Modular, Multi-span, and Multi-cover Units

The Ironmaster system from Rhino delivers an engineering solution to replace, rebuild and re-bed multi-span access covers and frames.

Failure of multi-span access covers:

There are various factors that can lead to the failure of multi-span access covers. Some of the possible causes include:  

  • Supporting structure
  • Mortars
  • Frame
  • Surround
  • Lids

Ultimately it doesn't matter. By the time we are alerted to the failure, it’s difficult to tell the original cause, nevertheless our solution is to tackle each of the failure mechanisms on every job and ensure they are all repaired, reinstated, rebuilt, and up to standard.

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Fleet Street, London

Images show Fleet Street in construction. These do not portray the final look of the Modular Large Access Cover.

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Patching over the collapse with asphalt:

As a holding measure, the covers have been patched on one or more occasions with asphalt, pending a permanent resolution. Eventually the stresses placed on the frame will result in a total collapse which means it is time to look for a permanent solution.

Rhino Asphalt Solutions have developed a specialist team to resolve these issues with large modular multi-span access covers and frames.

An inspection visit to open the lids and ascertain the correct sizing for a replacement is needed. The lids require opening to determine the clear opening size of the frame, as this is not necessarily the same as the cover/lid size, or the internal dimensions of the pit/chamber. A quote for this visit is provided which necessitates a Hiab lorry, a Rhino installation lorry, a lift plan & RAMS, temporary patching, and of course, traffic management.

BBA HAPAS approved reinstatement materials will be used for temporary patching. Jointmaster IMP material (HAPAS certificate 09/H149) will give you assurances of a safe, temporary reinstatement prior to the main works commencing.

We can then issue a quotation for the manufacture and replacement of the unit. Following acceptance of this we can order the manufacture of the bespoke ironwork and the replacement works are planned. All this can be done whilst leaving the site safe for traffic.

The Hiab lorry & the Rhino installation lorry need access alongside the works area simultaneously

A rapid-set, flowable, modified concrete bedding mortar is used for bedding the frame and flange reaching 25N/mm² compressive strength in one hour.

Backfill with rapid-set fibre-modified concrete to encase the unit reaching 20N/mm² compressive strength in 90 minutes, ready to receive the surface course layer.

Ironmaster is a BBA HAPAS approved ironwork reinstatement system covered by certificate 06/H123 which covers testing and inspection of bedding & infill mortars as well as the surface course material.

Originally approved in 2006, Ironmaster has become the industry standard for durable ironwork repairs & reinstatements.

Using the knowledge and materials gained from this experience we have successfully utilised the system to deliver a durable replacement of failed large & multi-span units in highways & tunnels.

Modular Large Access Covers

Large chambers with modular access solutions are often considered a specialist activity due to their size, weight, and complexity. 

Rhino are specialists in understanding the specialist issues of repairing and re-bedding large modular access covers in environments such as tunnels, ports, car parks and highways. 

These large units require lifting equipment, and materials capable of fast setting times and supporting heavy loads. They conceal underground services which require maintenance, so accessibility is paramount. 

Services we offer: 

  • Re-bedding and adjusting modular frames and covers
  • Replacing modular systems in their entirety
  • Inspecting, measuring, and sourcing replacement sections
  • Lifting, inspecting, and re-greasing to maintain access for your maintenance teams 
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We work in conjunction with manufacturers of the covers and frames to ensure that the specification is right for your job and that available special features are specified accordingly. 

Utilising our knowledge and experience of installing over 10,000 ironmaster units in UK highways, we install these large access covers using the tried and tested Ironmaster systems adapted specifically for use on modular access systems. Rhino enables your project to be installed by fully trained specialists ensuring that a long-lasting solution is in place and suited to the specific requirements of this specialist area. Utilising mobile lifting cranes, high strength mortars and our unique surface finish, the Ironmaster system installed by our own trained crews is the ideal solution to your difficult modular system troubles. 

How do we work: 

  • In the first instance we need full access to the site to measure and assess the requirements. 
  • We will then have the units manufactured off-site to the specific requirements of the job. 
  • Our crews will then attend site to install the units 

To start the process, contact us and we can arrange a visit to discuss the next steps. 

 

Multi-spans

The Ironmaster system from Rhino delivers an engineering solution to replace, rebuild and re-bed multi-span access covers and frames. 

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Failures of multi-span access covers:

There are various factors that can lead to the failure of multi-span access covers. Some of the possible causes include issues with the:    

  • Supporting structure
  • Mortars
  • Frame
  • Surround 
  • Lids

By the time we are alerted to the failure, it’s often difficult to tell the original cause. Nevertheless, our solution is to tackle each of the failure mechanisms in every job and ensure they are all repaired, reinstated, rebuilt, and up to standard. We offer a permeant solution, as many temporary solutions, such as patching, can cause stress on the frame and cause total collapse.  

Before installation, an inspection is needed to open the lids to ascertain the correct sizing for the replacement. We provide BBA HAPAS approved reinstatement materials which will be used for temporary patching until the main works commence. This means that the site is safe for traffic whilst we issue a quotation with you and the manufacturer.  

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Fitting a Multi-span

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Safety

Lift plans & RAMS are submitted for approval prior to works commencing.

A sufficient working window of minimum 8 hours needs to be allowed for the installation works.

Installation timescales vary according to size & complexity.

The hot applied Jointmaster IMP surface course material is applied by hand from the Rhino installation lorry into the remaining recess around the new ironwork and then granite aggregate applied for a skid resistant finish. Once cooled & swept, the site can be safely opened to traffic.

Medway Tunnel Work

Multi-lid units are commonly found in tunnels and contain apparatus such as pumps. They can also have concrete filled lids. The measuring process is the same and installation work is unchanged. When planning the works, please take into account the timeframe for tunnel closure constraints, particularly the reopening times

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Multi-lid units are commonly found in tunnels and contain apparatus such as pumps. They can also have concrete filled lids. The measuring process and installation work are the same. When planning the works, please take into account the timeframe for tunnel closure constraints, particularly the reopening times.  

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We rely on Rhino because of their system, certification, workmanship & reliability. They applied the same skills and attention to detail in getting the multi-span cover correct. It is a specialist job for which they are ideally suited

Rhino Asphalt Solutions Ltd were in all aspects of planning very professional, and the quality of their products at the Medway Tunnel are great.