No. M30grade 8.8 bolts - min tightening torque 1085Nm.
Working bending moment capacity of flange under zero axial load = 336kNm.
Swivel Pin 120mm Ø (EN19T) - optional load pin can be used in lieu.
Ancillary Components
End Bearing Plate: The bearing plate has been designed to efficiently distribute load internally into
the waling beam or structure over a stiff bearing length of 750mm up to a maximum inclined thrust
angle of 45° to the normal. Up to 25°, the central pinhole can be used (depending on direction of
the angle) from 25° up to 45° the offset pinhole is used to ensure that the line of action of the
thrust remains through the bearing plate.
The effective strength of the strut is also dependant on the local bearing and buckling strength of
the waling member and/or the shear capacity of the web if a UC section waling beam is used for
example. This should be checked as a matter of course. The 750 mm wide end bearing plate
includes several 33mm diameter holes to enable bolted connections to waling members or to
attach a cleat attachment plate.
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MP250 Hydraulic Strut
5.3.3
4m Extension 2m Ext 1m
8m Extension
8m Extension 1m
8m Extension 2m Ext
8m Extension 2m Ext 1m
8m Extension 4m Extension
8m Extension 4m Extension 1m
8m Extension 8m Extension
The strut has a modular format comprising a hydraulic ram unit and a series of bolt together fixed length extension units to obtain the
desired length. The table below shows standard configurations of the strut. The list is not exhaustive as other permutations are possible
and valid, however the strut should not use more than four extension pieces in a single assembly.
Additional mid-span vertical support via say king piles, or plunge columns, can extend the range of maximum performance. This and
requests for non-standard configurations other than those shown below must be verified by the Groundforce Technical Services
Department.
To connect the standard extensions and the hydraulic ram (all 610mm dia) to the larger
“Super” Extensions (1220mm), a 1.0m long tapered adapter piece is utilised. For each
strut assembly, two adapter pieces are required. Brief Technical Specification - refer to
Struts incorporating super tubes are very heavy, it is therefore essential to have a Super Tube: 1220 x 16mm wall
detailed lifting and installation / removal plan in place prior to commencing work. It is thickness grade S355 CHS.
essential that the on-site assembly and installation of these struts is supervised by a Flange connection: 8/16 16 No. M30
Groundforce Engineer. grade 10.9 bolts on 1150mm PCD.
Due to the many variables and checks involved in designing using super tubes, it is Flange diameter: 810mm / 1420mm.
strongly recommended that any such design work is carried out by a Groundforce
engineer, Please contact the technical department for advice. Schedule of Component Weights:
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MP250 Hydraulic Strut
5.3.5
MP250 Hydraulic Strut - Working Load Chart - refer to section ‘i’ for more information
The lines on the chart below indicate the maximum working axial strut loading at various spans and includes an allowance for either 0kN,
10kN or 20kN accidental load applied at mid-span (see load effect diagram below). The area under the lines indicate the envelope for a
safe solution. It is not considered necessary to account for thermal effects in MP250 struts when used in the UK and therefore this is not
included in this chart. Please refer to section ’i’ for more information on load effects on struts.
Explanation: The horizontal Green portion of the lines on the chart indicates the working axial capacity of the strut assembly as limited by
the capacity of the hydraulic unit i.e. 2500kN. The sloping lines indicate a load reduction from this value due to the potential for buckling of
the steel tubular extension members. The sloping Green Line represents the working load after taking into account a 20kN mid-span
accidental load. The Red Line represents the working load after taking into account a 10kN accidental load. The Blue Line represents the
working load without allowing for any accidental loading effects. The blue line must be used with caution and after a full risk analysis. The
Black Line represents the working load with super tube extensions used in lieu of the standard 610mm diameter items. It is strongly
recommended that strut configured with super tube extensions are verified by a Groundforce Engineer
The lines on the graph below are expressed in terms of working load limit. These values represent the remaining structural capacity or
resistance once allowances have been made for the bending effects induced by self weight, accidental loading, eccentricity and secondary
moments (see diagram below and also notes in section ‘i’). A minimum global factor of safety of 2.0 has been applied to all hydraulic
components in order to determine the overall working axial capacity of the hydraulic ram. Regarding steelwork, structural resistances have
been calculated in accordance with BS5950: 2000. A global factor of 1.6 has been applied to ULS values to reduce them to working values.
For raking strut applications, it is necessary to use bespoke strut end adaptors in
lieu of the standard end bearing plates to enable their range of struts to connect
safely and effectively to standard waling beams.
There are three different types of Raking Strut Adapters which permit various
strut / waling combinations as indicated in the matrix opposite. The Raking Strut
Adapters are designed to allow efficient load transfer, distribution and line of
thrust into the waling beam without risk of failure by overturning. It will be
necessary however to provide some form of uplift restraint to the waling beam as
shown in the picture opposite.
Advantages
Provides a connection between waler and prop whilst ensuring efficient load transfer.
Compatibility Matrix
Connection Method
Connection of the Raking Strut Adapters for the Mega Brace can only be made at the web stiffener locations. Careful consideration must
therefore be given to the layout of the struts within the excavation. For the Maxi Brace adapter these can be positioned anywhere along
the beam face (except at joint locations) where full contact can be made between the bearing plate and the beam.
Mega Brace and 125 and 150 Tonne Struts - 10° to 45° to the horizontal.
Bespoke connections
We have developed a range of ancillary components to assist in facilitating load bearing connections between frame components and the
wall member being supported. Below is a sample of some connection details that can be specified on a site specific basis. Please contact
the Technical Department for more information or advice.
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Load Monitoring of Struts
5.4.3
Groundforce are able to offer a real time monitoring system to report on the actual loads in insitu props. The system uses
wireless technology linked to the GPRS network to provide a 24/7 monitoring service of prop loads from any site location . The
heart of the system is a specially designed, electronic load pin which replaces the standard item within the strut end swivel unit.
When connected to an acquisition module, the pin transmits load data at pre-programmed intervals which is captured either by a
simple hand held reader or via a sophisticated web based system.
Manual data access via a hand-held reader, or fully automated web based system
through the Groundforce Online site.
Multiple warning or trigger level alert levels can be programmed into the processor
unit which automatically generates email or SMS notifications if exceeded.
6
6.1 MP500 - 500 Tonne Hybrid Strut
HYBRID
STRUTS
MP500 Strut
6.1.1
The strut has been designed to combine the well known benefits of
hydraulic adjustment and pressurisation with the safety and security of
the axial being resisted by large diameter screw jacks. A specially
designed release mechanism on the screws enables the strut to be
released in a controlled manner, even when under significant residual
loading.
Typical Applications
The strut employs an integral hydraulic ram with 0.5m stroke for rapid
installation and on-site adjustment.
The mechanical load holding feature provide increased strut stiffness over
non-mechanical hydraulic struts.
Employs a modular extension system using 1.2m Ø super tubes to enable Product Link:
large clear spans to be achieved. For further information on
An optional integral wireless on-board load monitoring system can be super tube exts’ refer to 5.3.4
Design Considerations
Although basic technical information is tabulated in the following pages, it is recommended that the design of MP500 struts and super
tubes is carried out from first principals on a job by job basis so as to fully assess the loads and combination of loads acting on individual
struts.
The MP500 strut is made up of a number of distinct components (see picture below) each with their own load characteristics, which when
bolted together in a specific configuration will dictate the overall load capacity of the strut. Some basic technical information on the various
components is provided within this document, however due to the complexity of the design considerations relating to these struts (see
section ‘i’) and the combination of components of differing strengths it is strongly recommended that design verification for MP500 struts
are carried out on a first principal, job specific basis by a qualified and experienced Groundforce Major Project Engineer.
5
4 3
1. Adjustable unit - Offers 0.5m of on-site adjustment. Maximum working axial load capacity is 5000kN: this includes a global FOS = 2.0
Note: this refers to the maximum load capacity (or resistance) of the twin screws without taking into account any load reduction into
account for potential buckling of the complete strut assembly at longer spans. Refer to the basis of design section (section ‘i’) and the
load chart accompanying notes on page 6.1.5 for more information.
