Brokk 100 - the next generation p. 34 Volume 11 â€˘ No. 5 Dec 11 - Jan 12
ACT saving important heritage structures in Chennai, India Floor Grinding:
Rhino solutions for any floor application pages: 26-27
Why bolt when you can clamp page: 28-30 Site Report:
A robot in a rotary kiln page: 32-33 Demolition:
Underground construction in Manhattan gets high performance with dust suppression page: 32-33
Robotics in demolition pages: 48-52
Dr Fritsch Master Tec series extended page: 72
Impressive attendance at German demolition summit pages: 82
PDi Concrete Cutting Survey
This is our industry 2011 page: 16-22
Creating the Link pages: 36-38
HTC introduces a new innovative dust extractor page: 35
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Address: P.O. Box 786, SE-191 27 Sollentuna, SWEDEN Visitors address: Sjöängsvägen 7, SE-192 72 Sollentuna, SWEDEN Phone: Telefax: E-mail: Website: ISSN Registration:
+46 8 631 90 70 +46 8 585 700 47 firstname.lastname@example.org www.pdworld.com ISSN 1650-979X
Editor-in-Chief Jan Hermansson, Jan.Hermansson@pdworld.com Assisting Editor-in-Chief Anita do Rocio Hermansson, Anita.Hermansson@pdworld.com Editor Europe: Mikael Karlsson, email@example.com Editor North & South America Jim Parsons, firstname.lastname@example.org Editor Scandinavia Petra Linderoth, Petra.Linderoth@pdworld.com Editor Demolition: Mark Anthony, email@example.com Editor Recycling: Heikki Harri, firstname.lastname@example.org Editor Asia Pacific: Jan Hermansson Jan.Hermansson@pdworld.com Editor Russia & Eastern Europe Andrei Bushmarin, email@example.com Editor Africa Kevin Mayhew, firstname.lastname@example.org
International Sales Director Germany/Austria/Switzerland/Liechtenstein /BeneLux/Finland/France/Spain/Portugal Andrei Bushmarin
Phone: +7 921 949 27 81
E-mail: email@example.com Sweden, Norway & Denmark Contact the Editorial Office Phone: +46 (0)8 631 90 70, Fax: +46 (0)8 585 700 47 E-mail: firstname.lastname@example.org Italy Monica Colleoni & Romano Ferrario, Ediconsult Internazionale S.r.l. Via Savona 97, 20144 Milano, Italy Phone: + 39 02 4771 0036, Fax: + 39 02 4771 1360 E-mail: email@example.com North & South America, UK & Ireland Dunay Associates P.O. Box 119, Westwood, NJ 07675, USA Phone: +1 201 781 6133, Fax: +1 201 664 1829 E-Mail: firstname.lastname@example.org Australia/New Zealand/Asia Pacific/Korea/Japan and rest of the world: Contact PDi editorial office in Sweden. Publisher Jan Hermansson The magazine PDI, Professional Demolition International is published five times per year with a worldwide circulation of 10000 copies. The annual airmail subscription rate is US$ 45. All subscription correspondance should be directed to: The subscription department, SCOP AB, P.O. Box 786, SE-191 27 Sollentuna, Sweden. PDI is mailed by second class postage. ©Copyright SCOP AB 2000-2011
6 6 8 10 12
Why bolt you can when clamp
32-33 A robot in a rotay kiln 74 ACT saving important heritage
structures in Chennai, India
36-38 Creating the Link 78-79 Bosch’s freudian dream 80-81 The Story of JCB Hydrodemolition
New Aqua Cutter 710 V Classic to debut at World of Concrete 2012
58-59 Back to Vegas
Indian contractor buys second Rockster Recycler Sandvik crusher helps Offerton development
pages: 36 -38 innovativ e dust ex tractor pa ge: 35
Metso’s new Lokotrack LT120 jaw plant Market success for CRS kinetic flow screen Ramtec launches new Robi Multi Master screening bucket Metso’s SmartTag - next generation and beyond Sima Diamant
Dr Fritsch story
Movers & Shakers
Impressive attendance at German demolition summit
rvey This industry is our 2011
76-77 Mobile recycling: The ultimate moving and shaking
28-30 Why bolt when you can clamp? 46-47 High-rise demolition with wallsaw 69 Basement Egress Window Systems
26-27 Rhino solutions for any floor application
Flex-Mat® Vibrating Wire Technology celebrates 15th anniversary
60 PDi • Issue 5 • Dec 2011 - Jan 2012
HTC intr oduces a new
Hilti ranks 15th in international employer survey Moviter invests in the Angolan market
Castle and Pryor take to the sky during water tower demolition Underground construction in Manhattan gets high performance with dust suppression
: attendan Impressive ce demolitioat German n summ it pa
Volvo’s Bangalore factory’s new excavator line Theisen expands rental fleet in Germany and Austria Atlas Copco Portable Air becomes Portable Energy Avant Tecno buys Finmac Demolition
A climate of apathy
Downwell Demolition scoops top industry recycling award Volatile environment and currency effects call for enhanced structural measures A new hub for the London building industry
Diamo Dr Fritsc h Mas nd Tools series ex ter Tec tended
Undergr construcound Manhatt tion in high perfan gets with dustormance supp page: ression
How membership can help you
Shows PDi Magazine is a member of the following associations:
