A guide to manhole and meter pit covers.

Learnyourlifts.

Manhole cover liftingThis booklet is a guide for all field operational staff who lift manhole and meter pit covers in the course of their work. It provides information about the most common covers in use across the Thames Water area. We have included descriptions of the typical equipment you need so that you can handle manhole covers, and provided advice on best practice lifting techniques.

This booklet is not a definitive guide to every cover you may encounter but every effort has been made to make sure the information included in this booklet is easy to understand and up-to-date. We hope that this will help you to carefully assess and make an informed judgement about each cover you may have to work with.

This guide should be used as a supportive reference guide to completing a Point of Work Risk Assessment (POWRA/SHE 5). This guide includes the process by which a POWRA/SHE 5 must be conducted and has detailed information about:

• manual handling potential hazards

• generic control measures

• guidelines that must be applied when conducting frequent lifting and lowering operations.

The advice and guidance in this booklet is additional to other Thames Water Essential Standards and Health and Safety policies.

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ContentsCarrying equipment 3

Before lifting a cover 4

Point of work risk assessment 5

Your typical tools 6

Pry bar lifts 8

Two-man lifts 11

Using two lifting keys or hooks 12

Two key liftsUp to 25kg 13

Over 25kg 16

Four key lifts 20

Two hook lifts 21

Lift and slide covers 22

Secure covers 24

Techno-covers 25

Index 26

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Carrying EquipmentThere are a number of things you can do to reduce strain and potential injury.

• Only carry essential items and tools with you and limit the weight you are carrying

• When you use a rucksack, wear it with both straps across your shoulders and preferably use a waist strap to keep it in its position. Pack your rucksack so that the load is evenly distributed and the pack feels comfortable to wear

• If you carry tools in a rucksack or tool bag, make sure all tools with points or sharp edges have a protective guard. This will protect you against stabbing and cutting while you carry the bag and when you reach into the bag to retrieve tools

• Take care when you pick up or put down your tool bags/rucksack. The twisting motion of swinging a bag off your shoulder or around your body can put extra strain through your mid-spine and unnecessary strain on muscles and ligaments.

• Avoid heavy lifting while you are wearing a rucksack or tool bag. Make sure you place the rucksack or tool bag on the ground away from the lift area to avoid causing a trip hazard while you are lifting.

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Before lifting a cover• Make sure you have the right clothing,

including your PPE, and regularly check that it is in good condition.

• Make sure you have the right tools and regularly check your tools are in good condition.

• Store your tools within easy reach to reduce the need to twist and stoop when picking them up.

• Assess how you plan to lift the cover. Use the information in this booklet about the weight of different covers to make sure that the cover is within your ability to lift.

• Think about how your work impacts on others such as obstructing public footways or carriageways.

• Gauge the weight of the cover and minimise the force or effort you will need to lift it by:

– establishing which item of equipment is the best for the job. For example, does it need lifting keys, and if so, where are they?

– identifying any mechanical lifting aids which might be more appropriate.

– checking the condition of the cover, especially the lifting point. Is the keyway excessively worn? How might this affect the lift?

Report any issue to your manager.

When you’re planning to lift a manhole cover, decide before

you lift the cover what direction to move it and where it will be

placed. Never prop up a cover and make sure that the cover is set down safely in your work area.

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Point of work risk assessment• Refer back to your risk assessment

related to the lifting, handling and moving of covers. Make sure that all controls identified in the risk assessment are in place before work starts.

• Refer back to your training and guidance on frequent lifting, application of your training, potential hazard information (pristine manual handling training).

• Make sure you have the right tool or tools to carry out and complete the planned work. Make sure all of these tools are fit for purpose and in good condition before you leave the yard or workplace.

• Examine the cover for defects and damage - pay particular attention to the keyways.

Make sure that any Health & Safety issues identified in your POWRA or SHE5 have been adequately controlled before starting any lifting of an access cover. Below is a basic summary for individual cover lifts:

1 assess the situation

Can I get hurt? How? What can I do about it?

How heavy is the cover? What effort is needed to conduct the lift?