2. Super tube extensions - Fabricated from 1220mm Ø x 16mm thk grade S355 cold formed CHS of cross-sectional area of 605.3cm2.
They are available in 1m, 2m, 4m, 8m, 10m, & 12m standard modular lengths. The 8m,10m & 12m extensions are pre-cambered to
reduce self-weight deflection. Overall flange diameter is1420mm and units are connected by 16No. M30 Grade 10.9 bolts - tightening
torque 1650Nm. Working bending moment capacity of the flange joint is 1567kNm.
3. 1220 / 610 Tapered adaptor piece - 1m long to connect super tubes to end bearing components. The large flange is as per the super
tube. The smaller flange is 810mm overall diameter and uses 8No. M30 Grade 10.9 bolts - tightening torque 1650Nm. The working
bending moment capacity of flange is 420kNm.
4. 0.5m long 610mm Ø short infill extensions - ex 610mm Ø x 13.5mm grade S355 tube with additional stiffening ribs.
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MP500 Strut
6.1.3
Nominal unfactored self-weight (udl) for design purposes = 5.5kN/m length of strut.
Hydraulic Ram Details: Note the ram is used for installation and pre-stressing purposes only.
Ram construction: Steel, double acting hydraulics incorporating a mechanical lock-off valve on the full bore (load bearing) side.
Ram dimensions: Bore - 250mm, piston rod diameter 140mm, stroke 500mm, full bore area 490.9cm², annulus area 336.9cm², fluid
volume required to achieve 50% stroke ~ 4 litres.
Pressure / load ratio: ~442kN per 1000psi (69 bar) - maximum possible induced pre-stress load ~1,800 kN Note: Higher pre-loads can
be achieved using specialist supplementary jacking equipment; refer to technical services for more information.
Screw Details: Note these are designed to resist all of the applied axial load shared equally between both screws.
Mechanical screws: 2 No. solid 160mm Ø acme thread screw bars with 100mm long locknuts (all Grade ST52 steel) - 500mm of
adjustment is available.
Working axial capacity: 2500kN per screw at max stroke which includes a FOS = 2.0 (proven by test).
The centrally mounted hydraulic unit (1) with integral hydraulic ram (2) is used to adjust the strut to its desired length and induce pre-load
(up to 1800kN maximum) whilst at the same time, interaction between the sliding inner and oversleeves resists the bending moment and
shear induced by the self weight of the prop. Once pressurised, the twin mechanical screw jacks (3) are locked in place to isolate the
hydraulics from further load increase. The twin screw arrangement transfers the axial load through a heavily reinforced diaphragm plate (4)
and into 1.2m Ø super extensions (5). Special tapered washers (6), retained by a radial spit collars (7), fit between the locking nut and the
bearing plate. The collars can be loosened off allowing the washers to self-extrude outwards. This enables the lock nuts to be released
even when the screw is under residual load. A 1.5m long x 0.6m deep 30mm thick stiffened end bearing (8) plate transfers load into the
support walls, waling or a capping beam. The bearing plate is pre-drilled with 36mm Ø holes to accept fixing bolts as required.
7 6
5
3
4
Video Link: Watch this video, 2
8
and more on our YouTube Channel:
www.youtube.com/vpgroundforce
MP500 - Key Component Identification
Ancillary Components
The MP500 strut is designed for spanning between walls or capping beams at a right angles. It is not designed for raking or knee bracing
applications. Consequently connection to non-perpendicular faces will need to be accommodated by corbels incorporated into the capping
beams.
Adjustable end: Plate size: 1500mm x 600mm x 30mm thick c/w 12No. 36mm Ø holes for fixing bolts.
Fixed end: Plate size: 1000mm x 800mm x 20mm thick c/w 8No. 36mm Ø holes for fixing bolts.
Load Pin
Bearing Plate - Fixed or Swivel End
Load Monitoring
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MP500 Strut
6.1.5
The strut assembly uses a modular extension format comprising an adjustable unit connected to a series of bolt together fixed length
extension units to obtain the desired length. The table below shows standard configurations of the strut. The list is not exhaustive as other
permutations are possible and valid, however the strut should not use more than four extension pieces in a single assembly. Note that
0.5m infill extensions can be incorporated at the non-adjustable end to increase overlap between strut configurations.
12m Extension
12m Extension 1m
12m Extension 2m
12m Extension 2m 1m
MP500 Hybrid Strut - Load Chart - see section ’i’ for definition of terms
The lines on the chart below indicate the maximum working axial strut loading at various spans and includes an allowance for either 0kN,
10kN or 20kN accidental load applied at mid-span (see load effect diagram below). The area under the lines indicate the envelope for a
safe solution. No allowance for thermal effects is included in this chart which can be significant. Please refer to the design
consideration note in the text box below.
Explanation: The Green horizontal line on the chart indicates the working axial capacity of the strut assembly as limited by the local
capacity of the adjustable unit i.e.5000kN. The sloping lines indicate a load reduction from this value due to the potential for buckling of the
steel tubular extension members. The sloping Green Line represents the working load after taking into account a 20kN mid-span accidental
load. The Red Line represents the working load after taking into account a 10kN accidental load. The Blue Line represents the working load
without allowing for any accidental loading effects.. The blue line must be used with caution and after a full risk analysis.
Design Considerations
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SHEETS
AND PILES
7
7.1 Trench Sheets
7.2 Sheet Piles
AND PILES
SHEETS
Trench Sheets
7.1.1
Groundforce offer a comprehensive range of cold formed lapped trench sheets and
interlocking light pile sections to provide a cost effective solution for most excavation
support applications. Many of the sections are produced from high yield steel which
provides an exceptional strength-to-weight ratio resulting excellent durability whilst
driving and resistance to on-site damage.
Range of light and heavier sections, ideal for most general situations.
Hot rolled sheet piles sections are also available (see section 7.2)
There are a number of factors that need to be considered when selecting a choice of trench
sheet. The first basic decision is whether to use a lapped or interlocking profile. This decision is
generally linked to the presence of groundwater within the dig zone. Interlocking sheets are
generally used where some degree of water retention is required and to resist the migration of
fines into the excavation i.e. in granular soils below the water table. Cold formed interlocking
sheets have relatively loose clutches and should be therefore be used with care particularly
where water flow is likely to be high such as in gravels.
Interlocking sheets are also recommended for use in cantilever type retaining walls up to 3m high
although deflections can be quite high due to relatively low section modulus when compared to
traditional hot rolled sheet piles. Refer to Groundforce Technical Services for further advice.
Strength (bending moment) requirement based on a structural analysis of the wall and levels
Re-roll Facilities
of supporting frame.
Driving hammer type (impact or vibratory methods). Product Link: For advice on
Specifications
The information below provides specifications for each profile to assist designers in specifying the most appropriate sheet type for any
given temporary works application.
Standard Lap - SD33 - A general purpose lightweight lapped sheet GFI - A heavy duty, cold formed, high yield interlocking sheet for
for relatively shallow trenches and shafts in non-water bearing propped excavations up to 6m deep and cantilever support up to
ground. 2.5m in water bearing ground. Can be driven with vibratory
methods. Excellent strength to weight characteristics. Corner piles
are available for closed cofferdam boxes.
GFI Corner
KD6 - A heavy duty highly durable lapped sheet for propped excavations up to 6m
deep and cantilever support up to 2.5m in non-water bearing ground. Can be driven
with both impact and vibratory methods.
HY6 - A heavy duty high yield lapped sheet for propped excavations up to 6m deep
and cantilever support up to 2.5m in non-water bearing ground. Excellent strength to
weight characteristics. Can be driven with both impact and vibratory methods.