A robot rotary kiin a ln
page: 32 -33
CSDA Celebrates 40 Years at World of Concrete
Distributor opportunities with Shanbao UK’S oldest JCB digger driver vows to work to 100 New Caterpillar media contact for EAME regions
Diamondial Feature: Tools page
Site Repo rt:
Specific training for a very specific activity
page: 28 -30
Playing for change
Roboticsature: demolitioin n pages:
DEC 11 -
pages: 26 -27
• NO. 5
Site Repo ACT savi rt: heritage ng important structur Chennai es in , India pa
Floor Grind ing:
PDi • issue no. 5-2011 Dec 11 - Jan 12 • Volume 11
Professional Demolition International Magazine
next gene ration p. 34
Introducing Brokk 100 - the next generation HTC introduce a new innovative dust extractor Atlas Copco’s new bulk pulverisers New model of Holer’s hydraulic handsaw Husqvarna wire sets new standards New Holer dust shroud Two new crushers from Husqvarna Atlas Copco’s new demolition cutter CC 950 Upgrade for Bobcat mini excavators Complete package for mobile lighting Diesel engine improvement on Hinowa lifts Jenny Products offers duplex compressors Sennebogen 6130 HD transports tons of gravel GLOBRAM Steelshear makeover New lighting equipment from Tower Light
Surveys & Features Concrete Cutting Survey
16-22 This is our industry 2011
48-52 Robotics in Demolition 66-67 Diamond Tools
1961 - 2011
Ye a r s
50TH YEARS FURUKAWA ROCK DRILL FRD-HYDRAULIC BREAKERS DEMOLITION ATTACHMENTS CRAWLER DRILL INNOVATIVE DESIGNS DURABLE AND RELIABLE
WHERE EXPERIENCE Furukawa Rock Drill Europe BV
Proostwetering 29, 3543 AB Utrecht, The Netherlands Phone +31-(0)30-2412277, Fax +31-(0)30-2412305 www.frd.eu, email@example.com
“Playing for change” Dear Readers I was recently sent a You Tube link that really caught my attention. You may have heard about it before and is called ‘Playing For Change’, which is a kind of movement on the Internet connecting people from all over the world through music. Playing For Change is a multimedia movement created to inspire, connect and promote world peace through music. The project idea stems from the belief that music disarms borders and helps us overcome our differences. Regardless of our geographical, political, economic, spiritual or ideological standing, music has the universal power to unite citizens of our planet. Playing For Change has developed a mobile recording studio, using the material used in top studios, to travel throughout the world and record where the music takes them. During this project they realized it was not enough to record and share this music, they wanted to find a way to give back to the communities they met during their travels and who had shared so much with them. Thus the Playing For Change Foundation was formed in 2007, a non-profit entity for the creation and development of music schools for these communities. The last chapter of Playing For Change movement has been the Playing For Change Band. Bringing together outstanding musicians from around the world, this band shows the power that comes from the union of cultures. For the public to see and hear musicians who have travelled thousands of miles to be on stage and sing together, the unifying power of music leaves no doubt. To me it is a splendid way to reach across any type of boarder by using music as the common vehicle. If you click on to You Tube and search ‘Playing for change’ you get a lot of hits, but I recommend one in particular, which is http://www.youtube. com/embed/XMkaBN3x5AM. You can also watch it as http://www.pdworld.com/ pd-tv.asp. As you can see one song is played and sung simultaneously by a lot of musicians from around the world. When I watched this I truly became warm in my whole body. There is a hope for the world after all despite all the difficulties we have been facing, particularly in the last decade. You might think that this is a subject very far from the international concrete sawing and drilling, demolition and recycling industries and a strange editorial column. But it is not. The idea of PDi as an international magazine in a very narrow field is to bring nations and its professionals in those fields closer to each other, to exchange knowledge, learn and develop. In every issue we have plenty of good examples of that and not least in the editorial columns from the associations IACDS, EDA, CSDA and IDE. And wherever we are located in the world we are also human beings with thoughts and opinions. And if governments in different nations or the people that rule can’t come to an understanding maybe we can in the fields or professions that unite us. Just the same way as the movement ‘Playing for change’ is trying to do. And isn’t this also a bit what Christmas is all about? Merry Christmas and a Happy New Year from the staff of PDi Magazine and thank you for your support.
