HESCO ACCOMMODATION BUNKERS

HAB 1
ASSEMBLY INSTRUCTIONS

July 2011
INTRODUCTION

This instruction booklet should be read in conjunction with the “HESCO®

Construction Guide for Engineers”. This booklet provides advice and guidance
on the correct use and construction of HESCO Concertainer® Units.

The construction of the HESCO Accommodation Bunker 1 (HAB™ 1)

NSN Number: 8340-99-813-3167 is ideally undertaken by 6 – 8 persons.
This number of persons will achieve 2 bunkers built in 2 days. One bunker will
take approximately 14 hours to complete. These figures are based on normal
working conditions.

Some tools are included in the kit. More basic tools such as shovels should be
supplied by the construction force.

Suitable ladders will be required to access areas above ground level.

Ladders will also be required when building the HESCO walls. Ladders when
used should always be fit for purpose.

Loading equipment such as a front end loading shovel, a Telehandler or an

excavator can be used. It is ideal that front end loading shovels are fitted
with a 4:1 bucket.

Transportation
Each HAB 1 is dispatched in 4 Crates to the following dimensions
Length = 2300mm Width = 1000mm
Height = 1100mm Weight = 960kg per crate

The crates have four way entry pallets as the base.

The crates can only be stacked a maximum of two high.
The weight of a HAB 1 including the 4 crates is 3840kg.

Each HAB 1 also has 1 pack of Plywood.

Plywood = 28 sheets 2100mm x 1200mm x 18mm
Strapped in 7s then re-strapped into 28
Pack = 2100mm x 1200mm x 550mm = 930kg
On Drop Skid = 2100mm x 1100mm x 1300mm

Total weight per HAB 1 = 4730 kg

4 off HAB 1`s can be dispatched on a 40ft trailer or container.

2 off HAB 1`s can be dispatched on a 20ft trailer or container.
The HAB 1 is capable of air despatch.

HEALTH AND SAFETY

As with all construction tasks there are some inherent risks regarding
Health and Safety. Task Commanders must ensure that all relevant and
practical Health and Safety precautions are taken.

1
 INTRODUCTION

The main risks to health and safety are:

• Manual handling injuries
• Working at height
• Collisions between personnel and loading equipment/crushing injury
• Lifting operations
• Tactical and operational risks
• Construction components becoming projectiles due to high winds

Simple precautions should be taken to ensure a safe build, such as:

• Only qualified and properly trained equipment operators should operate
the loading equipment
• Ladders when used should be secured at the top and bottom
• A minimum number of persons should be employed when carrying out
tasks at height
• Keep good site organisation
• Ensure personnel only lift the weight they are safely able to
• Provide a properly briefed and competent banksman for the loading
equipment. He is to ensure correct employment of the loading equipment,
correct placement of fill material and that working areas for the loading
equipment are free from personnel
• Assess the wind speed and its potential for damage. Some construction
components may be susceptible to being blown about by the wind during
construction. This in some cases has the potential to cause injury.
It is recommended that the construction commander makes an assessment
of the wind speed before and during the construction to ensure that
components such as the roof infill panels and plywood do not become
dislodged and injure other persons.
• All personnel should be fully briefed on the task in hand.
This should include:
- Safe methods of work
- Safety around moving plant equipment
- Correct manual handling techniques
- Work positions when working above ground level
- Avoid where possible any work within 1m of any edge
when working at height

Fill Material
It is recommended that a good fill material is chosen for the wall construction
and fragmentation screen. A well graded construction aggregate, single size
aggregate or sand is ideal. It is important that the material has a moisture
content compatible with good construction practice (it should not be too wet).
You will require approximately 80m3 of fill.

Site preparation
Wherever possible the site should be firm and level. Further detailed on site
requirements can be found at 03.1.

2
01 PARTS

4 x HAB 1 Walltop (457mm tall)

2 cell length (with additional
21" long cell)
HAB 1 – 1060

4 x HAB 1 Walltop (457mm tall)

5 cell length
HAB 1 – 1059

1 x HAB 1 unit 3 cell length

(with additional 21" long cell)
fitted with vent aperture (38kg)
HAB 1 – 1058

3 x HAB 1 unit 3 cell length

(with additional 21" long cell)
(38kg)
HAB 1 – 1057

4 x HAB 1 unit 4 cell length (38kg)

HAB 1 – 1054

Note: Diagrams are not to scale

3
 01 PARTS

2 x HAB 1 unit 4 cell length

(with additional 12" long cell)
(38kg)
HAB 1 – 1055

4 x HAB 1 unit 5 cell length (46kg)

HAB 1 – 1056

28 x 7’ x 4’ plywood sheets ¾” thick

HAB 1 – 1045

26 x Anchor assembly (18kg each)

