Pulse carriageway 2 & 3 locking and and unlocking instructions

This method statement provides step-by-step instructions for the safe opening, closing, and basic maintenance of the security variant of Pulse Carriageway 2 and 3 frames and covers.

It is intended to support product handover, ongoing operational use, and ensure compliance with site standards.

All operations described in this document must be carried out in strict accordance with:

• HSE working procedures for the lifting, removal, and refitting of covers into frames.
• Site-specific Health & Safety procedures, including (but not limited to):
  • Manual handling regulations.
  • Use of correct PPE (Personal Protective Equipment).
  • Traffic and pedestrian management where required.
  • Safe working in and around highways and carriageways.

All lifting of covers must follow HSE guidance on safe working loads and approved lifting techniques.

Locate the padlock housing sub-covers.

Each triangular cover has one padlock housing, as shown circled in the image.

Using a 17mm socket, remove the ISO 4016 - M10 x 25 bolts securing each padlock housing sub-cover.

Use a pry bar or flat-head screwdriver to carefully disengage the sub-cover engagement feature. This allows the sub-cover to hinge open, giving access to the padlock underneath.

Use the Pulse / BT padlock key to unlock and remove the padlock body completely. The shackle will remain in place in the housing.

Once both padlocks have been removed from a pair of covers, the covers can be lifted out following standard cover handling process.

• CW2 units = 2 pairs to unlock and remove.
• CW3 units = 3 pairs to unlock and remove.

Lift and lower the coupled pairs of triangular covers carefully back into the frame, following standard cover fitting process.

Important
As you lower the covers, ensure that the locking shackle located in the frame passes through the hole in the underside of each cover correctly.

This is essential to allow the covers to be securely locked.

Insert the padlock body onto the exposed shackle and lock it securely using the BT padlock key.

Confirm the padlock is fully engaged and locked.

Hinge the padlock housing sub-covers back into their closed position. Apply firm pressure (by foot) onto the sub lid to ensure the spring retaining feature in the sub-lid engages when closed.

Secure each sub-cover down using the ISO 4016 - M10 x 25 bolts previously removed.

Tighten using a 17mm socket.

The locking system is designed to be low maintenance.

Routine Actions:

• No regular maintenance is required for the locking system components under normal operating conditions.
• During site visits or inspections, it is recommended to check for and remove any debris, silt, or buildup around the locking shackles and padlock areas.
• Keeping the locking points clear will ensure smooth operation and prevent obstruction when locking or unlocking the covers.