Jan Hermansson Editor-in-Chief firstname.lastname@example.org
PDi • Issue 5 • Dec 2011 - Jan 2012
Words from the IACDS President
Specific training for a very specific activity
Engineers, architects and general contractors in construction and rehabilitation industries take advantage of the technology provided by the contractors specialized in concrete drilling and sawing. These specialized companies are experts in their field, and use diamond cutting techniques that can ensure the success of any kind of project, no matter how difficult or how extreme the conditions involving the project. In this field, training and expertise become really important. Since it is possible to use a wide range of different procedures for the project’s several stages, it is essential to know exactly which one to choose in each moment. Nowadays no one would argue that training is a vital component for competitive companies, and also is mandatory in order to prevent accidents on the jobsite. Diamond cutting and drilling requires trained and qualified staff. IACDS strongly believes in the value of training. As a quick overview of how important education is for our National Associations, we will give you some examples about what is going on regarding training in different countries. For instance, the German Association, FBS, has several training documents and handbooks about drilling and sawing, as well as compact application techniques site reports and offers different sorts of seminars. Associations from close countries have also very high standards for training, as it is the case with Switzerland and Austria. The American Association, CSDA, has a complete catalogue with different training opportunities. DSA, the English National Association, has a Trainers’ Resource Manual, as well as PPT presentations, DVDs and more materials they use regularly for training of operators. Concerning the Spanish Cutting and Drilling Association, AEDT has
developed a training course, which has been already taught as a pilot program, and it is expected to soon become mandatory across the whole country. Another example is the Australian National Association, which offers a Technical Manual for Concrete Cutting Specialists and other interesting documents for training of professionals. Also very soon there will be two opportunities to learn more about this industry and network with its professionals; the 17th IACDS Annual Meeting, 2012. The meeting will be held on 6 March 2012 on the island of Maui, Hawaii. Our General Meeting will coincide this year with the 40th Annual Convention and Tech Fair of the Concrete Sawing & Drilling Association. Further I would like to inform that the next IACDS Diamond Award will be in 2013. It was decided to organize next Diamond Award’s edition within the course of the IACDS Bauma 2013 seminar. Winners will be invited to present their award-winning job as part of the seminar. We encourage you to participate, to prepare and to submit your job stories. Best regards Jose Blanco President IACDS
The new facTory Is compleTeD!!!
In times, everybody goes east, we invest in Germany
Diamond tools and machines from Germany into the world
Words from O’Brien
CSDA Celebrates 40 Years at World of Concrete special survey CSDA became the first sawing and drilling association when it formed 40 years ago. It has been a cosponsor of the World of Concrete show for 35 years and the exhibition has become a showcase for manufacturers to introduce their new diamond tool and machine offerings.
want to learn or participate in the future
So this exhibition is a perfect place to
direction of CSDA, become part of this
celebrate CSDA’s major milestone.
The focal point for the CSDA celebra-
CSDA is also sponsoring several
tion and other events will be the CSDA
training sessions. The CSDA Hand
booth in the Central Hall (#C4457).