HAB 1 – 1013

42 x Angled roof beam

(37kg when assembled in
3 piece beam)
HAB 1 – 1002

Note: Diagrams are not to scale

4
01 PARTS

56 x Angled flitch plate

HAB 1 – 1014

390 x Roof infill panel

HAB 1 – 1005

8 x Roof beam (56kg when

assembled into 4 piece roof beam)
HAB 1 – 1001

12 x Straight flitch plate

HAB 1 – 1015

8 x Half straight flitch plate

HAB 1 – 1016

Note: Diagrams are not to scale

5
 01 PARTS

36 x Swivel brackets
HAB 1 – 1018

6 x 90º HAB 1 - elbows

HAB 1 – 1022

37 x Sleeves
HAB 1 – 1023

36 x Short swivels
HAB 1 – 1020

10 x Height adjuster (Steel)

(comes complete in three sections)
HAB 1 – 1019

Note: Diagrams are not to scale

6
01 PARTS

10 x Cell leg base and top plate

(ten fitted with coil springs)
HAB 1 – 1026

10 x 150mm height adjuster sleeve

HAB 1 – 1019

50 x Wood screws
HAB 1 – 1046

200 x Roof ties (cable ties)

HAB 1 – 1048

20 x 38mm height adjuster washer

HAB 1 – 1019

13 x Geotextile liner panels 6m x 1m

HAB 1 – 1033

Note: Diagrams are not to scale

7
 01 PARTS

Poles:
Yellow 40 x eaves pole1325mm long
HAB 1 – 1004
Green 18 x ridge pole 1583mm long
HAB 1 – 1003
Blue 2 x Cross brace poles 2150mm long
HAB 1 – 1009
Red & Black 12 x truss pole 1400mm long
HAB 1 – 1007
Yellow & Green 14 x truss pole 1200mm long
HAB 1 – 1008
White & Blue 12 x truss pole 1050mm long
HAB 1 – 1006
White 12 x Tent poles (2mm Steel) 1.8m long
HAB 1 – 1010

Steel Tubes:
10 x Internal vertical roof beam
support legs 1795mm long
HAB 1 – 1017

Red 10 x Cell leg tube steel 1670mm long

HAB 1 – 1024

5 x Roof beam spacer stud

(threaded bar) HAB 1 – 1043

5 x Roof beam spacer

(2 fitted with door tarpaulin)
HAB 1 – 1011

4 x Steel bar with outer door tarpaulin

HAB 1 – 1012

Note: Diagrams are not to scale

8
01 PARTS

40 x 90˚ cross joints

HAB 1 – 1021

4 x Brace coupler
HAB 1 – 1025

1 x HAB 1 - Vent
HAB 1 – 1047

130 x HAB 1 - Clip

HAB 1 – 1034

20 x Cell leg securing clip

HAB 1 – 1035

Note: Diagrams are not to scale

9
 01 PARTS

1 x Tent roof (85kg)

HAB 1 – 1038

24 x Ratchet straps
HAB 1 – 1040

Plywood sheets
(narrow approx 16 linear metres)

1 x Roll of Tape

4 x Timber beam (2m long)

Note: Diagrams are not to scale

10
 01 PARTS
110 x Sandbag

1 x Bag of Hog rings

1 x Bag of 250 M16 x 55mm bolts,

nuts & washers HAB 1 – 1041

1 x Bag of 10 M8 x 25mm bolts,

nuts & washers HAB 1 – 1042

8 x M16 x 220mm bolts,

nuts & washers

Note: Diagrams are not to scale

11
 01 PARTS
4 x M16 x 180mm bolts,
nuts & washers

1 x Tool kit

4 x Crates (A1, A2, B1 & B2 crates,

these form part of the entrance
over head protection - OHP)
HAB 1 – 1044

1x Wall lining kit optional extra

Part No. HAB2-1050

Note: Diagrams are not to scale

12
 02 PRE-ASSEMBLY

Some operations can be performed concurrently to other operations, this is

particularly applicable for the pre-assembly of many of the roof components.

To ease unpacking of some materials it is strongly recommended that one end

of each packing crate is removed. The end should be retained for refitting prior
to the crate being used as the doorway cover.

02.1 Angled Roof Beams

Assemble 14 three piece roof beams, each complete roof beam is made up of:
• 3 x Universal angled roof beams
• 6 x Angled roof beam flitch plates

Each joint is formed from 2 angled flitch plates, 2 angled roof beams and 4
nuts and bolts. However, only fit the bolts into the 2 centre holes. The outside
holes should be left open to facilitate a later operation.

See the below diagram for an example of a completed 3 piece roof beam.

Angled Flitch Plate Angled Roof Beam

Assembled Angled Roof Beam.

Note: The ends are cut at an angle. Keep black colour code on the outside ends of beam assembly.

