User Guide

Mr cropper_user guide_1.5_EN_21-03-19

Rev Date Comments Initial

1.5 21/03/19 Update DSW

Mr Cropper Range of Equipment

Important Notes

All piling and associated excavation work must be thoroughly planned before work commences on site to identify hazards and assess risk.

These instructions form guidance for Mr Cropper Equipment. Non-standard

applications should be approved by a suitably qualified engineer.

Ensure all personnel engaged in cropping operations are properly briefed and adequately supervised by a competent person.

The range of Mr Cropper equipment is available to watch now on our YouTube channel.

ID:001031

IF IN ANY DOUBT SEEK FURTHER ADVICE:

0870 60 777 44

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Introduction

Mr Cropper is a specialist company offering Pile Croppers to suit all applications, including; pre-cast square, circular, multi-bar or single cast reinforced piles through to croppers designed for use in narrow trenches and confined spaces.

All croppers come supplied with chains and are powered by the excavator’s in-board hydraulics. While it is possible to break off the pile and rebar in one go, most croppers have the ability to leave the rebar intact and undamaged. All equipment is dispatched for nationwide delivery and a team of experienced engineers can provide on-site assistance anywhere in the UK; backed by unrivalled technical support.

Equipment

Single Bar Pile Cropper For cutting square pre-cast single reinforcement

piles.

The Power Cropper Used for ultra-fast pile reduction of pre-cast and four bar piles. Can break off the pile and rebar in one go and then nibble the pile leaving the rebar exposed.

The Multi-Bar Cropper For cutting square, pre-cast piles with four to

eight rebar.

The C.F.A. Cropper For fast reduction of cast in-situ, circular concrete piles from Ø300mm to Ø1200mm (see modular configurations on page 5).

See the tables on page 4 for equipment specifications for each type of pile cropper.

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Equipment Cont...

The C.H.D. Cropper For cutting C.H.D. or ’corkscrew’ piles. Can also

be used for secant piles.

Trench Cutter Used for cutting 300mm - 400mm piles in a

trench of only 700mm wide.

The 4 Jaw Cropper (Standard and Large) Used for cutting cast in-situ piles ranging from

300mm - 750mm leaving the rebar intact.

Note: All croppers are of considerable weight and therefore it is essential that the excavator in use is of the correct tonnage class. See tables on the following page for the required excavator class for each cropper.

CHAIN FRAMES

LIFTING FRAME WEIGHT (KG)

6 Chain 82

8 Chain 112

10 Chain 143

12 Chain 305

15 Chain 356

12 Chain H/D 800

Multi Chain H/D 835

The 4 Jaw Cropper (Mega and Super Mega) Used for cutting cast in-situ piles ranging from 8000mm - 1200mm leaving the rebar intact.

The HD435 Super Heavy Duty CFA Cropper Used for cutting large round concrete piles from

1200mm to 2100mm

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Equipment Specification

Pile Size Excavator Requirement/Min (t)

Weight (KG)

Width (mm)

Length (mm)

From To

Pile Cropper 6” 5” (125mm) 6” (150mm) 6 360 250 560

10” 7” (200mm) 10” (250mm) 6 500 425 800

12” 10” (250mm) 12” (300mm) 6 530 520 910

14” 14” (350mm) 14” (350mm) 6 575 580 980

Power Cropper 12” 6” (150mm) 12” (300mm) 13 1000 550 1025

14” 12” (300mm) 14” (350mm) 13 1225 600 1035

Multi-Bar 12” 200mm 300mm 6 550 1300 1300

14” 275mm 350mm 6 550 1400 1400

Trench Cutter Small 300mm 300mm 8 630 600 1300

Old Large 300mm 400mm 8 750 600 1300

New Large 350mm 400mm 8 750 700 1550

CHD Cropper 300mm 600mm 16 1840 1500 1500

4 Jaw Standard 300mm 600mm 13 1425 1650 1650

Large 600mm 750mm 16 1640 1800 1800

Mega 800mm 900mm 20 2300 2200 2200

Super Mega 1000mm 1200mm 30 3500 2420 2420

Pile Size No of Links

CFA No of Links 354 CFA

Excavator Requirement/

Min (t)

Weight Long Ram

(KG)

Weight Short

Ram (KG)

Weight 354 Rams

(KG)

C.F.A.

300 6 Short 5 6 624 585

350 6 Short 5 6 624 585

400 6.5 S / 7 L 6 6 756 663 702

450 7 S / 7.5 L 6 6 795 728 702

500 8 Long 7 10 864 819

550 8.5 Long 7 10 903 819

600 9 Long 8 13 972 936

650 9.5 Long 8 13 1011 936

700 10 Long 9 13 1080 1053

750 10.5 Long 9 13 1119 1053

800 11 Long 10 13 1188 1170

850 11.5 Long 10 13 1227 1170

900 12 Long 11 13 1296 1287

950 12.5 Long 11 13 1335 1287

1000 13 Long 11 13 1404 1287

1050 13.5 Long 12 16 1443 1404

1100 14 Long 12 16 1512 1404

1150 14.5 Long 13 16 1551 1521

1200 15 Long 13 16 1620 1521

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HD435 Super Heavy Duty CFA Pile Cropper