Sawing and Drilling 101 course will be
Stop by any time during the show from
held January 24-26 and offers students
January 24-27, 2012 to say hello to your
introductory classroom and hands-on
fellow concrete cutting professionals,
training in these two disciplines. Come
CSDA staff and Board and committee
learn from a team of first-class instruc-
members. The 40th Anniversary celebra-
tors and start cutting right away in the
tion will be held at 10:00 AM on Wednes-
outdoor demonstration area. If you want
day, January 25th with champagne, cake
to advance your career, the Estimating
and presentations. Come join CSDA
course that will be held January 24-25
President Jim Dvoratchek and the CSDA
is a perfect opportunity. Learn about the
Board for this momentous occasion.
role of an estimator, different methods
Prior to the Anniversary celebration,
of estimating, comparisons of estimates
the CSDA Board will meet in room N201
and actual costs and how estimators
on January 25th from 7:30-9:00 AM. This
affect the company’s bottom line.
is a perfect opportunity to learn about
CSDA training doesn’t stop there.
CSDA, as the Board reviews the many
Lead instructor Rick Norland will con-
accomplishments from the recently
duct a WOC seminar on January 27th
completed year. Then, the Next Genera-
at 8:00 AM entitled “Utilizing Concrete
tion members will meet on Thursday,
Structure GPR (Ground Penetrating
January 26th at 9:00 AM in room N207
Radar) Data to Avoid Problems.”
to review the goals for 2012 and begin
If you are headed to Las Vegas for
to make plans to achieve them. So, if
the World of Concrete be sure to take
you are an up and coming professional
advantage of the many opportunities
in the concrete cutting industry and
sponsored by CSDA. Or just stop by the booth and say hello. Be sure to register in advance for free registration courtesy of CSDA. Let’s make 2012 a great new year! Best regards Patrick O’Brien Executive Director CSDA, US Concrete Sawing & Drilling Association
PDi • Issue 5 • Dec 2011 - Jan 2012
Volvo’s Bangalore factory’s new excavator line After a SEK 144 million investment, Volvo Construction Equipment’s factory in Bangalore started producing its first excavators in September. Plans are in place to increase excavator production significantly next year, and this new development will see factory capacity tripled in 2012. The local production of excavators will mean greater machine availability for Indian customers, as well as shorten delivery lead times and respond to customer requirements more quickly. Volvo CE has also introduced six new products to the Indian market. These include the locally produced EC210B Prime and EC290BLC Prime excavators, the 70 t EC700C crawler excavator, the DD100 and SD110 compactors, the L220G wheel loader and the P6820 asphalt paver.
Equipment. “Changing the division to Portable Energy is a logical step in light of the extension of our product range we can offer our customers,” says Portable Energy Division President Geert Follens. “This extended product offering, together with the intensified focus on the construction business as a part of the new Construction Technique business area, will provide us with the tools we need to give our customers the right focus and the best service.”
Avant Tecno buys Finmac Demolition Theisen Expands Rental Fleet in Germany and Austria Theisen Baumaschinen Mietpark GmbH & Co KG, one of the largest construction machinery rental companies in Germany, has purchased 32 new wheeled and crawler excavators from Doosan. They will be available for hire from regional Theisen centres throughout Germany and in Vienna in Austria. The new additions include six 15 t DX140LCR and four 23.7 t DX235LCR reduced radius excavators, 10 of the 17.7 t DX180LC crawler excavators and 12 of the 14.3 t DX140W wheeled excavators.
Avant Tecno Oy, the Finnish compact loader manufacturer, has acquired the demolition robot business of Finmac Demolition Oy. Finmac has been producing two demolition robot models since the foundation of the company in 2006. Avant Tecno has a turnover of EUR 72 million, and the company is exporting the loaders to over 40 countries. Avant Tecno is market leader in its class and has developed many innovative products in the field of multi functional compact loaders and attachments. Jukka Karjalainen, Business Unit Director, states that Avant sees demolition as very interesting business sector in the future. “We are very excited about the new product, as always. We did see this as an excellent way to expand our product offering. Over the past years construction sector has been a rapidly growing customer segment and is very important for us. Also, Avant has existing customers who are operating in the demolition business. We have received positive feedback about the business acquisition and there have been a lot of inquiries. There are several new opportunities when implementing this product to our range.”
Atlas Copco Portable Air becomes Portable Energy Atlas Copco’s Portable Air Division is changing its name to the Portable Energy Division, which more accurately reflects the division’s extended product portfolio. The Portable Energy division focuses on five sectors, each one relating to a product group, which are Air (compressors), Power (generators), Light (light towers), Water (pumps), and Used
Thank you for a successful 2011 and best wishes for the upcoming year.