13
 02 PRE-ASSEMBLY

02.2 Straight Roof Beams

Assemble 2 four piece straight roof beams, each beam is made up of:
• 4 x roof beams
• 6 x straight flitch plates
• 2 x half flitch plates

Each joint is formed from 2 straight flitch plates and 4 nuts and bolts.

Roof Beam Half Flitch Plate Straight Flitch Plate

Note: The ends are cut square.

02.3 Fit the half flitch plate to the end of the beam.

Note: All bolts should be fitted to these beams.

Assembled Straight Roof Beam.

14
 03 LAYOUT

03.1 Prepare foundations and drainage as appropriate. The space required is

approximately 14m long x 7m. The foundations should whenever
possible be firm and level.

14m

7m

15
 03 LAYOUT

03.2 Lay out the units in the configuration shown. Check dimensions.
To achieve 8.1m the end wall must be pushed out slightly.

Key
3 cell unit with aperture Securing Clip.
and extra 21” cell Shown in position securing
the top of the fragmentation
3 cell unit and screen support tube to the
extra 21” cell HESCO Unit.
4 cell unit and
extra 21” cell
4 cell unit 1.5m

m
8.1

4.8
m

Fragmentation
Screen Support Tube

Note: The 4 cell unit which houses the aperture for the service duct can be fitted at either
end and on either side.

03.3 Check all the walls are in line. A tape and string line is supplied in the kit.

03.4 Assemble and fit 10 fragmentation screen support tubes and bases,
securing into position using the supplied securing clips.
Each support is made up of:
• 1 x 1670mm fragmentation screen support tube
• 2 x fragmentation screen support tube base plate, one filled
with a coil spring
• 1 x securing clip
• 1 x coil spring

Note: Pin required to make up the 3 cell and extra 21" long cell. 21” cell is loose during transit.

16
 04 FILLING

04.1 Place 150mm of fill material in the base of the corner cells.

04.2 Re-check that cells are lined up.

04.3 Place 150mm of fill in the base of each cell.

04.4 Pull out the bottoms of the cells.

04.5 Place 300mm of fill in each cell. Ensure fill is placed equally in cells
and that no adjacent cell has more than 300mm of fill than its neighbours.

04.6 Continue to place fill in layers in each cell and once practical the fill
should be compacted by foot. This is most likely to be when the fill has
reached around the half way mark.

04.7 Continue to fill the cells compacting each layer of fill in turn.

04.8 The end walls should be filled to within 100mm of the top of the cells.
The side walls should be filled completely and ideally be left with a
25mm surcharge.

HAB 1 - Vent Pole Base Plate Securing Clip

with coil spring

Note: The HAB 1-Vent should be fitted into the preformed aperture in the selected end wall
once the fill material is up to that level. Once fitted the filling can continue. This vent will
allow the fitting of air conditioning and heating ducts into the bunker as and when required.

17
 05 ROOF SUPPORT

05.1 Place the narrow plywood boards on top of the side walls.
These are designed to spread the weight of the roof over the
complete wall. The next component (the Anchor Assembly)
will sit on top of these boards.

Plywood sheets
(narrow approx 16 linear metres)

05.2 Place the 26 HAB 1 anchor assembly pieces on the plywood

with the arms facing into the centre of the bunker.

Anchor Assembly

18
 06 ROOF BEAM

06.1 Take the first of the pre-assembled three piece angled roof beams
and bolt into place on the outside of the first anchor assembly piece.
Only fit the inner bolt, leave the outer bolt clear for a later operation.

First 3 piece angled roof beam being placed.

3 piece angled roof beam

being bolted to anchor assembly.
Only place the bolt on the
inside bolt hole.

19
 06 ROOF BEAM

06.2 Continue to position and bolt in the angled roof beams. Each should be
fitted between two anchor assembly pieces. Continue this operation
until all the beams are fitted.

06.3 Ensure the roof assembly is sitting squarely; adjust as required.

Diagram showing roof beams bolted to the anchor assembly

which is sat on the plywood sheets on the HESCO walls.

20
 07 ROOF INFILL PANELS

07.1 Fit the roof infill panels, smooth side down. The roof infill panels are
designed to interlock as shown below. It is important that each
section is fitted from one end only, placement of the roof infill panels
from each end of one run may result in the failure to match them up
in the middle leading to the requirement to strip out one side.

Safety: No one must stand on the roof whilst placing the panels as the roof will be unstable
and may shift laterally causing a partial collapse.

Roof Infill Panel

Interlocking Roof Infill Panel

21
 08 VERTICAL SUPPORTS

08.1 Assemble 10 internal vertical supports.

Each complete support is made up of:
• 1 x Height adjuster
• 1 x 1.795m steel Internal vertical support
• 1 x 150mm height adjuster sleeve
• 2 x 38mm height adjuster washer

08.2 Roughly position two internal vertical supports one at each end of the
inside of bunker. They should be positioned just either side of the doors.