Where is the cover? Is it in a safe location?

Is the cover free to lift? Are the lifting points in good condition?

Can anybody else get hurt? How? What can I do about it?

Is the task one that I can undertake following my risk assessment?

2 apply control measures

Do I have the correct tools – are they in good condition?

Do I have the necessary PPE – is it in good condition?

Do I need to erect signs and barriers?

Is the environment in which I am working safe?

3

conduct the lift safely Continue to monitor and review.

continue to monitor and review

Consult your team manager / supervisor if you have any concerns over the assessment you have made or the application of the control measures.

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Your typical tools

There are a variety of lifting keys of different lengths and key widths. Always choose the right tool for the task. Use a lifting key that best fits the keyway and select the length of key that best enables you to lift by using your legs and not your back.

Protective gloves and a screwdriver

Lifting key set Pry bar set

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Proteus lifter

The Proteus Lifter is used to lift heavy covers. It takes two people to manhandle and assemble this lifting device. Under no circumstances should anyone attempt to assemble or use the Proteus lifter without completing the relevant awareness training.

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Pry bar lifts

1. When you are lifting from a kneeling position make sure you use a kneepad or kneeling board to reduce the strain placed on your knees.

2. Select a pry bar that is suitable for the size of cover and offers maximum leverage.

3. Clear any debris from the meter cover using either the pry bar or a flat-headed screwdriver.

4. Get a firm grip of the pry bar handle.

5. Remove lid by prising open with pry bar and place safely to one side. (Do not use a screwdriver).

6. When you use the pry bar to lift the lids avoid using a rotating/twisting motion to protect your elbow and wrist. Lever the lids with an up/down motion.

7. When you have finished the task, replace the lid making sure that it is securely inserted and flat with its housing. Do not create a trip hazard.

8. Throughout the day, alternate your activity by using different positions which are comfortable for you to lift the cover. For example, one knee kneeling (alternate knees), full kneeling (both knees) or squatting.

Technique is everything.

When you have to lift a Stanton Warrior lid, follow the same principles as with a pry bar lift. You can use the

Stanton key as an alternative to a large pry bar to remove the cover.

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Atplas100 x 100mm

Double Atplas250 x 200mm

Talbot150 x 150mm

Saunders150mm diameter

Atlantic (6 port Talbot)600 x 250mm

Ashworth Frazer380 x 280mm

10

G&C Bulls Eye750 x300mm

G&C Bulls Eye100mm diameter

D400 D/triangularGrade A (Heavy Duty) ductile iron surface boxes to BS 5834

• 150 x 150 x 100 / 8.4kg

• 225 x 225 x 100 / 13.2kg

• 300 x 300 x 100 / 21.3kg

Stanton Warrior400 x 250mm / 27kg

When lifting a Stanton Warrior lid follow the same principles as with a pry bar lift. The Stanton key may be used as an alternative to a large pry bar to remove the cover.

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1. Make sure there is enough space to manoeuvre as a group.

2. Each person must:• check the cover is free to lift and

free of any defects that may affect the lifting of the cover.

• adopt a stable position, stand directly in front of the load, with your feet about shoulder-width apart.

3. Insert the lifting keys into their slots and get a firm grip of their handles. Keep close to the load.

4. Bend and unlock your knees and tighten your stomach muscles.

5. Lift with your legs, not your back.

6. Keep the natural curve in your spine.

7. Move your feet. Do not lift a cover by bending and twisting at the same time. Avoid jerky movements.

8. If you think it is necessary, conduct the lift in two stages to avoid over-reaching. Lift the cover from the frame, put it down at an angle on the frame and then reposition your feet before placing the cover in its final location. Do not overstretch, and ensure you communicate with the other lifter.

9. Do not attempt to lift any cover you feel you cannot lift safely, using two lifting keys or hooks.

Two-man lifts

Two-man lifts should follow the same principles as a single person lift, but it is essential that you plan the lift together and communicate throughout. Always refer back to the pristine training you have received.

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1. Inspect the cover for potential wear or damage and clear the debris away from the cover and out of the keyways using a screwdriver. Before you lift, decide where you will put the cover.