Industriestraße 15 • 29227 Celle / Germany Tel. +49 (0)5141/90905-0 • Fax +49 (0)5141/90905-22 E-Mail: email@example.com • Web: www.rellok.com
EDA Words from the EDA President
liament. Our goal is to work closely
“How membership can help you”
bers’ concerns are fully understood
Following the previous column on how professional associations can help in times of crisis, we will now focus on communication and marketing advantages that are profitable when participating in certain
with regulators to ensure that mem-
whatever the issue, meeting with the managers and decision making people of leading companies in the guild, both European and international. The EDA also deals with the media to ensure that the industry’s position is known on the hot topics of the day.
Contacts and networking
associations such as the European
An interesting aspect of being an
EDA member is the possibility to
As an active association, the EDA
network with other demolition
receives and generates information
contractors and industry stakehold-
related to the demolition industry.
ers at the general meetings, social
Through marketing, communication
gatherings and working groups. The
and public relations services the
next major gathering will be at the
Association aims to increase the
2012 EDA Convention, which will be
visibility of its partners’ activities,
held from 14-16 June.
to provide a channel to all members to present their projects, news or services, and also disseminate the
Giuseppe President of the European Demolition Association
activities of the association. The EDA aims to speak for the European demolition companies, advising government departments
Giuseppe Panseri, EDA President, founder and chairman of Despe S.p.A, Italy.
and other bodies on demolition education and practice to improve the climate in which its members operate. EDA members can influence that voice. The EDA wants to work with its members to ensure their views are represented at the highest levels within Government, the European Commission, and the European Par-
PDi • Issue 5 • Dec 2011 - Jan 2012
Hilti ranks 15th in international employer survey Hilti achieved a high ranking in the Great Place to Work Institute’s international best employer survey. This comes on the heels of Hilti having achieved top rankings in both national and European employer surveys conducted by the Great Place to Work Institute. For the first time Hilti is ranked among the best employers worldwide by the international Great Place to Work Institute. The announcement was made at an awards ceremony held in New York at the end of October. Hilti was placed 15th in the multinational workplaces category and was
Moviter invests in the Angolan market The official Hitachi Construction Machinery (Europe) NV (HCME) dealer for Portugal and southern Spain, Moviter, is expanding its operations into Africa. The Portuguese company is increasing sales within its European territories by focussing on after-sales for its existing customers and exporting to new areas, such as Angola and other countries with historical links to Portugal. Moviter was established in 1989 as part of the Movicortes group and is based in Leiria, central Portugal. It currently has customers in more than 14 African countries requiring Hitachi support. Fortunately, Moviter already has a foothold in Africa, having been appointed as the Hitachi dealer for the Angolan market. Angola was an obvious choice for Moviter, as explains, “Angola is a Portuguesespeaking country and it was a colony until 1975. This means that the language and similar culture are two of the main advantages that Moviter, and other Portuguese companies, have in trading with this huge African country,” says Movicortes Manager and Board Member Arnaldo Sapinho. “However, the 27-year civil war only ended seven years ago and this had a devastating effect on Angola’s infrastructure. At that time, there was an intensive rebuilding programme that helped the construction market to recover. As well as public investment, there was an increasing trend toward privately funded housing and commercial
the second-highest ranked European company on the list. To qualify for participation companies had to have appeared on at least five national Great Place to Work lists. “The various good rankings achieved by Hilti are largely due to our employees,” says Hilti Executive Board Member Jörg Kampmeyer. “This solid international ranking is all the more appreciated as a positive signal from our team regarding the course, culture and values pursued by our company.”
construction projects.” In 2009, Angola suffered its own financial crisis when the price of oil bottomed out. With 95% of the country’s revenue coming from this natural resource, it had a further negative impact on the construction industry. The signs for recovery in 2011 are encouraging, as projects recommence and Moviter’s existing and potential customers use subcontractors to complete the work on their behalf. “As the Angolan construction industry starts up again, the companies who stayed in the country through these turbulent times have a distinct advantage,” says Arnaldo. “The big issue is that we need to continue to build relations and then develop the network. We believe that the power of Moviter’s organisation and the consistency of the Hitachi brand will help the industry to believe, not just in the reliability of the machines, but also the level of service behind them.”