Safety: It is important once all the vertical roof support beams are positioned that they
are checked for verticality and that they are adjusted to ensure that they are all taking
an equal load.

1.5m

Vertical Supports

Roof Beam 100mm inside joint

1.5m

Diagram showing the internal props set at

1.5m centres supporting the 4 piece roof beams.

22
 08 VERTICAL SUPPORTS

08.3 Lift, position and secure the straight roof beams. Once roughly in position
adjust each end to ensure the beam is sat approx 100mm inside the
join in the angled roof beam. This will ensure that the beams are sitting
approx 1.5m apart.

08.4 Carry out this operation to the other side. Spreaders may be required
under the vertical support if the bunker is built on soft ground.

08.5 Position the remaining vertical support beams at approximately

1.98m apart longitudinally. This will in effect mark the edge of each
man’s space if 8 men are to occupy the bunker.

Internal vertical
support being
positioned under a
4 piece roof beam
Cut away showing vertical
support beams approximately
1.98m apart

Layout of vertical supports.

23
 08 VERTICAL SUPPORTS

Safety: Do not attempt to secure the vertical supports until the roof has been stabilised by
the installation of the HESCO end walls at serial 9.2.

08.6 Drill an 8mm hole into the straight roof beam to secure the vertical
support tube to the roof beam.

Picture showing roof beam

secured to the purlin support

08.7 Fit and secure the cross bracing. The cross bracing piece comes in 2
parts, a threaded bar and a sleeve. Remove one nut and bolt from each
straight roof beam joint and on one side, remove its opposite number.

08.8 Slide the threaded bar through the hole on one side.

08.9 Slide the sleeve onto the threaded bar.

08.10 Insert the threaded bar through the opposite hole and secure by fixing a
washer and nut on each end.

08.11 Carry out the same procedure until all five bracing pieces have been
fitted and secured.

Note: 2 x Sleeve are fitted with door tarpaulins, these should be fitted at the door ways.

Remove one nut and bolt from Threaded bar and

each straight roof beam sleeve in place

24
 09 DOORWAY WALLS

09.1 Fit and secure the 2 cell length (with additional 21" long cell)
of Concertainer unit on top of the existing walls either side of
the doorways. Secure by hog ring.

3 Cell Segment

09.2 Place fill, compacting in layers until the units are full.

25
10 FRAGMENTATION SCREEN CONSTRUCTION

10.1 Fit tape over the open ends of the swivel brackets to prevent fill
material ingress.

Correctly positioned
swivel bracket.

Note: Tape should be fitted

over the end of the swivel
bracket prior to positioning.

10.2 Fit and secure the Swivel brackets onto the anchor assembly pieces.
The brackets are fitted on the:1st, 4th, 6th, 9th, 11th, and the last
angled roof beam.

Safety: For all work on the roof and predetonation screen, personnel are to stand on the
fragmentation screen and not on the HESCO units.

14th
11th
9th

6th
4th

1st

Layout of swivel brackets.

26
 10 FRAGMENTATION SCREEN CONSTRUCTION

10.3 Fit swivel brackets in the centre at the same spacing as used
on the outside.

Cut away showing positions of swivel brackets.

10.4 Fit M16 nuts and bolts to all remaining empty positions and secure.

27
 11 FRAGMENTATION SCREEN FILL

11.1 Place geotextile strips over the roof. The geotextile is placed to prevent
fill material dropping through any small gaps in the roof. It also adds
strength to the fragmentation screen. The geotextile should be wrapped
around the detonation support brackets and then secured by using
the HAB 1 clips.

Note: Placement of geotextile cover over the roof infill panel, wrapping around the swivel
brackets and securing by means of the HAB 1 Clip.

11.2 Place 450mm of fill material on the roof. Fill to the top of the
swivel bracket. Try to leave the edges clear at this time, this
will assist later when the plywood sheets are fitted to the side.

Placement of fill on the fragmentation screen.

Note: Try to avoid placing the fill around the edges as this will assist a later operation.

28
 12 DETONATION SCREEN

12.1 Remove the tape from the end of the swivel brackets.

12.2 Fit 1050mm long truss poles (white & blue) into the outside swivel brackets.

12.3 Fit 1200mm long truss poles (yellow & green) into the two centre rows
of swivel brackets.

12.4 Fit 1400mm long truss poles (red & black) into the remaining swivel brackets.
(Two outside centre rows).

1200mm truss poles

(yellow & green)

1400mm truss poles

(red & black)

1050mm long truss poles

(white & blue)

450mm Fill Material

Truss poles.

Layout of truss pole.