Cross
“t” “d” “p” Section Moment Maximum bending Available
Sheet “w” section Weight Weight
Thickness Pan Depth Pan Width Modulus of Inertia moment1 & 2 Lengths3 & 4
Type Width (m) area (kg/Lin.m) (kg/m²)
(mm) (mm) (mm) (cm³/m) (cm4/m) (kNm/m) (m)
(cm²)
Std SD33 0.33 3.4 35 110 13.8 10.9 32.9 48.8 81.4 8.5 2 to 4
KD4 0.4 6.0 50 150 70.4 22.1 55.2 102.0 254.0 19.0 3 to 6
KD6 0.6 8.0 80 120 106.0 50.0 83.3 242.0 968.0 45.0 3 to 7
5
HY6 0.6 6.0 70 125 42.9 33.7 64.8 160.0 560.0 63.2 4 to 7
GFI 0.5 6.0 75 230 43.1 33.8 67.6 186.0 738.0 62.0 4 to 7
interlocking
Notes:
1. The working bending moment is based on global factor of safety of 1.5 applied to the nominal or characteristic minimum yield stress. A
higher factor is recommended for permanent works applications.
2. Includes a reduction for local buckling effects where appropriate.
3. Longer lengths may be available on request for sale or hire.
4. Supplied in 0.5m increments between the stated limits (GFI sheets are only available in 1.0m increments).
5. Determined from test results, based on statistically reduced characteristic values.
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Sheet Piles
7.2.1
Groundforce, through their sister company Piletec, offer a comprehensive range of “U”
section hot rolled interlocking sheet piles for use in a variety of temporary or permanent
applications. The available pile sections are designed to be as light as possible without
compromising strength and durability, whilst the design of the interlocks offers a good
degree of water-tightness and aids pitching and driving.
Factors which need to be considered in selecting an appropriate pile profile include; bending
strength, presence of groundwater, soil type retained, permeability of soil, method of
de-watering (if applicable), installation method (pre-drive using a hammer is recommended),
driving hammer type (impact or vibratory methods), handling and / or weight issues.
Note: Piletec, with the use of their “GFdrive” software, are able to offer to customers guidance to assist the customer in selecting the
correct hammer specification for specific ground conditions and pile specification.
Interlocking sheet piles are generally used where some degree of water retention is required and to resist the migration of fines into
the excavation i.e. in granular soils below the water table.
Hot rolled sheet piles utilize tighter clutches than the cold formed trench sheet alternative (section 8.1) and hence offer greater degree
of water retention. For watertight sheet piled walls, an additional oil based sealant may be required. Refer to Piletec for further advice
(0800 731 4960).
Interlocking sheets are recommended for cantilever type retaining walls, although retained heights of greater than 3.5m can lead to
large deflections and may not be a suitable retaining structure. Refer to Groundforce Technical Services for further advice.
The correct choice of pile is dependent on the steel strength, soil type and required penetration. These must be considered well in ad-
vance of the driving operation to ensure the best results and avoid potentially costly damages through incorrect pile specification.
Sheet piles are not suitable for dig and push installation methods and consequently must always be driven with a suitable combination
of hammers, guide frames or leader rigs.
Specifications
The table below gives detailed specifications for each profile to assist designers in specifying the most appropriate sheet type for any given
temporary works application.
PU8S 0.6 8.0 8.0 283 318 112 52.8 87.9 200 845 11930 166
PU12 0.6 9.8 9.0 360 258 140 66.1 110.1 200 1200 21600 240
PU18-1 0.6 10.2 8.4 430 269 154 72.6 121.0 200 1670 35950 334
-1
PU22 0.6 11.1 9.0 450 297 174 81.9 136.5 200 2060 46380 371
PU22+1 0.6 13.1 10.0 450 297 192 90.4 150.7 200 2335 52510 467
PU28-1 0.6 14.2 9.7 452 339 207 97.4 162.3 200 2680 60580 536
Various corner sections are available for applications where fully closed cofferdams are required (high water table, poor ground conditions
etc.). This will offer the advantage of greater water/fine material retention. The use of corner sections will result in specific excavation
dimensions depending on the combination of piles / corner sections used.
Note: Groundforce are able to advise customers of exact cofferdam dimensions by the use of their “Sheet to Sheet” pile configuration
software as a means of calculating cofferdam size for a combination of pile / corner / junction combinations. Please contact Groundforce
Technical Services for further advice.
Permissible
Weight “t” thickness
Corner Pile Steel Grade working stress
(kg/m) (mm)
(N/mm²)
Delta 13 C9
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TRENCH SUPPORT -
LIGHT WEIGHT SYSTEMS
8
8.1 Walers
8.2 Vertishore
8.3 MAP Box
8.4 Quick Access Box
Each waler unit comprises two horizontal rails, expanded against the
sheeted trench walls by (typically) two externally interconnected
63.5mm bore hydraulic rams. The rams are expanded and pressured
between the walls of the trench by a manually operated hand pump.
Waler Rail
Note: the system does not articulate once assembled. See 8.1.4 for ram
specifications.
Min Sheet-to-Sheet Trench Width (mm) 570 1000 1500 2100 2700 3300
Max Sheet-to-Sheet Trench Width (mm) 1050 1500 2400 3000 3600 4200
The system comprises two steel UC section rails strutted apart two hydraulic
rams.
Six different ram types enable the support of different trench widths
between 850mm and 4300mm wide (sheet to sheet).
Note: the system does not articulate once assembled. See 8.1.4 for ram
specifications
The maximum working loads, frame weights and achievable trench widths
for each combination of rail and ram unit are indicated in the table below.
Min Sheet-to-Sheet Trench Width (mm) 850 1100 1600 2200 2800 3400
Max Sheet-to-Sheet Trench Width (mm) 1150 1600 2500 3100 3700 4300
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Walers
8.1.3
The system comprises two extruded aluminium rails strutted/supported by either two
or three cylinders. Suitable for light duty applications in trenches up to 4.0m deep
where the low weight of equipment is a primary consideration.
Waler Rail
A = 39.0cm² / 39.1cm²
Min Sheet-to-Sheet Trench Width (mm) 550 800 1300 1900 2500 3100
Max Sheet-to-Sheet Trench Width (mm) 850 1300 2200 2800 3400 4000
A range of six hydraulic rams are available to accommodate nominal overall trench width ranges of 0.55m - 4.0m alloy rails and 0.85m -
4.3m when used with steel rails. The ram units themselves are predominantly of aluminium construction and are single acting (pump out
only). A mechanical lock-off valve (see photos below) is incorporated for additional hydraulic security and to enable the pump hose to be
connected and disconnected with zero fluid loss.
Type C rams can be extended using a bolt together extension system as illustrated below. The working load of the rams is as follows:
Ram types A, B, C & C1 - Rated load = 100kN (min FOS 2:1 - hydraulic failure dictates failure criteria).
Ram Types C2 & C3 - Rated load = 80kN (min FOS 2:1 - piston rod buckling dictates failure criteria).
Pressure to axial force ratio ~ 1000psi (69 bar) pump pressure induces - 21.5 kN jacking force.
Steel oversleeve system - flange connection is 4No. M16 x 50 grade 8.8 bolts.
Oversleave 16.0
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Aluminium Waler End Bearers
8.1.5
Waler End Bearers (WEB`s) have been developed as an alternative method to close off the end of
a trench, when using trench sheeting, a problem that over the years has often been resolved by
inserting timber beams behind the waler beams or worse still, using the hydraulic rams to
provide lateral support.
WEB’s comprises two sliding telescopic aluminium box sections that connect to the ends of the
Groundforce aluminium waler rail (section 8.1.3) and thus allow multiple-sided support for light
duty applications in trenches up to 4.0m deep. The inner & outer box sections of the WEB are
free to “telescope” and therefore provide resistance to bending but not to axial compression and
tension. Design checks are therefore limited to ensuring that the moment capacity of the
The Waler End Bearers incorporate a
extrusions is adequate and that the locating pin is adequate in shear and bearing. The lateral load stainless still spring and transit bolts
capacities stated in the table below are based solely on the structural capacity of the WEB and to ensure that they can be handled/
its connection, but take no allowance for potential sliding of the waler frame along the trench, an operated in a safe manner.
issue that becomes more problematic with short/wide walers frame configurations. They are compatible with both the GF
and GFS type Aluminium Waler Rails.