2. Adopt a stable position. Stand directly in front of the cover, with your feet about shoulder width apart and, if possible, place one foot slightly forward of the other.

3. Insert the correct lifting keys (they should not be loose in the keyway and be fully engaged). Get a firm grip of the handles.

4. Test that the cover is free in the housing before trying a full lift. Bend and unlock your knees and tighten your stomach muscles.

5. Lift evenly with the legs – not your back – and do not yank, snatch or jerk.

6. Keep the natural curve in your spine. Do not bend your back any further during the lift.

7. Do not lift a cover by bending and twisting.

8. When you have finished your work, reverse this procedure to replace the cover. Make sure the cover is securely inserted back into place and sitting correctly in its frame.

9. Do not attempt to lift any cover you feel you cannot lift safely.

Using two lifting keys or hooks

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Two key lifts

Meter Inspection Lid550 x 400mm / 9kg

Clarcon DOM500 x 350mm / 9kg

MWB Double Cover450 x 300mm / 9kg (per cover)

Up to 25kg

Galvanised Lid600 x 450mm / 11kg

Wilder & Sons247 x 212mm / 13kg

No markings600 x 450mm / 14 - 15kg

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Thomas Dudley400 x 250mm / 15kg

MWB Kensington Palace900 x 450mm / 22kg

M260600 x 450mm / 24kg

D400 Hydrant boxBadged ‘W’ & ‘Thames Water’380 x 230 x 125mm

LCC FH Cover Replacement Kit c/w Badged ‘FH’ & ‘Thames Water’700 x 350 x 75mm

Ductile Iron Single Seal Cover & Frames‘Kitemarked’

• 600 x 450 / 40kg

• 600 x 450 / 40kg

• 600 x 450 / 75kg

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D400 - ‘HIGHWAY’ Ductile Iron Cover & Frames‘Kitemarked’

• 450 x 450 / 100kg

• 600 x 450 / 100kg

• 750 x 600 / 100kg

• 750 x 600 / 150kg

• 750 x 750 / 100kg

• 900 x 600 / 100kg

• 900 x 600 / 100kg

• 900 x 900 / 100kg

• 1220 x 675 / 100kg

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Concrete lid600 x 400mm / 25kg +

(Weight depends on thickness and make up of fill. Individual, careful assessment is needed.)

Stanton Rapide 75900 x 600mm / 27kg

Brickhouse Dudley900 x 600mm / 28kg

Over 25kg

Brickhouse ductile Valiant900 x 600mm / 28kg

No markings600 x 400mm / 34kg

Stanton Trojan 75600 x 450mm / 34kg

Two key lifts

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PAM OPT-EMAX 150 Range 37kg

Glynwed Dreadnought600 x 450mm / 38kg

Stanton Briton610 x 610mm / 40kg

Peter Savage600 x 450mm / 42kg

Large galvanised lid900 x 900mm / 43kg

Guest & Chrimes500 x 300mm / 46kg

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Stanton Trojan 57600 x 750 / 49kg

Stanton & Staveley900 x 600mm / 49kg

Stanton Challenger620x610mm / 49kg

Clover leaf Steel Slide750 x 600mm / 49kg

Stanton Chieftain600x600mm / 50kg

City of Westminister split lid600 x 600mm / 50kg

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Four key lifts

Concrete lid• 600 x 400mm / 25kg +

• 600 x 600mm / 25kg +

(Weight depends on thickness and make up of fill. Individual, careful assessment is needed.)

Bripave (brick infill)600 x 450mm / 44kg (Weight depends on bricks used.)

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Two hook lifts

No markings600 x 450mm

Concrete fill 800 x 600mm / 25kg +

(Weight depends on thickness and make up of fill. Individual, careful assessment is needed.)

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Lift and slide1. Inspect the area and clear it if it

needs it, so that there is a clear way to lift and drag. Inspect the cover for potential wear or damage.

2. Clear the debris away from the cover and confirm it is free to lift.

3. Adopt a stable position. Stand directly in front of the cover, with your feet about shoulder-width apart and, if possible, place one foot slightly forward of the other.