29
 12 DETONATION SCREEN

12.5 Fit and secure a short swivel coupling to the ends of all truss poles.

6 x 1583mm Long ridge poles Short swivel

Example of short swivel with Example of sleeve on

ridge pole running through ridge poles

Diagram showing the truss poles in position when joined to the ridge poles.

12.6 Fit six 1583mm ridges poles (green) in the position shown above.

12.7 Use sleeves to join the ridges poles together.

30
 12 DETONATION SCREEN

12.8 Fit ten 90˚ cross over joints to each side and then 20 in the centre.

12.9 Fit forty 1325mm eaves poles (as shown). Use sleeves to join the
eaves poles together.

90˚ cross over joint used to Sleeve used to join the

secure the eaves poles eaves poles
to the ridge poles

This diagram also shows the positions of all joints

(10 on each side and 20 in the centre).

12.10 Tighten all joints.

31
 12 DETONATION SCREEN

12.11 Fit and secure side brace poles. These are designed to prevent the
predetonation screen from racking. The pole should be fitted from top to
bottom on one side and bottom to top on the opposite. Brace coupler
clamps are provided to secure the poles to the truss poles.

Diagram showing positions of brace poles.

Note: The pole goes from top to bottom on one side and
goes from bottom to top on the other. Example of side brace poles
on truss pole.

32
 12 DETONATION SCREEN

12.12 Slide 2 pieces of ply across the gable end of the pre-detonation screen.
These sheets fit between the 3 cell segments and the frame. The ply
should slide far enough in so that it does not protrude out the side.

12.13 Fit plywood boards along the sides. Two men should pass the boards
up to one man on the fragmentation screen. The boards should extend
until they overlap the end cells by half of their depth. There will be a
requirement to overlap some of the plywood sheets. Where this is the
case the boards should be secured together by screws or roof ties.
All other boards should be secured to the pre-detonation frame.

Plywood fitted to the sides of the predetonation screen.

Safety: All work should take place from the inside of the frame.

12.14 Pull fill material to the edges of the fragmentation screen ensuring
that there is a uniform 450mm of soil cover over the complete roof.

12.15 Fill and place sand bags along the wall up against the Anchor
Assemblies. Approx 30 sand bags will be required on each side.

33
 12 DETONATION SCREEN

12.16 Fit the plywood boards number 1-4 to the roof. The boards should be
secured by drilling through the ply on either side of the supporting
eaves poles and then fixed by using the supplied roof ties.

15 7 1
11 5
13 8 2
14 9 3
12 6
16 10 4

Sandbags

Diagram showing plywood configuration.

12.17 Once boards 1-4 have been placed and secured the tent roof (tarpaulin)
should be lifted by loading shovel onto boards 2 and 3. The tent roof
should then be unfurled as subsequent boards are placed and secured.

12.18 Place and secure boards 5 and 6 and unfurl the tent roof to the edge.
Continue fitting and securing board and unfurling the tent roof
as you progress.

34
 12 DETONATION SCREEN

12.19 Boards 13 and 14 should be fitted and secured. The tent roof should
be unfurled over them and then boards 15 and 16 fitted and secured.

Safety: It is important that the above procedure is followed for the placing and securing of
the plywood sheets and the tent roof. This ensures that no one has to climb onto the roof.
The plywood will only support 65kg/m2

Example of tent roof being unfurled.

35
 13 DOORWAY FRAGMENTATION WALLS

13.1 Place the fragmentation walls as per the diagram below.

Ensure that there is no line of sight into the bunker. Angle the end
of the wall as required.

13.2 Fill the end walls in the same manner as the main walls.
Fill until 100mm from the top.

13.3 Fit and secure the small 5 cell units on top. Secure by hog rings.

13.4 Fill in layers, compacting each in turn.

0.8m 0.9m 1.1m 0.9m 0.8m

View of doorway fragmentation walls.

36
 13 DOORWAY FRAGMENTATION WALLS

13.5 Place A1 and A2 crates together for connection, then B1 and B2 also.
Position but do not secure and tighten the two 220mm long bolts and
nuts in the lower holes of the crate then position the four 180mm long
bolts in the side and top holes. Do not tighten.

Example of wooden crates in position over the doorway.

13.6 Slide the two 2m timber beams into the fork lift recess on the crate,
push fully through from A1 to A2. This may require hammering in.

13.7 Secure all nuts and bolts. Repeat at opposite end.

13.8 Lift each pair of wooden crates A1, A2, B1 and B2 by means of the
loading equipment fitted with fork attachment and place them centrally
over the doorway.

13.9 Place 450mm of fill material in the base of the crates over each doorway.
Pull the tent fabric to the edge of the open box.

Note: The interior of the crate may require lining with geotextile to prevent fill material loss.

13.10 Place two sheets of ply to close the top of the box.
Secure using the supplied screws.

13.11 Pull the remainder of the tent roof over the end of the bunker.

13.12 Fit the 4 steel tubes with outer doorway tarpaulin against the base
of the wooden crate. Secure by cable tie and or sandbags.

