Product Overview and Tech Specs
Advantages of the Dawson Capping System
Capping Equipment

Method of Operation

Note - the information given below in this section is intended to give the potential user an indication of how to use the system. Fully detailed operating instructions are supplied with the equipment and under no circumstances should the user work only on the information contained herein! See Safety Points for further general guidance.

 

Basic System Configuration

 


Safety Points

 



Setting up the Redeb Support Brackets

 

Scribe a setting out line at the correct height on the pan of every alternate pile. Using a counter punch, mark a position on this line. Allow a distance of 40mm from the fixing centres to the top surface of the bracket.

 

 

Lower the bracket into position and with the Quick Release mechanism in its extended position, with the release lever pointing downwards, tighten up the Jacking Bolt at the other end of the bracket with a torque wrench to the required torque (180Nm). By doing this the two hardened steel points will enter into the sides of the piles.

 

 

The axis of the bracket is now at the correct level. The leg of the bracket has to be levelled by adjust the levelling bolt at the base of the leg. Place a spirit level on the horizontal arm to obtain the correct level.

Repeat this procedure until a bracket is correctly positioned in every alternate pile pan.


The intermediate brackets can now be positioned, by leveling them up to a straight edge between two previously positioned brackets.

Once all the brackets are secured, go back and check that they all have the correct torque. The brackets are now ready to receive the soffit shuttering.
 

Setting up the Soffit Shutter Panels
(For use in conjunction with the Redeb Support Brackets)

Install the Redebs as described under Setting up the Redeb Support Brackets, in every outside pile pan. Ensure that they are at the correct level, correct torque (180 Nm) and horizontal (see Safety Points).

 

Fix a Back Stop inside the end of the longer arm of each Redeb Bracket and bolt it to the Redeb. Lower the Soffit Panels onto the Redebs and ensure, where possible, that the front edge of the panel is tight up against the outside edge of the sheet piles.

 

Next, ensure that the Back Stops are tight up against the back of the panels. This can be achieved by use of wedges. These Back Stops prevent the Soffit Panels moving back along the Redebs and take any horizontal load that may try to cause such a movement.


The guardrails are an integral part of the 2.5m Soffit Panel.

Using a nail bar or similar, lightly tap on the ends of each of the steel bars, until they have all been pushed hard up against the sheet piles; start by tapping the bars into the centre of the pan of the piles and then work outwards. Oil the bars generously with shutter oil.

 

The side Shutter Panels can now be positioned straight on to the top of the offit Panel bars. The trapping bar member on the top-side of the panel can be used to aid positioning of the side shutter. However, the horizontal load exertion by the wet concrete should not be taken by the Panel, but by some other method, such as ties passing through the concrete and fixed to the sheet piles.

 

Any small gaps between the steel bars and the sheet piles can be filled with mastic or other filler plugs to prevent grout leakage. Use mould oil or shutter oil on the bars to minimise any adhesion from the concrete.

 
Join each Soffit Panel together with fixing bolts provided.

Removal of the system

Removal of the system After 36 hours the Soffit Panels and Redebs are ready to be stripped.

From underneath the concrete cap, turn the leveling bolt on the Redeb to slightly lower the Soffit Panel. This helps the removal of the Soffit Panel which can now be done, followed by the Redebs -by way of the Quick Release cam release!

The lifting of the Soffit Panel will automatically cause free movement of the steel bars, and will help to shed any grout. With a stiff brush sweep all concrete grout and debris off the bars to ensure no concrete becomes encrusted. The sooner the panels are scrubbed and cleaned after the concrete pour, the easier and quicker it is to prepare them for re-use.

The panels will be supplied with as many bars in them as possible, which ensures a minimum of grout leakage between the bars. However, after a number of concrete pours, the free movement of the bars in the panel may become restricted and in practice this can be eased by removing one or two of the bars. Any 'gaps' caused by this will immediately be taken up by the remaining bars.