4. Insert the lifting key and get a firm grip of the handle.

5. Bend and unlock your knees and tighten your stomach muscles.

6. Lift evenly with your legs not your back and do not yank, snatch or jerk.

7. Roll backwards on the balls of your feet, transferring the load smoothly from your leading leg to the other.

8. If necessary, put the cover down before taking a further step backwards.

9. Keep the natural curve in your spine. Do not bend your back any further while you are lifting.

10. Do not lift a cover by bending and twisting.

Do not attempt to lift any cover you feel you cannot lift safely.

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PAM lift and slide900 x 600mm / 53kg

Stanton Rapide 50 Slideout450 x 300mm / 19kg

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Thames Water uses a number of secure covers across the business. For obvious reasons they are not illustrated and the technique for unlocking is not given.

Secure covers cannot be opened without a specific key and you should not attempt to lift these covers.

Contact your team manager for further guidance when you come across a secure cover.

A welded cover indicates that an asset housed below the cover may have been isolated or taken out of use. Do not attempt to break a weld or seal of any cover. Stop and escalate this situation immediately.

To avoid injury, we place the same emphasis on checking secure covers before lifting as mentioned earlier in this booklet.

Secure covers

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Techno-covers

Different styles of this type of cover exist with variation around the locking device. It is important to understand the release mechanism for each type of cover.

Unlock the cover and apply a slight downward pressure to the cover which will release the retaining bolts.

Release this pressure to the top of the cover and allow the sprung hinge to lift cover.

Standing to one side of the cover, hold the handle and lift the cover to fully engage the locking device.

To close the cover, stand to one side, release the locking device and lower the cover until it is in position 2 (cover supported by a sprung hinge, apply pressure to the cover top and engage locking pins, lift locking hasp and refit lock.)

1 2

3 4

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IndexCover Type KgAshworth Frazer N/AAtlantic (6 port) N/AAtplas N/ABrickhouse Ductile Valiant 900x600 28Brickhouse Dudley 5253 900 x 600 28BRIPAVE brick infill 44City of Westminster (split lid) 600x600 50Clarcon Dom 500x350 9Concrete infill 400x600 / 600x600 25+Concrete lid 400x600 25+Double Atplas N/ADouble Galvanised Lid Petrol Station 600x450 29Galvanised lid 600x450 11Galvanised lid 900x900 43Guest & Chrimes 500x300 46Guest & Chrimes Bulls Eye N/AM260 45 600x450 24MA60 (split lid) 600x450 38Meter Inspection lid 500x450 9MWB double cover 300x450 9MWB Double mesh top 600x450 32MWB Kensington Palace 900x450 22PAM 5474 (lift and slide) 900x600 53Peter Savage (split lid) 600x450 42Proteus lifter ---Saunders N/ASecure Covers ---Stanton Trojan 57 600 49Stanton Challenger 620x610 49Stanton & Stavely (split lid) 900x600 49Stanton Rapide 50 Slide out 450x300 19Stanton Rapide 75 600x900 27Stanton Trojan 600x750 48Stanton Trojan 75 600x450 34Stanton Chieftain 600x600 50Stanton Warrior 400x250 27Talbot N/ATechno- covers ---Thomas Dudley 400x250 15Wilder & Sons 350x250 13Solid Top DMT0D4/6060/KUTW 54.1Solid Top DMT0D66060/KUTW 54Solid Top DMT0D4/6767/KUTW 74.5Solid Top DMT0D6/6767/KUTW 78.6DMT0D6/6060/KUULL 72DMT0D4/6045/KTHATW 75.3DMT0D4/7560/KTHATTW 37.3DMT0D4/9060/KTHATW 63.8DMT0D4/1267/KHATW 78.1Solid Top KMS1A2/6045/KTW 56.6Solid Top DMS1B2/6045/KTW 36Solid Top DMS1B3/6045/KTW 15.5Solid Top DMS1B3/9060/KTW 15.8

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Keeping you healthy and safe, every day at work.

thameswater.co.uk