37
 14 WATERPROOF COVERING

14.1 Slide the tent poles into the sleeve of the tent cover.
Place 2 at each end and 5 on each side.

Fitting the tent poles into the tent cover.

Tent pole

14. 2 Identify the securing positions, mark the tent cover fabric and then cut
to expose the tent poles. Thread the ratchet strap webbing through the
welded mesh and then over the tent pole.

Example of
ratchet strap

Marking and then cutting the tent cover to gain access to the tent poles
for the ratchet strap.

38
 14 WATERPROOF COVERING

14.3 Once all the ratchet straps are fitted they should be tightened securely.

14.4 Secure the tent roof over the crates by screws into the crate.

Fitting the ratchet straps to secure the tent cover.

14.5 Check the finished HAB 1 for any irregularities.

The structure is now complete.

39
 15 MAINTENANCE

15.1 As discussed earlier the plywood will only sustain a load of 65kg/m2,
therefore, when snow accumulates it should be cleared when it reaches
a depth of 150mm. Information stickers have been affixed to the internal
longitudinal beams to ensure that future occupants are aware of this fact.

15.2 The following action must be carried out if the bunker suffers either a
direct hit or near miss

• All predetonation and fragmentation screen nuts and bolts and grub
screws must be checked for tightness. Information stickers have been
affixed to the internal longitudinal beams to ensure that future
occupants are aware of this.
• Ratchet straps should be checked for security. The welded mesh can be
damaged by the ratchet strap due to the bounce effect that the blast causes.
Where this is the case the strap should be moved to an undamaged
portion of welded mesh.
• The ten vertical support tubes supporting the long roof beams should
be checked for damage and replaced if required. If removal and
replacement is required the roof beam should be propped on either side
of the tube to be replaced before it is removed.

15.3 Routine maintenance inspection should be conducted on the

accommodation units and repair work carried out where required.
Inspection should cover issues such as:

• Mechanical or weapon damage to the welded mesh and or geotextile

• Security and serviceability of the tent roof
• The internal vertical support tubes for verticality and any deflection

15.4 If the bunker is to be in place for some time (in excess of 2 years)
particularly in a harsh UV environment, then additional protection for
the geotextile in the HESCO units may be required. Additional protection
can be provided by shading of the structure from the sun, application of
UV CAM™ or cement slurry.

40
 16 REPAIR PROCEDURES

16.1 Minor Repair:

It is very rare for a complete unit or cell to require replacing but more common
for an exterior panel to have suffered some damage. This can be repaired by
the application of a repair panel if using a repair kit, or a small section of panel
if cannibalising materials from unused units rather than the repair kit.

16.2 • Measure the size of repair patch required (Figure 1)

• Decide whether to apply a patch over the damaged area or
apply a complete panel.

16.3 For a small patch:

• Cut an oversize patch from the repair panel or cannibalised unit.
• Cut 2 coils to the patch’s depth (Figure 2).
• Cut a geotextile patch. Leave a generous overlap, 150mm all round
is generally sufficient (Figure 2).
• Place the weldmesh patch over the damaged area.
• Secure the left side to the existing wall by means of a coil coiled
through the patch and the existing cell panel (Figure 3).
• Place the cut geotextile behind the weldmesh patch ensuring the
150mm overlap is folded within the weldmesh patch (Figure 4).
• Close the weldmesh patch over the area of repair, then wind in
the right-hand coil (Figure 5).
• Refill or top up the fill in the unit, as necessary.

Figure 1 Figure 2 Figure 3

Figure 4 Figure 5

41
 16 REPAIR PROCEDURES

16.4 For a panel overlap:

Obtain a full size panel to the correct size, two coils, two joining pins and a
piece of geotextile 150mm larger on all sides (Figure 1).

• Fit coils to both sides of the repair panel (Figure 1).

• Interlink the coil on one side with the coil of the existing unit and fit
a joining pin (Figure 2).
• Place the geotextile patch on inside of the repair panel and fold in
the 150mm overlap (Figure 3).
• Close the repair panel tight. Interlink the coil on the opposite side
and fit a pin (Figure 4). Fit additional coils until the new coil and
existing can be interlinked and a joining pin fitted.
• Refill the unit to complete the repair (Figure 5).

Note: It may be necessary to fit additional coils to increase the length of the repair panel
to enable the coils to be overlapped and a joining pin fitted.

Figure 1 Figure 2 Figure 3

Figure 4 Figure 5

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 16 REPAIR PROCEDURES

16.5 The HAB 1 predetonation screen is made up of various components:

• Support frame
• Plywood sheets
• Waterproof tarpaulin secured by steel poles and ratchet straps

16.6 The predetonation screen is designed to act as a sacrificial layer when

the HAB 1 suffers a direct hit. If this occurs it is likely that the water
proof tent cover and plywood screen may be damaged.