Where the width of the trench is greater that the waler rail length it is recommended that
additional checks for resistance to sliding be made refer to the Groundforce Technical
Department for more information.
A = 30.13cm² A = 32.44cm²
*FOS = 1.6
Pin Properties
Technical Specification Used with Ram Type A Used with Ram Type B Used with Ram Type C
AA AB BA BB CA CB C1 C2
Weight (kg) 8.7 10.0 12.0 14.1 19.0 22.9 28.7 34.0
Min pin-to-pin Width (mm) 457 562 687 887 1212 1612 1812 2412
Max pin-to-pin Width (mm) 602 762 937 1187 1662 2112 2712 3312
Min Sheet-to-Sheet Width (mm) 545 650 775 975 1300 1700 1900 2500
Max Sheet-to-Sheet Trench Width (mm) 690 850 1025 1275 1750 2200 2800 3400
Working Load Limit (kN/m) * 54.4 54.4 54.4 54.4 40.6 27.4 14.2 10.6
*The Working Load Limit stated include for a global FOS of 1.6 and are the maximum possible values. Please be aware
that the safe working load capacity of the overall system could be limited by the strength of the waler being used and
hence this section should be checked in conjunction with section 8.1.3
The Vertishore is a lightweight compact easily installed shoring unit designed for short term
use in relatively shallow trenches in stable non-water bearing ground conditions. The units are
designed to be installed from ground level by one man in a matter of seconds thus providing
safe effective shoring without operatives having to enter an un-shored excavation.
Each unit comprises two aluminium rails, expanded against the cut trench walls by a pair of
interconnected hydraulic rams. The rams are expanded and pressured between the walls of the
trench by a manually operated hand pump.
The units are designed to be used intermittently along the trench without additional trench
sheeting, however horizontal spacing of Vertishores should not exceed 1.2m centres along the
trench.
Vertishores are available in two alternative rail lengths and with a range of four hydraulic rams to
cater for trench widths from 0.45m - 1.6m wide.
Vertishores
Technical Specification
Type A Type
** The cantilever effect of the shore rail under the lower ram is the limiting factor on uniformly distributed load ratings. The
working axial load capacity of individual cylinders is 80kN
Rail Details
Rail Properties
Ix-x = 61.04cm4
Zx-x = 23.4cm³
A = 39.1cm²
Cross-section through Vertishore Rail
Weights: Type A - 8.6kg: Type B - 12kg.
Ram Details
2 550 880 80
3 650 1080 80
4 1000 1600 80
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Vertishore
8.2.3
Technical Specification
Support of the trench relies on the ground behind the units “arching“ between the Vertishore centres
as illustrated in the diagram below. Compact or cohesive soil will demonstrate a greater ability for soil
arching than will loose and cohesion less soils. It is therefore essential that Vertishores are only
considered for use in ground that is “self supporting” or has the ability to stand, once excavated, to a
vertical face as in predominantly cohesive soil.
Arching in soils occurs any time the stiffness of the supporting structure is different than the stiffness
of the surrounding soil. If the structure is stiffer than the soil then load arches ONTO the structure. In
this instance the supports are the Vertishore units which, once pressurised hydraulically against the
walls of the trench, form a very rigid support which consequently induces this arching effect in the
surrounding ground.
The amount of arching depends on the relative difference in stiffness and the amount of load
available to arch.
The general design procedure for Vertishore rails is to assume one half the Vertishore spacing either
side acts as a panel loaded with active soil pressures and surcharge loadings above the depth of
excavation.
The strength characteristics of the Vertishores have been determined to satisfy the worst case load
conditions within the depth limitation of the units. No further support calculations are therefore
generally necessary. If in doubt however about the suitability of Vertishores, a close sheeted system
of shoring such as walers and trench sheets or trench boxes is recommended, designed by an
experienced engineer.
Take care to protect the Vertishore unit from accidental strikes and concrete accumulation
Using just three main components - panels, struts and corner posts - the MAP
system can be configured to provide either 2, 3 or 4-sided support offering
the user great versatility on site. Being predominantly of aluminium
construction, an assembled box can weigh as little 243kg, whilst providing
the strength of a conventional steel trench box.
Technical Specification
Clearance between corner posts (mm) Strut/Panel length - 102mm Strut/Panel length - 102mm Strut/Panel length - 102mm
Earth to Earth distance (mm) Strut length + 228mm Strut length + 228mm Strut length + 228mm
# Weights may vary with strut lengths and box configurations used.
Panels
Three panel lengths are available extruded from grade 6005-T6 aluminium alloy. Panel
type A is 996mm long, type B is 1606mm long and type C is 2743mm long. Individual
panel assemblies are 600mm high and have an allowable* bowing moment capacity
(M1)** = 11.7kNm. Therefore a 1.8m high box comprising three panels will have a
total (allowable) bowing moment capacity of 35.1kNm
Corner posts
Two lengths of corner posts are available, either 1.2m or 1.8m long, they are extruded
from grade 6005-T6 aluminium alloy. Posts can be joined together with connectors to
form taller boxes. It is not recommended that more than two posts of any size be joined
together. When assembled with panels to form a box plate, it is the posts that provides Lifting Eye set into top of corner post
longitudinal strength i.e. resistance to kicking moments (M3)**. Individual posts have an
allowable* kicking moment capacity (M3)**= 11.3kNm.in both X-X and Y-Y axes.
Therefore a box panel comprising a number of panels and two end posts will have
a total (allowable) kicking moment capacity of 22.6kNm
Struts
Side panels
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Modular Aluminium Panel (MAP) Box
8.3.3
System Specification
Taking into account the limiting structural resistances (as defined on the previous page) when the panels, posts and struts are combined in
the various configurations, the allowable uniform pressures on the pox panels are defined in the tables below for each configuration of box
(The following data assumes uniform pressure distribution on the back of the box panels)
Each unit comprises two lightweight aluminium plates, held apart at each end by pairs
of “acrow” type adjustable struts. The latter are available in a range of four different
sizes to accommodate trench widths between 0.4m to 1.8m.
The maximum recommended depth of trench that can be supported (without specific
supporting calculations) is 1.8m; equivalent to a base and single top unit combined.
Technical Specification
# Weights may vary with strut lengths and box configurations used.
** Limiting by the bowing moment (M2) capacity of the corner posts (see page 2).
Note: The allowable axial load capacity of the struts is 30kN (all lengths) with a factor of safety of 2
Retaining Pins = 2 No. 124mm long, 9.5mm Ø (S275). 3 7.7 700 1100 30 -24
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TRENCH SUPPORT -
BOX SYSTEMS
9
9.1 Box Systems - Basis of Design
9.2 Trench Boxes
9.3 Manhole Boxes
9.4 Backhoe Trench and Manhole Boxes
9.5 Box Spindles and Struts
9.6 Drag Boxes
9.7 Box Ancillaries
TRENCH SUPPORT -
BOX SYSTEMS
Box Systems - Basis of Design
9.1.1
Introduction
All trench and manhole boxes are designed as standalone products unlike other
support systems such as sheets and frames. It is therefore common practice to
specify the structural capacity of trench and manhole box systems by
the allowable uniform panel pressure that the panels can sustain
over the full panel area. Simple verification calculations can thus
be completed by comparing the worst case calculated soil
pressure with the allowable panel pressures. Whilst this simplified
approach will provide a safe solution it can result in pessimistic
values and sometimes render solutions where the box is
inadequate to resist the loads. A more rigorous analysis may
demonstrate otherwise.
The latter is a common situation where excavations are deeper and/or
ground conditions are poor. Note that trench boxes are heavy and can be
difficult to remove from the ground due to suction pressures on the panels. Using
a detailed lifting plan consideration should always be made to the weight of the
box, potential extraction forces and the capability of the lifting equipment
employed to safely lift, handle and extract it.
