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E: sales@smp.co.uk - W: smp.co.uk - T: +44(0)845 260 1655

INSTALLATION INSTRUCTIONS

CAPE HORN EC202S & EC202B

CAPE HORN EC202

Page 2 ISSUE B 25-04-2012

CAPE HORN EC202

Section 1 Page 3

Section 1:

EC202S3.90 X 1.70 X 1.70

248.00 0.455.00 X 3.00 0.40m T = 4h

EC202B 261.00 0.49

x 2 = T

6700

3250

0.40 m

TYPE 1/2/3 101/144

1500R

1500R

1500R

1500R

1500R

1500R

1625

1625

ISSUE B 25-04-2012

CAPE HORN EC202

Section 1 Page 4

EC202B

3750

0.40 m

300

700

0.0

TYPE 1/2 101/144

1100

300

750

0.0

A

1 LTB83

450 X 450

775

1150

100

0.0

450 X 450

B

A

A A

A

B B

450 X 450450 X 450

775 40

0 X

400

400

X 4

00

3450

ISSUE B 25-04-2012

CAPE HORN EC202

Section 1 Page 5

EC202S

0.40 m

850

300

0.0

1 LTB83 TYPE 3 101/144

350

1150

1100

0.0

3750

A

775

450 X 450

A A

A

B B

450 X 450450 X 450

775 40

0 X

400

400

X 4

00

3450

B

A

ISSUE B 25-04-2012

CAPE HORN EC202

Section 1 Page 6

ITEM REF EC202S EC202B kg

1 781-018 1

51.00X 4

10.90X 1

2 780-504 4 0.50

3 RYBL200 2 7.5

4 780-559 2 1.62

5 780-593 4 0.40

6 780-594 8 0.003

7 780-595 8 0.02

8 786-925 8 0.03

9 10301002 8 0.014

LTB8 X 42800

2400PCH X 1

910 CRSRTB4

200

MCH

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CAPE HORN EC202

Section 1 Page 7

ITEM REF EC202S EC202B kg

10 803702 2 5.00

11 305802 2 6.0

12 10231040 8 0.05

13 10261000 8 0.01

14 10381600 4 0.007

15 10321600 4 0.031

16 786-904 4 0.03

17 782-000 1 0.05

18 10051025 4 0.03

19 RYADHBK 1 -

20 10120400 1 -

420

Aro-Seal 1132 Polyurethane Sealanthttp://www.alansonsuk.com/downloads.asp

ISSUE B 25-04-2012

CAPE HORN EC202

Section 1 Page 8

STEP 1

1 LTB81415

5

X 4

1 LTB8

ISSUE B 25-04-2012

CAPE HORN EC202

Section 1 Page 9

STEP 2

1 PCH

9

4

1 PCH

8

8

9

4

ISSUE B 25-04-2012

CAPE HORN EC202

Section 1 Page 10

STEP 3

1 LTB8 1 LTB8

0.0

3750 CRS

45°

4&5

1550

CR

S45°

45°45°

1100

1700

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CAPE HORN EC202

Section 1 Page 11

STEP 4A - EC202B

3450 CRS

12

13

X 2

11

0.0

TYPE 1/2 4

0.0

11

300

100 10

X 2

10

10

775

TYP

10

1550 CRS REF

4750 CRS REF

10

10

‘A’ ‘A’

‘A’ - ’A’

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CAPE HORN EC202

Section 1 Page 12

STEP 4B - EC202S TYPE 3 5

775

TYP

4750 CRS REF0.0

0.0

10

X 2

10

10

10

10

1550 CRS REF

3450 CRS

‘A’ ‘A’

‘A’ - ’A’

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CAPE HORN EC202

Section 1 Page 13

STEP 5

X 4

6 7

24

1 PCH

1 PCH

ISSUE B 25-04-2012

CAPE HORN EC202

Section 1 Page 14

STEP 7

X 2

1 LTB8

4&5

STEP 6

1 LTB8

267

5

X 2

2

5

14

76

X 2

15

5

15

14

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CAPE HORN EC202

Section 1 Page 15

3

3

10

Aro-Seal 1132 PolyurethaneSealant Black

http:/www.alansonsuk.com/downloads.asp

STEP 8

STEP 9

X 4

16

19

10

ISSUE B 25-04-2012

CAPE HORN EC202

Section 1 Page 16

1 LTB**

STEP 11

STEP 10

500

17

18

1 LTB8

0.0

ISSUE B 25-04-2012

CAPE HORN EC202

Appendix A Page 17

Appendix A:

144

TYPE 3 SYNTHETIC 144

TYPE 1/2 LOOSEFILL

1010

3270

1010

1010

1010

1010

6720

1010

1635

1010

1010

1635

1010

3270

1010

1010

1010

1010

6720

1010

1010

1635

1010

1635

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CAPE HORN EC202

Appendix A Page 18

144TYPE 5 GRASSMATT FR

3750

1875

1775

1500

144TYPE 5 GRASSMATT FR - WEAR AREA

6000

2000

1000

1275

TY

P

1500TYP

1000TYP

7000

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CAPE HORN EC202

Appendix A Page 19

1 SAFE WORKING PRACTISE

A full risk assessment should be carried out prior to commencing the installation, which will be specific to the siteselected. The major risks associated with purely the assembly of this product are highlighted below, which can formpart of this overall assessment.