Maximum distance needed from edge of pile 750mm

Minimum spacing required for rebar de-bond 100mm

Minimum hydraulic oil flow rate 75 LPM

Maximum operating pressure 300 bar

Maximum chisel penetration 200mm

Minimum excavator size 35 tonne

Chains Included

Weight (kg) 265kg per link

HD435 SUPER HEAVY DUTY CIRCULAR PILE CROPPER SPECIFICATION

Pile Size 1200 1300 1400 1500 1600 1700 1800 2000 2100

No. Links 11 11 12 12.5 13 14 15 16 16.5

Weight (kg) 2882 2882 3144 3406 3406 3668 3930 4162 4424

Recommended frame

CF8503 CF8503 CF8503 CF8503 CF8503 CF8503 CF8503 CF8503 CF8503

The C.F.A. Modular System

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Safety Notes

Personnel not involved with using the cropper should stay WELL CLEAR of the procedure.

The operator should also stay well clear of the cropper until needed for the final crop at the cut-off mark.

If the operator has to work underneath the cropper, ensure that the excavator is TURNED OFF

and that the driver’s hands are in clear view.

TAKE EXTREME CARE TO AVOID THE TRAPPING OF FINGERS

Croppers should be moved on a pallet with the use of a forklift. If this is not possible, the cropper chains

can be used. Note: all croppers come supplied with certified lifting chains.

Hydraulic Hose Connection

The above photos show the quick release couplings typically used for connection to the excavator’s in bound hydraulic system. All customers will need to ensure that the excavator in use has corresponding fittings. Any additional adapters, connectors or hoses are the responsibility of the end user.

Safety Notes

Ensure the excavator’s hydraulic system is de-pressurised before any hoses are disconnected. Failure to do this may result in serious injury caused by a sudden release of hot fluid under pressure.

Any damage to hydraulic couplings or hoses, including leaks, should be reported immediately to Mr Cropper.

Operational Instructions

The left image shows a typical hydraulic hose connection attached to the cropper unit.

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Type of Cropper

Depth of cut (mm)

Final Depth of cut (mm)

Operating Pressure

Comments

Single Bar 250 - 300 60 above blinding Instruct the driver to make an initial cut below the collar

Power Up to 2m 50 - 75 above blinding Cut off any excess by lowering the cropper down the pile by one metre and closing the blades

Multi Bar 150 - 200 50 - 75 above blinding After 15 mins cutting, check the blades and bolts are still secure. A loose blade will cause damage to the piston; a loose bolt could damage the ram/cylinder

C.F.A. 200 - 300 115

For oversized piles, a half link can be used: ensure the safety plate is correctly positioned and tightened. For durability, all blades should penetrate the concrete in between the reinforcement bars.

C.H.D. 300 - After breaking the concrete, open the blades slightly and remove the cropper from the pile. Place any remaining pile from the jaws in a designated area

Trench Cutter 200 - 300 130 above blinding See Multi Bar and C.F.A comments.

Four Jaw 200 - 300 Up to 150 above blinding

See C.F.A comments

Mega 4 Jaw 200 - 300 Up to 150 above blinding

See C.F.A comments

Super Mega 4 Jaw

200 - 300 Up to 150 above blinding

See C.F.A comments

HD435 Super Heavy Duty

200 - 250 100 above blinding 300 BAR See C.F.A comments

Recommended Cutting depths* / Operating pressure

*All cutting depths are advisory and results will differ according to the concrete being cut.

Adjust or reduce as necessary should the rebars begin to break.

General Information

Always cut piles from the top and not from any other position on the pile. The rebar/s will snap if an attempt is made to cut from the base.

It is recommended that a saw mark is etched around the finish level of the pile to prevent over cutting. This can be done with a cut off saw or similar.

Always move to a safe distance once the pile cropper has been lowered over the pile.

Remember: The cropper being used will require an excavator capable of carrying its weight.

X Overload chains

X Overload the cropper unit

X Stand directly under any elevated croppers or related

equipment

X Use any cropper or its chains for anything other than

their intended use

X Use the hydraulic hoses as a handle

X Disconnect or tighten any of the hydraulics from the

excavator without first releasing the pressure

X Use the cropper for stripping the piles

X Attempt to cut piles from the base up

X Continue to use if unsure - contact Mr Cropper

X Exceed operating pressure without consulting Mr

Cropper

Ensure operatives have familiarised themselves with

the cropper being used

Use a Banksman

Ensure the Banksman and the excavator operator are

fully conversant with standard hand signals

Maintain visual and verbal contact with the Banksman

at all times

Maintain a safe exclusion zone while cropping

Keep clear of all moving components

Check all bolts, blades, hydraulic hoses and fittings

for any movement and tighten at least twice a day,

ensuring appropriate PPE is worn during this process

Load the grease nipples daily

Check the hydraulic connections for leaks before and

during use - inform Mr Cropper if any found

Check the chains after every operation

Wear adequate PPE

Do Do Not

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BA

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