Failure mechanisms
Boxes generally comprise just two structural elements, side panels and struts, the latter
usually incorporating some form of mechanical adjustment facility.
There are three main potential failure mechanisms in a simple box assembly namely:
Inward bowing of the box panel between the struts - Bowing moment
(denoted M1).
Plan view of box panel indicating
Bending (in plan) of the end return panels (denoted M2) this applies to manhole bowing moment (M1)
boxes only.
Bending of the panel under the lower strut - kicking moment (denoted M3).
There are several types of strut within the Groundforce box fleet comprising
fixed, incremental (by pin) and fully adjustable (by screw) mechanisms. These
are illustrated in the pictures opposite.
Considering the axial capacity of any strut assembly, there are typically two
modes of failure; either by local failure of an individual strut components such as
a pin or screw, or at longer spans, lateral buckling of the unit as a whole. For
Fully adjustable box strut
simplicity and to produce the most conservative result, we have considered the
various modes of failure at the maximum length stated within relevant
configuration specification for the particular box in question. The limiting load
capacity is therefore dictated by failure criteria (either local component failure or
buckling).
Note that to allow for robust design and hard use on sites which boxes are
typically subject to, struts are over typically over-designed in bending and
buckling so that it is generally a local component failure such as a pinned
connection that determines the limiting strut capacity.
Very large frictional and suction forces can be generated on box panels which Incrementally adjustable
can make them difficult to pull out of the ground. This problem can be telescopic strut
particularly acute when working in soft clay type ground conditions. Damage to
lifting points and lifting equipment can easily occur if over-large extraction forces
are used, or the chain is “snatched” during the extraction process.
Summary
Structural data is published within the relevant section for each box type, to
enable a designer of checker to verify the limiting system capacity. It is the
designer’s decision whether they adopt a simple panel pressure verification
approach or a more detailed resistance check using limiting component
resistances.
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Trench Boxes
9.2.1
Trench boxes are generally the first choice for the rapid
shoring of trench runs in non-urban environments due to the
speed and simplicity of installation. In reasonable ground
conditions, they are generally suitable for use in trenches up to
4m wide x 6.6m deep, depending on box type, and used where
prevention of ground movement is not a key issue. They are often
installed longitudinally in multiple units to continuously support a
length of trench. A minimum of three boxes installed end to end
should be used at any one time.
Groundforce offer a wide range of trench box sizes with two basic strut
types. The “Multi-Box” type of strut is a heavy duty, incrementally
adjustable, telescopic strut whereas the “spindle” type uses the more
traditional screw thread method of adjustment. Multi boxes struts are
more suited to wider trench widths. A maximum of two top extension
boxes can be added to increase the height of a base box.
It is recommended that all trench boxes are used with integral Edgesafe
and Laddersafe barrier and access systems.
Strut Types
Product Link
Box Struts - Section 9.5
Box Ancillaries - Section 9.7
Technical Specification
The table and cross sections below states box dimensions, weights, and the various structural parameters for all available Trench Boxes.
Design verification can be undertaken by either a simple panel pressure comparison or by a more rigorous bending moment and strut
capacity check. (For further details see Box Systems - Basis of design, section 9.1. Strut capacity data can be found in section 9.5 – box
spindles & struts). All of the boxes can be used in conjunction with Groundforce end closure panels in applications where full width earth
retention across the end(s) of the box is required.
Plate Height (m) 2.0 (base) 1.0 (top) 2.55 (base) 1.35 (top) 3.9 (base) 1.35 (top)
Weight of Plate (kg) 580 (base) 316 (top) 1042 (base) 616 (top) 1600 (base) 630 (top)
[1]
Maximum Trench Depth (m) 4.0 5.3 6.6
Strut length from pin to pin (mm) 430 – 4210 430 – 4210 430 – 4560
[2]
Allowable plate bowing moment, M1 (kNm/m) 30.4 81.5 55.1
[2]
Allowable plate kicking moment, M3 (kNm) 21.6 51.6 226.8
[2 & 3]
Allowable plate panel pressure (kN/m²) 32.8 35.2 39.7
Max allowable extraction force per lifting lug (t) 3.0 6.0 12.0
[4]
Allowable strut load (kN) Dependant on strut type used – refer to section 9.5 (box spindles & struts)
1. Maximum depth is based on 1No. base and 2No. top extensions being connected together.
2. For all above data, the minimum global load (or safety) factor is 1.6.
3. The allowable uniform panel pressure is determined from limiting values of kicking and bowing moments and can be affected by
the strut type/length used within the box make up.
4. Refer to section 9.5 on box struts for more information.
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Manhole Boxes
9.3.1
Note that manhole boxes are heavy and therefore great consideration should always
be made to the weight of the box and the capability of the lifting equipment employed
to lift and handle it.
It is recommended that all manhole boxes are used with integral Edgesafe and
Laddersafe barrier and access systems.
A full range of integrated handrail systems are available along with end
closure panels.
End closure panels are available to support the open ends of the manhole
box (see Box Ancillaries 9.7.2).
The table and cross sections below states box dimensions, weights, and the various structural parameters for all available Manhole Boxes.
Design verification can be completed by either a simple panel pressure comparison or by a more rigorous bending moment and strut
capacity check. (For further details see Box Systems - Basis of design, section 9.1. Strut capacity data can be found in section 9.5 – box
spindles & struts). All of the boxes can be used in conjunction with Groundforce end closure panels in applications where full width earth
retention across the end(s) of the box is required.
2.5m, 3.0m, 3.5m and 4.0m Manhole Boxes 4.7m Manhole Box
1045 (base) 1163 (base) 1282 (base) 1400 (base) 1450 (base)
Weight of Plate (kg)
745 (top) 824 (top) 903 (top) 982 (top) 900 (top)
[1]
Maximum Trench Depth (m) 5.5 5.26
Clearance between struts on plan (m) 2.15 2.65 3.15 3.65 4.43
Strut length (from pin to pin) (mm) 440 - 4210 - depending on strut type fitted 2750
[2]
Allowable plate bowing moment, M1 (kNm/m) 81.5 93.0
[2]
Allowable plate kicking moment, M3 (kNm) 153.7 234.4
[2]
Allowable plate end moment, M2 (kNm) 175.0 166.4
[2 & 3]
Allowable plate panel pressure (kN/m²) 50.5 42.1 36.0 31.5 33.6
Max allowable extraction force per lifting lug (t) 8.0 8.0 8.0 8.0 10.0
[4]
Allowable strut load (kN) Dependant on strut type used – refer to section 9.5 (box spindles & struts)
1. Maximum depth is based on 1No. base and 2No. top extensions being connected together
2. For all above data, the minimum global load (or safety) factor is 1.6
3. The allowable uniform panel pressure is determined from limiting values of kicking and bowing moments and can be affected by
the strut type/length used within the box make up.
4. Refer to section 9.5 on box struts for more information
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Backhoe Trench & Manhole Boxes
9.4.1
Trench widths of up to 2.2m (earth to earth) for the Trench Box and
3m for the Manhole Boxes can be achieved by using a variety of
fixed length strut extensions. These are connected to the box
plates using a simple pin arrangement for speedy on-site assembly.
A robust yet lightweight box system suitable for use with backhoe (180°
degree) and mini excavators.
Base box weighs typically only 740kg (Trench Box) or 915kg (Manhole
Box).
End closure panels are available to support the open ends of the boxes
Product Link
(see Box Ancillaries 9.7.2).
Box Struts - Section 9.5
Box Ancillaries - Section 9.7
Technical Specification
The table and cross sections below provides box dimensions, weights, and the various structural parameters for all available Backhoe
Boxes. Design verification can be undertaken using either a simple panel pressure comparison, or by a more rigorous bending moment and
strut capacity check. Note: strut capacity data can be found in section 9.5 (box spindles & struts). When specifying backhoe boxes,
consideration should always be made to the weight of the box and the capability of the excavator employed to lift and handle it.