16.7 Access to the roof space should be gained. All roof joints and couplings
should be checked for serviceability and tightness. Poles should be
replaced where required.

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 16 REPAIR PROCEDURES

16.8 A repair to the damaged waterproof cover and plywood is affected by

overlaying the damaged areas with new plywood and tent cover segment.

• Identify the area to be repaired

• Estimate number of plywood sheets required to cover the damaged area
• Place plywood sheets over the damaged area and secure by screwing down.
The plywood should be placed directly over the existing tent cover.

Safety: The plywood used as the predetonation screen only has a load limit of 65kg per m².
If you are to walk on or put weight on the existing sheets then additional sheets should be
placed to act as crawling boards.

16.9 • Place tent cover repair kit on one side

• Unroll the ropes for the tent cover repair kit
• Throw ropes over to the other side

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 16 REPAIR PROCEDURES

• Using the ropes pull the tent cover over the roof until it hangs down
the same distance as the originally placed cover
• Slide the tent poles into the sleeve of the cover

• Identify the securing positions, mark the cover and then

cut to expose the tent pole

• Thread the ratchet strap webbing through the welded mesh

and then over the tent pole
• Once all the straps are fitted they should be tightened securely

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 17 DISMANTLING INSTRUCTIONS

HEALTH AND SAFETY

As with all construction tasks there are some inherent risks regarding
Health and Safety. Task Commanders must ensure that all relevant and
practical Health and Safety precautions are taken.

The main risks to health and safety are:

• Manual handling injuries
• Working at height
• Collisions between personnel and loading equipment/crushing injury
• Lifting operations
• Tactical and operational risks
• Construction components becoming projectiles due to high winds

Simple precautions should be taken to ensure a safe build, such as:

• Only qualified and properly trained equipment operators should operate
the loading equipment
• Ladders when used should be secured at the top and bottom
• A minimum number of persons should be employed when carrying out
tasks at height
• Keep good site organisation
• Ensure personnel only lift the weight they are safely able to
• Provide a properly briefed and competent banksman for the loading
equipment. He is to ensure correct employment of the loading equipment,
correct placement of fill material and that working areas for the loading
equipment are free from personnel
• Assess the wind speed and its potential for damage. Some construction
components may be susceptible to being blown about by the wind during
construction. This in some cases has the potential to cause injury.
It is recommended that the construction commander makes an assessment
of the wind speed before and during the construction to ensure that
components such as the roof infill panels and plywood do not become
dislodged and injure other persons.
• All personnel should be fully briefed on the task in hand.
This should include:
- Safe methods of work
- Safety around moving plant equipment
- Correct manual handling techniques
- Work positions when working above ground level
- Avoid where possible any work within 1m of any edge
when working at height

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 17 DISMANTLING INSTRUCTIONS

All of the HAB 1 material when stripped out in a methodical manner can
be reused. As material is removed and stored a note should be taken of these
items which cannot be used again. Replacement items can be sourced from
HESCO Bastion Ltd.

17.1 Prelims:
• Ensure the HAB 1 is emptied of all equipment and material.
• Turn off, disconnect and remove all electrical supplies and
any other services installed.

17.2 Removal of tent cover:

• Remove all ratchet straps.

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 17 DISMANTLING INSTRUCTIONS

• Pull the waterproof tent cover free from the wooden crate covering
the doorways.

• Pull the waterproof tent cover from the roof and roll up for future use.

17.3 Wooden Crates:

• Remove the wooden crates from above the doorways.
• Remove fill material from inside the crates.
• Stow previously removed equipment in the crates.

Note: The wooden crate with sand fill weighs approx 2.9 tonnes. Some material may have
to be unloaded prior to removing the crate from above the doorway.

17.4 Side wall sandbags:

• Remove and empty all sandbags.

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 17 DISMANTLING INSTRUCTIONS

17.5 Plywood Predetonation Screen:

• Remove side wall plywood.
• Remove end wall plywood.
• Remove roof plywood.

Safety: On removal, plywood should be lowered to the floor and not thrown. It is important
when removing the roof plywood that the persons stand on the fill material and do not walk
on the plywood.

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 17 DISMANTLING INSTRUCTIONS

17.6 Predetonation screen frame:

• Remove all eaves poles.

Note: Remove end pole last.

• Remove centre spine ridge poles.

• Remove remainder of ridge poles.
• Remove side bracing poles.
• Remove truss poles.

Eaves pole

Centre spine ridge poles

Truss poles

Side bracing poles

Safety: All poles should be lowered to the ground and not thrown.

17.7 Fragmentation Screen:

• Remove fill material.
• Remove Geotextile strips.
• Remove swivel brackets.