1.1 RISKS:

i) Large parts which could be difficult to lift or handle.

ii) Structure unstable until concrete footings have fully cured.

iii) Parts at height that may require working overhead.

iv) Heavy parts at height that require support during assembly

1.2 CONTROL MEASURES:

i) Warn the public of the risk of injury, by placing signs and fencing the surrounding area, before commencinginstallation.

ii) All staff working on installation to wear suitable PPE including Toe Protective Shoes, Hard hat and Gloves.

iii) Any staff or other persons on site, not working directly on the installation, to be kept away from the installation.

iv) Ensure adequate personal and equipment are on site to handle and support the structure whilst it is beingassembled.

v) Suitable working platform to provide secure access and provide support for parts required.

2 SPECIFICATIONS

SMP Playgrounds Ltd recommends an effective Impact Absorbing Surface tested to EN1177 & BS7188 beneath thisplay equipment. Refer to manufacturers instructions for details of installation. The surface should have a Critical FallHeight greater than the Maximum Free Fall Height of the equipment.

Constructional Space is the approximate working area required to lay out and assemble the equipment.

For the safe operation of this equipment it must be installed on horizontal ground with the required minimum space.

The concrete foundations indicated are for average ground. Care should be taken concerning abnormal conditions.

If a loose fill surface is selected for this item it will require a very high level of maintenance to ensure a sufficientthickness is in place at all times to provide ‘critical fall height’ protection.

3 PREPARATION

All equipment assembly and fixing must conform to EN1176.

Tools / ancillary equipment: Plumbline, 5m tape measure, spirit level, TT-25 fixing tool (supplied with unit), metricsocket set - inc 10-24 sockets, 2.5mm AF Allen Key. Loose fill: Masking tape, Paint brush, Black paint.

3.1 ESTABLISH ORIENTATION

vi) Measure out the site to ensure the space required fits into the allotted area, it is horizontal and free from trippoints or other obstructions.

vii) Ensure the equipment is to be provided with an effective Impact Absorbing Surface which has a tested criticalfall height rating greater than the maximum Free Fall Height of the equipment.

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Appendix A Page 20

3.2 MARK OUT HOLES

Consult SMP layout drawing for structure position on site.

See page 4 & 5 for concrete foundation sizes.

NOTE: This is a minimum guide only.

3.3 ESTABLISH DATUM LEVEL

i) If a rubber tiled Impact Absorbing surface is to be laid, see separate instructions (base may incorporate up to2% falls etc).

ii) If equipment is to sit in loose fill or wet pour rubber surfaces allowances will need to be made for itsrecommended thickness. Generally it is recommended that loose fill surfaces are installed to a depth of300mm, however, with certain loose fill materials an alternative depth may be required. This will need to bedetermined by allowing 100mm for the dispersal in addition to the thickness required for the particular FreeFall Height. The foundation illustrated will allow for a thickness up to 300mm.

PRE-INSTALLATION INSPECTION

Inspect all parts for damage (that may have occurred during transportation & storage). Finish Coatings, if found to bedamaged these should be made good before erection (Refer to maintenance instructions). Any damaged or missingparts must be replaced.

4 INSTALLATION & ASSY PROCEDURES

i) Refer to site layout for position and orientation of product, then, mark the outline of the position of the footingswith e.g. spray or chalk etc. Excavate the holes. (SEE PAGE 4/5).

ii) Fit 1 off BTN 135 Bolt (item 5) to each Upright Post (item 1 - LTB8), secure using 1 off M16 Washer (item 14)and M16 Nyloc Nut (item 15). Check counterbores and holes are clear, ensure BTN Bolts are located in theshallow counterbore on inside of posts. Ensure slots of BTN Bolts are positioned vertically (rope must pivotvertically only) and the pins are pulled into the grain of the timber when tightened. (STEP 1).

iii) Assemble to 2.4m Plank (Item 1- PCH) 2 off Plate (item 4) using 8 off M10 X 50 Coach Screws (item 8) andM10 Armour Rings (item 9). Fully tighten. (SEE STEP 2).