Plate Height (m) 2.0 (base) 1.0 (top) 2.0 (base) 1.0 (top)
Internal width between plates (m) 0.3 - 2.1 1.35 - 1.88 1.35 - 2.38 1.35 - 2.88
External width (m) 0.43 - 2.23 1.47 - 2.0 1.47 - 2.5 1.47 - 3.0
Distance between struts centres on plan (m) 2.68 1.93 2.43 2.93
Strut length to achieve a “square” box (mm) - N/A 850 (800) 1280 (1230) 1780 (1730)
pin to pin length shown in brackets.
[2]
Allowable plate bowing moment, M1 (kNm/m) 18.4 43.6
[2]
Allowable plate kicking moment, M3 (kNm) 30.1 117.4
[2]
Allowable plate end moment, M2 (kNm) N/A 58.7
1. Maximum depth is based on 1No. base and 2No. top extensions being connected together
2. For all above data, the load (or safety) factor is 1.6
3. The allowable uniform panel pressure is determined from limiting values of kicking and bowing moments and strut capacity
4. Refer to section 9.5 on box struts for more information
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Trench and Manhole Box Struts
9.5.1
Due to continuous development of the Groundforce range of box systems, there are several
types of struts that can be used throughout the box range, some dedicated to specific box
types and some interchangeable. This document will cover struts that can be used in the
following box types:
Standard range (see section 9.2) - mini and standard trench boxes.
The table below indicates the application or each type of strut to each box type and the adjustable strut
subsequent pages within this section describe the physical and structural properties of each
strut type.
Strut Type
Box Type
Fixed Incremental Fully Adjustable
Not
Backhoe Trench Box Compatible Compatible
Compatible
An example of fixed length strut
Not Not
Backhoe Manhole Box Compatible
Compatible Compatible
Not
Mini Trench Box Compatible Compatible
Compatible
Not
Standard Trench Box Compatible Compatible
Compatible
Not
Premier Trench Box Compatible Up to 2.5m only
Compatible
Not
Standard Manhole Box Compatible Compatible
Compatible
Not
4.7m Manhole Box Compatible Compatible An example of a fully
Compatible
General description
This is a fully adjustable strut, traditionally known as a spindle due to its relative slender profile. It
comprises an adjustable left and right handed screw threaded section (four sizes are available) a series of
fixed length “plug in” extension pieces and a pair of spring spindle holders located at each end to form
the connection to the box panels. The latter allows a degree of strut articulation to facilitate a typical dig
and push installation sequence. The spindle assembly, although robust, does need to be specified with
care at longer spans as the “plug in” joints between the extension bars will promote a degree of sag in
the struts, reducing its load carrying capacity due to potential buckling effects (see load/span chart below).
Limitations
On Premier Boxes, the maximum length of strut is limited to 2.5m due to their greater load carrying capacity.
On all other box types, the maximum length of strut is limited to 4.2m.
The number of joints in a single strut assembly is limited to a maximum of 4 (including end connections to the spring spindle holders).
3
3
5 2
3 5
3 5
5
4
2
7
6
1
Components
1. Adjustable Spindle
2. Spring Spindle Holder
3. Spindle Pin (20mm dia.)
4. Spring Spindle Holder Pin (40mm dia.)
5. Small R Clip
6. Large R Clip
7. Spindle Extension Tube(s)
Description Pin to Pin Range Weight (kg) Allowable axial Allowable axial tensile
(mm) compressive force (kN) force (kN)
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Box Struts - Multi-Box Type
9.5.3
General description
This family of struts comprises inner and outer telescopic steel box sections incorporating end rockers with
a series of pin location holes along the length to provide an incrementally length adjustment facility. The
end rockers allow a degree of strut articulation to facilitate a typical dig and push installation sequence.
Multi-box struts are constructed out of sufficiently large box section steel so that lateral bucking is not a
design limitation within the operating width range of the box. Consequently the axial resistance or
capacity of these struts is limited by local effects such as shear strength of the 20mm diameter adjustment
pin. A pair of standard rockers combine with a central oversleeve to increase their length and range of
adjustment (Figure 1). Mini and narrow rockers permit narrower trenches and both incorporate a standard
rocker, but no central oversleeve (Figure 2 and Figure 3).
Design data
Mini/Std Narrow Inner Rocker 80x80x6.3 SHS, Grade S355 (50C) steel.
Connection between rocker and the box panel is by a 40mm 605M36T (EN16) Ø pin.
Bearing and side plates are all 10mm thick Grade S355 (50C) for both rockers.
Figure 1. 3
3
1
2
Components
1. 40mm dia. Pin and Clip (Ref. 1 Pin).
2. 20mm dia. Pin and Clip (Ref. 3 Pin).
3. Multi-Box Standard Rocker.
4. Strut Oversleeve (various sizes available).
Description Component Pin to Pin Range Weight (kg) Allowable axial Allowable axial tensile
Combination (mm) compressive force (kN) force (kN)
Standard - 1190 o/sleeve 1358 - 1758 61 +83.8 with a FOS = 1.6 -83.8 with a FOS = 1.6
Standard - 1690 o/sleeve 1858 - 2258 75
(as limited by shear in the (as limited by shear in the
Standard - 2190 o/sleeve 2358 - 2758 89 20mm pin connections) 20mm pin connections)
Figure 2.
3
2 1
5
Figure 3.
1
2
Components
1
1. 40mm dia. Pin and Clip (Ref. 1 Pin).
2. 20mm dia. Pin and Clip (Ref. 3 Pin).
3. Multi-Box Mini Rocker.
4. Multi-Box Mini Inner Rocker. 1
5. Multi-Box Standard Rocker.
6. Multi-Box Standard Inner Rocker. 7
7. Panel Connector (4 required per panel extension).
Data table for mini and narrow strut combinations (note that no oversleeve extensions are required)
Description Component Pin to Pin Range Weight (kg) Allowable axial Allowable axial tensile
Combination (mm) compressive force (kN) force (kN)
Std Inner / Mini Rocker 597 - 747 25.5 (as limited by shear in the (as limited by shear in the
20mm pin connections) 20mm pin connections)
Std Inner / Std Rocker 604 - 804 28.0
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Box Struts - Premier Multi-Box Type
9.5.5
General description
Due to their greater load capacity and physical size Premier boxes have a stronger version of the
multi-box strut. Various permutations of multi-strut are available for these boxes including both fixed and
incrementally adjustable struts. The fixed length strut comprises heavy duty end rocker units linked
together by a series of fixed length oversleeves whilst the incrementally adjustable strut incorporates an
incrementally adjustable oversleeve unit. The rockers allow a degree of strut articulation to facilitate a
typical dig and push installation sequence. Multi-box struts are constructed of sufficiently large box
section steel so that lateral bucking is not a design limitation within the operating width range of the box.
Consequently, the axial resistance or capacity of these struts is limited by local effects such as shear strength of the 40mm diameter
adjustment pin.
Design data
Adjustable Unit (A1) 180x180x10 and 150x150x12.5 SHS, Grade S355 (50C) steel.
Components
1. 40mm dia. Pin and Clip (Ref. 2 Pin).
2. Premier Rocker.
3. Fixed Extension (various sizes available).
Strut Reference Pin to Pin Range Weight (kg) Allowable axial Allowable axial tensile
(mm) compressive force (kN) force (kN)
Strut B 962 75
Strut C 1062 80
Strut D 1162 85
+266.0 with a FOS = 1.6 -266.0 with a FOS = 1.6
Strut E 1262 91
Strut F 1462 103 (as limited by shear in the (as limited by shear in the
40mm pin connections) 40mm pin connections)
Strut G 1762 118
Premier Multibox Telescopic System (incrementally adjustable) - Strut Assembly Option 2 & 3
Configuration and data for the adjustable strut options is shown below:
2
3
4
2
1
1
1
1 2
4
3
4
1
2 1
1
1
1
Strut Assembly Option 3
1
Components
1. 40mm dia. Pin and Clip (Ref. 2 Pin).