Swivel bracket.

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 17 DISMANTLING INSTRUCTIONS

17.8 Internal Support Beams:

• Slacken off and remove nuts and bolts securing the roof beam
bracing pieces.

• Slacken off and remove the nut and bolt securing the roof beam
support to the roof beam.
• Slacken off and remove the six central vertical support poles.

Picture showing roof beam secured to the

roof beam support.

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 17 DISMANTLING INSTRUCTIONS

• Two persons support one roof support beam while two others
remove the vertical supports.
• Repeat this procedure for the other beam.
• Disassemble beam.

Cut away showing

two persons
supporting beam
prior to removal of
vertical supports.

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 17 DISMANTLING INSTRUCTIONS

17.9 Fragmentation Screen:

• Remove roof infill panels.

Roof Infill Panel

53
 17 DISMANTLING INSTRUCTIONS

• Remove bolts securing the roof beams to the Anchor Assembly pieces.
• Remove each roof beam as it becomes free.
• Disassemble each roof beam.
• Remove the anchor beam assemblies
• Remove small section of plywood from the top of the side walls.

3 piece angled roof beam being

removed from anchor assembly.

Note: Check all components are cleared from the HAB 1 and stowed in the two crates prior to
proceeding further.

17.10 HESCO Walls

Remove joining pins from all Walltop units, rock units back and forth
until the unit can be lifted free of the fill material. In the event that this
proves difficult, remove fill material by shovel until it can be achieved.

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 17 DISMANTLING INSTRUCTIONS

• Identify and remove all material and equipment that is not to be

disposed of.
• This method involves extracting the removable pins from the corner of
one side panel, splitting each cell. It is likely that MHE will be required
to remove the pins.
• Select a pin to remove, on the side you want the opening to start from.
After removing this pin, the cell will swing open to release the fill material.
All personnel must stand clear at this point.

Pin being removed from concertainer cell

• The cell being remove is still attached to the unit at one corner;
this will act as a hinge, allowing the cell panels to be turned away
from the released fill material.
• Bulldoze the released fill material away from the wall. Continue this
process until the wall has been completely removed.
• Remove the concertainer unit cell material, and clean, inspect and
repair any damaged panels as required. Reassemble and re-palletise
the units ready for transportation or storage.

55
 17 DISMANTLING INSTRUCTIONS

Pin to be removed

All other personnel to stand clear

before the removal of each pin.

Plan view of concertainer cell

Note: It is important the area around the cell to be split is free from even the smallest obstruction.
This allows the cell to be opened freely.

• Remove units, fold up and stow away.

17.11 Tidy and clear site of all equipment, fill material and debris.

56
 COMPLETED HAB 1

Completed HAB 1

57
 COMPLETED HAB 1

Completed HAB 1

Note: Above pictures shows the generation 1 round HAB poles which are now square for
increased strength.

58
HESCO Bastion Ltd
41 Knowsthorpe Way
Cross Green Ind. Est.
Leeds LS9 0SW
United Kingdom

Tel: +44 113 248 6633

Fax: +44 113 248 3501
Email: info@hesco.com
Web: www.hesco.com

Disclaimer
The information contained in this publication is provided by HESCO Bastion Ltd
('HESCO') or is derived from sources that HESCO reasonably believes to be reliable
and accurate or are otherwise expressions of independent third party opinion.
Whilst HESCO has made reasonable efforts to ensure the accuracy, completeness
and relevance of such information, any reliance on it, in whole or in part, is entirely
at the risk of the party using it and it will not rely on such information in substitution
for making all proper and necessary enquiries from HESCO or other relevant third
parties. The selection, configuration and installation of any of HESCO’s products on
site is not HESCO’s responsibility and, HESCO, its directors, employees, agents,
distributors, suppliers or contractors shall not be liable for any failure of any of
HESCO’s products caused by improper installation.

At the sole and absolute discretion of HESCO, the contents of this publication are
subject to change at any time without notice.

HESCO further reserves the right to amend specifications without notice.

Copyright Notice
Certain material featured in this document is subject to copyright protection.
Any lawful reproduction of such material is subject to obtaining prior written
permission from HESCO Bastion Ltd. Any requests for such permission should be
made in writing.

Copyright © HESCO Bastion Ltd

Patents
HAB 1 is covered by patent nos. 2145064, 1992768 (UK) and 7856761 (US); and is subject to
application nos. 0803661.8 (UK) and 12/595,436 (US) and other international equivalents.

Trade Marks
HESCO, Concertainer and HAB are registered® trade marks of HESCO Bastion Ltd.

Quality Standards
HESCO Bastion Ltd manufactures to quality standards ISO 9001 (1987),
BS 5750 Part 1 (1987) and EN 29001 (1987) certificate no. 910654.

08.07.11