1. |
Form the access pit and rebate to the size required. See Figures 5, 6 & 7 for the recommended rebate dimensions for the required load class. |
2. |
Remove all the dust caps and locking bolts from the covers and remove the covers from the frame using the appropriate Rhinocast lifting key. See Figures 8, 9 & 10 for the different Rhinocast lifting key options. |
3. |
For 2 part or 3 part covers, mark the frame & covers at the lifting end to ensure that covers are reinstalled in the same position. The marks on the frame should line up with the lifting key holes. |
4. |
Position the frame in the rebate and ensure that the lifting end of the frame is not obstructed by a wall, bollard etc.; otherwise cover removal will be restricted after installation. The frame must not protrude into the pit opening. |
5. |
Pack under the corner of the frame joints to raise the level of the frame to the finished floor level. Ensure the packing does not protrude into the pit opening. For 2 and 3 part cover systems, pack under the additional frame joints to prevent the frame from sagging. |
6. |
Set up the internal formwork to ensure that the frame will be fully supported after the concrete pour. For Class D and Class G covers block out the holes in the cover with metal sheeting. |
7. |
Thoroughly clean the seat areas of the covers and frame. It is important that these surfaces are dirt and dust free. |
8. |
Using the marks on the frame and covers (Step 3), place the covers back into the frame ensuring that the top edges of the frame and cover are level with each other. Check the covers for any diagonal rocking movement and adjust the packing under the frame where required. It is critical that the covers are properly seated in the frame and are not obstructed by any internal formwork. |
9. |
Check that the top level edges of the covers and frame are level over the entire perimeter of the access cover. If the covers are not level, the covers and frame seats may not be dirt and dust free (Step 7) and/or the frame is damaged. |
10. |
Replace all the dust caps in the covers. |
11. |
Simultaneously fill the rebate gap, cellular frames and recessed covers with concrete as specified in Table 1 |
12. |
Tap the covers and frame to ensure that the concrete is well compacted and the frame is fully supported. Ensure all cavities and pockets are completely filled with concrete. |
13. |
Screed off the excess concrete and finish the surface as required. The edges of the cover and frame should be visible. |
14. |
Concrete must be allowed to cure for at least 24 hours before removing the covers from the frame. Early removal of the covers may cause twisting of the frame and damage to the supporting concrete. This may prevent covers from fitting back into the frame. |
15. |
After the concrete has cured, remove the covers and strip the internal formwork. |
16. |
Clean the seat area of the covers and frame. It is important that these surfaces are dirt and dust free. |
17. |
Liberally apply sealing grease to the seat & vertical surface area of the covers and frame. This should be done periodically to assist in the maintenance procedure. |
18. |
Using the marks on the frame and covers, place the covers back into the frame. |
19. |
Tap down on the keyholes with a rubber mallet until the top of the covers are level with the top of the frame. |
20. |
Replace all the locking bolts and dust caps in the covers. |