2. Premier Rocker.
3. Fixed Extension (various sizes available).
4. Adjustable Extension A1.
Strut Reference Pin to Pin Range Weight (kg) Allowable axial Allowable axial tensile
(mm) compressive force (kN) force (kN)
Strut F 1662 - 1962 128 (as limited by shear in the (as limited by shear in the
40mm pin connections) 40mm pin connections)
Strut G 1962 - 2262 143
Strut Reference Pin to Pin Range Weight (kg) Allowable axial Allowable axial tensile
(mm) compressive force (kN) force (kN)
Strut G 2162 - 2762 206 (as limited by shear in the (as limited by shear in the
40mm pin connections) 40mm pin connections)
Strut H 2462 - 3062 222
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Box Struts - 4.7m Manhole Box
9.5.7
General description
Due to their size and specialist nature, the 4.7m manhole box has its own dedicated struts. Both
fixed length and incrementally adjustable struts are available. Two types of fixed length unit are
available, the original design provides a square box configuration whilst the later design permits
varying widths. The incrementally adjustable struts are similar the struts used in the premier
trench box but with a different end connection. All types of strut are constructed out of
sufficiently large box section steel so that lateral bucking is not a design consideration at the
relative small spans involved. Consequently the axial resistance or capacity of these struts is
limited by local effects such as shear strength of the 40mm diameter adjustment / connector
pins.
Design Data:
Maximum Strut Length (pin to pin) - 2.75m. Note that when assembled
this will provide a “square” box configuration.
These struts use the premier box fixed length beams fitted with a shoe
adaptor pinned on at each end to facilitate the connection to the panel at
each end.
Strut Reference (and Box width (external) Strut Weight Allowable axial Allowable axial tensile
length #) (mm) c/w two end compressive force (kN) force (kN)
adaptors (kg)
Strut G - 1414mm 3938 146 (as limited by shear in the (as limited by shear in the
40mm pin connections) 40mm pin connections)
Strut H - 1714mm 4238 162
General description
These struts utilise the premier box range of strut components in combination with a heavy duty rocker at each end to facilitate the
connection to the panel. Two different configurations options are available incorporating an “A1” adjustment sleeve at one or both ends of
the strut.
Data for these two strut options is given in the tables below.
Strut Reference (and Box width (external) Strut Weight Allowable axial Allowable axial tensile
length #) (mm) c/w two end compressive force (kN) force (kN)
adaptors (kg)
Strut H - 1714mm 4438 - 4738 207 (as limited by shear in the (as limited by shear in the
40mm pin connections) 40mm pin connections)
Strut J - 2214mm 4938 - 5238 233
Strut Reference (and Box width (external) Strut Weight Allowable axial Allowable axial tensile
length #) (mm) c/w two end compressive force (kN) force (kN)
INCREMENTAL TYPE 2
adaptors (kg)
Strut G - 1414mm 4338 - 4938 236 +266.0 with a FOS = 1.6 -266.0 with a FOS = 1.6
Strut H - 1714mm 4638 - 5238 252
(as limited by shear in the (as limited by shear in the
Strut J - 2214mm 5138 - 5738 278 40mm pin connections) 40mm pin connections)
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Box Struts - Backhoe Type
9.5.9
General description
Backhoe manhole and trench boxes are designed as relatively lightweight units and therefore have their
own dedicated strutting system designed to minimise weight. Both fixed length and incrementally
adjustable struts are available. The former tend to be used for manhole boxes to form a square box
configuration, the adjustable struts are generally used on the trench boxes to provide the ability to adjust
the box width on-site.
The fixed length unit is a single piece 100mm Ø tubular steel section with a single 20mm Ø pin connection
at each end. The incrementally adjustable struts employ a central oversleeve section with a selection of
adjustment holes. Both types of strut are constructed out of sufficiently large section steel so that lateral
bucking is not a design consideration at the relative small spans involved. Consequently the axial
resistance or capacity of these struts is limited by local effects such as shear strength of the 20mm
diameter adjustment / connector pins.
Connection
Connection between box panels and all strut components is by a 20mm Ø 605M36T (EN16) pin.
The controlling section size of the various sections for the basis of structural assessment is:
Allowable axial compressive and tensile force = 98kN with a FOS = 1.6
(As limited by the bearing stress of the 20mm Ø pin in the 9.5mm wall
thickness innersleeve sections).
Incrementally
Strut Reference adjustable strut type
Strut Length 2
Strut External External Strut Reference Strut Length Strut External
(and length #) (pin to pin) weight Trench Box Manhole (and length #) (pin to pin) weight Trench Box
(mm) (mm) (kg) width Box width (mm) (mm) (kg) width
(mm) (mm) (mm)
# - refers to the overall length of the tubular extension piece Note: Strut length must not exceed 2m (pin to pin)
All Groundforce drag boxes use incrementally adjustable, telescoping, heavy duty, 180mm square steel box section struts. Width
adjustment, in 50mm increments, can be simply achieved by removing a 40mm Ø locating pin and sliding the inner sleeve to the required
pin hole. The same basic strut configuration is used for all six box sizes throughout the range.
Drag Boxes are moved along the trench by hooking the excavator bucket around the front strut.
1. Excavate in front of the box, battering the sides of the trench to an angle so
that the ground will stand unsupported.
2. Drag the box forward by the use of chains via the pulling points.
3. Lay pipe & make connections within the safety of the box. Backfill and repeat sequence.
Structural verification
Despite their intended use as shields, drag boxes are still able to provide structural resistance to earth pressure loading commensurate with
their height should the trench walls collapse. If required, it is recommended that structural verification is simply carried out by comparing
the calculated lateral pressure within the trench, taking into account any surcharges with the allowable panel pressure for the relevant box
type as stated in the table below.
Pulling Points
Boxes can be connected together for deeper
(for chain
excavations subject to handling restrictions. attachment)
Ou
ter
Front (telescopic) struts.
Note: These struts must
Lifting / connecting points
not be used for dragging
Inn
Housing er the box along when over
1m wide
Super Super
Technical Specification Super Mini Super Midi Super Maxi Super Mega
Standard Magnum
Internal width (m) 0.65 - 2.75 0.65 - 2.75 0.65 - 2.75 0.65 - 2.75 0.65 - 2.75 0.65 - 2.75
External width (m) # 0.77 - 2.87 0.83 - 2.93 0.83 - 2.93 0.85 - 2.95 0.85 - 2.95 0.95 - 3.05
Clearance below rear strut (m) 1.5 1.5 1.5 2.0 2.1 1.7
Plan clearance between struts (m) 2.6 2.9 3.9 4.1 4.1 6.1
Allowable uniform panel pressure (kN/m²) 25.0 25.0 25.0 25.0 25.0 20.0
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Box Ancillaries
9.7.1
Groundforce Shorco are always striving to develop ancillary equipment to enhance their product offerings. Illustrated above is
an example of associated products that can be used in conjunction with Trench and Manhole Boxes to improve safety and
access in and around trench runs.
Key:
2. TrenchSafe - Handrails
4. LadderSafe - Access Systems, available in Mini, Maxi, Mega and Premier versions
EndSafe closure panels are used to close off the open end of a trench run to
avoid battering back the ground to a safe angle of repose. The panels are
designed to transfer lateral load from the ground into the strong points of the
box panels as opposed to adopting the bad practice method of using the box
struts to support lateral load.
EndSafe panels are available in various lengths from 1.5m to 4.5m to accommodate
most box types as indicated in the table below.
Advantages
Deflection (mm) 7 18 34 33
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Box Ancillaries
9.7.3
Cost effective, light weight and quick and easy to erect without lifting equipment.
Laddersafe systems
Mini and maxi systems are ideal for trenches supported with boxes.
Premier system is used for framed excavations where a larger platform outstand is required.
Integral handrails.
Maximum allowable load on platform and stairs 1kN/m2 (one person access).