iv) Place upright posts into designated excavations, rotate posts by 45° so all BTN Bolts are facing inward, asshown. Brace in position and ensure all the posts are level, plumb and spaced to correct dimensions, this iscritical for the correct tension of the ropes. (SEE PAGES 4 & 5, STEP 3)

v) Place 2 off 200mm Bollard Fixing Posts (item 10) into designated excavations, brace in position taking noticeof surface type and requirements. For Type 1/2 attach Bollard Fixing Posts (item 10) to Extension Posts (item11) using 8 off M10 X 40 Hex. Bolt (item 12) and M10 Nut (item 13). (SEE PAGES 4 OR 5 & STEP 4A OR 4B).

vi) Attach 1 off Rope (item 2) to Plate (item 4) which is connected to the Plank (item 1 - PCH), secure using 1 ofPivot Bar (item 7) and M5 X 25 Grub Screw (item 6), utilise 2.5mm AF Allen Key ensuring grub screw goesthrough Pivot Bar to full depth of tapped hole. Fully tighten. Repeat instruction for other 3 Ropes (item 2).(STEP 5).

vii) Verify ropes fit - remove before concreting. (STEP 6).

viii) Fill the holes with concrete to the required level, taking into account any Impact Absorbing Surfacingrequirements. Ensure that the full volume of concrete is used. The top of the concrete should gradually (1:100)slope down & outwards locally from the equipment upstand to the required level to form a watershed.

Concrete mix is recommended at:1 part cement;2 parts sand;

4 parts aggregate; by volume with 20mm aggregate

(20 N/mm2 min compressive strength)

ix) Keep installation off limits to the public until the concrete has completely cured. (Recommended initial curingtime is 48 hours). (STEP 6).

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CAPE HORN EC202

Appendix A Page 21

x) If installation is with a loose fill type (type 1/2) surface, the upright posts should be marked with ‘Basic levelmark’ to indicate the recommended finished surface level. (SEE PAGE 4).

xi) Remove any installation aids before fitting ropes. Place Plank with Plates and Ropes attached, into centre ofthe 4 Upright Posts (item 1 - LTB8). Attach two of the rope ends (item 2) to two of the BTN 135 Bolts (item 5)found at one end of the unit on the two Upright Posts (item 1 LTB8), secure using 2 off Pivot Bar (item 7) andM5 X 25 Grub Screw (item 6), utilise 2.5mm AF Allen Key ensuring grub screw goes fully into hole of pivot barto full depth of BTN fitting. Fully tighten, allowing ropes and plank to hang freely. (STEP 7).

xii) Upon the other Upright Posts (item 1 - LTB8), remove the BTN Bolts and their fixings, connect each free endof Rope (item 2) to a BTN 135 Bolt (item 5) using 1 of Pivot Bar (item 7) and M5 X 25 Grub Screw (item 6).Replace the BTN Bolts back within the counterbores on the upright posts and secure using 1 off M16 Washer(item 14) and M15 Nyloc Nut (item 15). Check counterbores and holes are clear, ensure BTN Bolts arelocated in the shallow counterbores on inside of posts, with slots positioned vertically (ropes must pivotvertically only) and pulled into the grain of the timber when tightened. Allow the ropes to take the weight of theplank. (STEP 7).

xiii) Fit 2 off 200mm Bollards (item 3) to Fixing Posts (item 10). Apply adhesive (item 19) to Fixing Post (item 10)and slide Bollards (item 3) onto posts until fully home. (Refer to instructions provided with adhesive). (STEP 8).

xiv) Fit 4 off Black PLastic Caps (item 16) to cover fixings within available counterbores of all posts. (STEP 9).

xv) Ensure Manufacturers label (item 17) is fitted to outside of Upright Post (item 1 - LTB8), 500mm up from FinishSurface Level (0.0) using 4 off 1” Self Tapping Screw (item 18). (STEP 10).

xvi) Ensure all paper labels and staples upon all timber (Item 1- LTB’s) are removed. (STEP 11).

5 POST INSTALLATION INSPECTION

CHECK CHECK

1 The unit is installed at the correct height.

2 All fixings are tightened and have no protruding sharp edges.

3 All wooden parts should have no sharp edges or cracks.

4 Ensure Pivot Bars and Grub Screws are fitted to BTN Bolts.

5 Ensure all plastic plugs are correctly fitted.

6 Ensure Manufacturers Label is fitted.

7 Ensure all paper labels and staples upon all timber are removed.

8 Concrete foundations are secure.

9 Concrete has a water shed away from leg.

10 Adequate provision of Impact Absorbing Surfacing with no obstructions or other hazardswithin the equipments minimum space.

11 Site is clear of all tools and rubbish.

12 Remove any warning signs.

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CAPE HORN EC202

Appendix A Page 22 ISSUE B 25-04-2012