Platform is strong enough to support a pyramid of wet concrete over its full diameter.
Lightweight design.
10
10.1 Rolling Strut - Basis of Design
10.2 Rolling Strut Trench Box
10.3 Rolling Strut Double Slide Rail
The multi position rolling strut concept does however, add a level of complexity to the
determination of structural capacity (or overall resistance to lateral earth pressures) of
the unit.
One can appreciate that the overall box capacity will be dependant on the position of
the strut within the post. It is therefore “safer” to specify its capacity when the strut is
positioned in such a way that it induces the most onerous forces in the supporting
components. This is generally with the strut at its uppermost position. As with traditional
trench boxes, capacity or resistance is usually quoted in terms of allowable uniform
panel pressure. Minimum values for RS system resistance are quoted in sections 10.2
and 10.3. Should the designer wish to carry out an analysis with the strut positioned
lower down in the posts to give higher system capacity, it is necessary to carry our a
more rigorous structural analysis as described in the following sections.
Failure mechanisms
Both RS slide rail and boxes incorporate three basic structural elements; posts, panels and
struts. In the case of boxes the posts are integral within the panels themselves. There are
three main potential failure mechanisms in a simple box assembly namely:
Inward bowing of the box panel between the struts - Bowing moment (denoted M1).
Plan view of box panel indicating
Bending of the post under the strut - kicking moment (denoted M3).
bowing moment (M1)
Failure of the strut; see page 10.1.2.
The overall structural capacity of the box or slide rail is the least value to induce failure
due to the following:
Bowing of the panels (M1). This is determined by the bending strength of the panel in
the plane of bending. Panels are typically of cellular construction and it the strength is
proportional to the section modulus of the component parts in the plane of bending (or
Section through a typical box panel
bowing).
indicating kicking moment (M3)
Bending of the end posts (M3). The panels themselves have little natural
strength in this (vertical) plane of bending. RS box panels incorporate
strengthened end posts to resist kicking moments whilst slide rail system used
separate posts.
Both RS box and slide rail use the same basic design of rolling strut albeit of
different sizes and capacities. The strut assembly comprises three basic
components namely left and right hand roller carriages connected together by
rectangular fabricated flanged box section spacers of variable width, as
illustrated in the photograph opposite.
In their simplest configurations both RS slide rail and box systems use a single
strut in each post therefore the struts themselves have to be capable of resisting
large bending moment (induced by kicking moments) as well as axial
compression induced by lateral pressure on the panels
Considering the overall capacity (or resistance) of the RS assembly; there are
typically three potential modes of failure:
Note that RS struts are not susceptible to lateral torsional buckling failure due to
their rectangular hollow section type of construction.
RS Design verification
Once the site specific geotechnical calculations have been completed in order to
determine lateral forces on the system, it is relatively straightforward to create a
simple statically determinate structural model of the RS systems from which the
design effects on the various components can be calculated. It is then a matter of
comparing these to the quoted resistance values for the various components (these
are tabulated in sections 10.2 & 10.3), using the limiting value as the measure of
overall system capacity.
Summary
The ability to position the rolling struts in various locations adds a degree of complexity
to the determination of overall RS system capacity or resistance when compared with
conventionally strutted box systems. Published values for capacity (in terms of
allowable uniform panel pressure) relate to the strut being positioned in its most
onerous location, that is when it is raised to its highest point. This will induce the
largest kicking moments in the support posts and greatest bending forces in the struts.
When the struts are to be positioned lower down the posts it will be necessary to carry
out a more rigorous check on individual system parameters . This will produce greater
values for overall system capacity.
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Rolling Strut Linear Support Systems
10.1.3
A B
After installing the Rolling Strut Boxes the struts can be moved easily, up or down, to provide the clearance required for the installation of
long pipes.
The pipes can be lowered into position easily without the obstruction that is usually caused by the fixed double struts of traditional box
systems.
As construction progresses the struts can be moved to create the required working space.
Dual Pipelines
Advantages
The maximum system capacity, or allowable lateral uniform panel pressure, is 35.6 kN/m2 (in terms of working load). This value is defined
by the limiting bowing moment in the plates for strut clearances up to 2.5m. Overall system capacity is significantly less than this when the
clearance under the rolling strut is increased and overall system capacity is then governed by the plate kicking moment. The allowable
uniform pressures for all of the RS Box strut positions is given on 10.2.3.
General data
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Rolling Strut Trench Box
10.2.3
Roller axial capacity (R): RT = 100kN (tension) RC = 639kN (compression) - global FOS =1.65.
Bolted connection: 4No. M30 (grade 10.9) bolts c/w washers – 1350Nm torque required
The Rolling Strut can be positioned at any one of five possible positions along the post depending on the required capacity of the box and
under strut clearance. Limit pins are inserted in pre defined slots in the posts above and below the roller carriage so as to limit the range of
movement of the strut; see diagram below. Refer to the user guide for more information on the correct use of limit pins.
1.775 35.6
2.295 35.6
2.565 35.6
2.835 29.0
3.105 23.8
Note: Clearances will be reduced by 270mm if the standard limit pin is used below the roller.
The Rolling Strut (RS) Double Slide Rail system is a high strength,
highly versatile trench lining system for the support of wide deep
trenches in all ground conditions. The system uses a combination high
strength steel posts, rolling struts and plate sections that link
together in bays to form continuous supports. The concept of a single
rolling strut offers the same functionality and versatility as with the
RS Trench Box in that larger and longer pipes and culverts can be
accommodated that with traditional fixed position strut systems. It is
possible to accommodate trench runs up to 9m deep and 7m wide.
Advantages
The maximum system capacity, or allowable lateral uniform panel pressure, is 39.5 kN.m 2 (in terms of working load). This value is
defined by the limiting bowing moment in the plates and generally governs the overall system capacity for all standard configurations
detailed in this section. Overall system capacity may however be significantly less than this for non standard applications. Checks should
therefore be made to determine the actual system capacity by calculating the post kicking moments, the plate bowing moments and strut
capacities and comparing them to the limiting values tabulated below. Refer to section 10.1. for more information.
General data
Maximum achievable trench depth (m) 9.0 Rolling Strut 903 (Base) 310 (Top)
Trench Width - internal, between posts (m) 1.24 - 6.24 150mm Extension 133 (Base) 80 (Top)
Strut centres on plan (bay length) (mm) 4.27 1.0m Extension 277 (Base) 188 (Top)
Extension length between roller carriages (m) 0 - 5.0 2.0m Extension 437 (Base) 306 (Top)
Limit Pin 3
Allowable plate bowing moment, M1 (kNm/m) 2.4m (Lining) - 189.8
1.2m (Ext) - 94.9
(FOS = 1.65)
Allowable plate panel pressure (kN/m²) see note 1 39.5 (FOS = 1.65)
Note: The stated allowable panel pressure considers the allowable bowing
moment, based on uniform pressure distribution, in the panels only
Groundforce Shorco | Technical File Issue 3.0 Download these files at: www.gftech.co.uk
Rolling Strut Double Slide Rail
10.3.3
Technical Specification - Rolling Struts and Extension Bars - note that the information stated below relates to the lower rolling strut
and extensions only, if upper rollers are required, these are identical to the rollers and struts used for the RS box (for the technical
specification of these struts see section 10.2.3)
Roller axial capacity (R): RT = 200 kN (tension) RC = 780 kN (compression) - global FOS =1.65.
Bolted connection: 8No. M30 (grade 10.9) bolts c/w washers – 1350 Nm torque required
The Rolling Strut can be positioned at any one of five possible positions along the post depending on the requirements of the system. Limit
pins are inserted in pre defined slots in the posts above and below the roller carriage so as to limit the range of movement of the strut; see
diagram and photograph below. Refer to the user guide for more information on the correct use of limit pins.
Note: Clearances shown are when the “Tuning Fork” limit pin is used below the roller. Clearances will be decreased by 260mm if
the standard limit pin is used below the roller.