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A special combination of diamonds and resin make these pads an ideal solution for floor maintenance Available in a wide variety of sizes including 7, 13, 17, 20, 21, and 27 inches Require only water For use under auto scrubbers, burnishers, and floor machines
Words from the IDE President
“A climate of apathy” It seems like a matter of minutes since I received the chain of office that signified my appointment as President of the Institute of Demolition Engineers. And yet my first year of office has expired, and my vice president – Steve Jack – is already straightening his tie and rehearsing the speech for his own inauguration that will take place shortly after London has hosted the 2012 Olympic Games. But we have come a long way in the past 12 months. In the UK, the IDE has continued to increase membership numbers, despite the economic difficulties foist upon the industry. Thanks in part to strengthening external links with the likes of the National Federation of Demolition Contractors and the Institute of Construction Management, the IDE’s reputation widens with each passing day. And our recent decision to terminate the membership of individuals that have failed to commit to a programme of Continuous Professional Development (CPD) merely underlines our determination to safeguard the reputation of our organisation and the members it serves and unites. I firmly believe that UK demolition contractors now recognise the business benefit of having within their ranks a qualified demolition engineer. The additional competence and credibility this brings provides those contractors with a unique selling point when competing in an ever more difficult marketplace.
If there is one disappointment from my first year as IDE president, however, it is the fact that so few overseas demolition engineers have chosen to follow the UK’s lead and to join our growing ranks. We have received applications from Brazil, Italy and the United States and we are currently working on a system to allow these applicants to sit the IDE examination from their native country and in their native language. But by comparison to the number of superb demolition professionals gainfully employed around the world, the number of applications we have received has been extremely small. Why this should be the case is a mystery to me as membership of the IDE demonstrates that the engineer is dedicated to his profession, supremely skilled and committed to Continuous Personal Development, all attributes that set him apart from others. As evidenced by the recent Demolition Awards, our industry is filled with companies and individuals determined to be recognised as the very best in their chosen field. What better way to demonstrate your abilities than membership of the world’s only institute for demolition engineers? So while you are all thinking about your New Year’s resolutions, I urge you all to apply for membership now, and would remind you that the letters IDE stand not just for Institute of Demolition Engineers but also for Individuals Demonstrating Excellence. John Woodward President of the Institute of Demolition Engineers
PDi • Issue 5 • Dec 2011 - Jan 2012
Distributor opportunities with Shanbao With over 1,200 employees Shanghai Jianshe Luqiao Machinery Co. Ltd is a leading Chinese mid-range manufacturer of screening and crushing equipment that includes a range of products encompassing crushing and screening solutions for the aggregates-minerals extractive industries. Shanbao is the trading brand name and the manufacturing facilities in Shanghai China, competitive cost-effective products, and global capabilities, will allow the company to expand and further develop the business into new markets, as well as provide customers with a comprehensive range of competitive products, services and solutions. Opportunities now exist for industry distributors to market the Shanbao product range on the global stage, including jaw crushers, cone crushers, vertical crushers, impact crushers, screens and feeders, accessories and aftermarket. Shanbao is inviting enquires from interested companies who wish to act as distributors for the Shanghai Jianshe Luqiao Machinery Co. Ltd product ranges, in territories where Shanbao presently does not have distributor relationships. Interested companies should be able to demonstrate suitable experience, familiarity of the industry, possess appropriate facilities and a profile that will enable them to represent the attributes of the Shanbao brand.
UK’S oldest JCB digger driver vows to work to 100 Handyman George Evans has become Britain’s oldest digger driver after investing in a brand new JCB excavator at the age of 92. Having already built his own house single-handedly, the WWII veteran is taking his DIY exploits to a new level by landscaping his back garden and bought a JCB 8008 micro excavator to carry out the work “Hard work and staying active is the secret of my good health. The JCB machine is my Godsend. With its help I aim to be still working on the garden at the age of 100,” said George. It’s his second JCB digger from JCB dealer Gunn JCB. His first, which he acquired three years ago, was an ex-demonstration machine, which he used to clear out premises he also owns a few doors away. Apprenticed as a joiner, George worked for Harris & Sheldon Group before he and his wife Ethel, now a sprightly 91, moved to Frankley, Birmingham to run their shop in 1958.
Shortly before his retirement George bought adjacent land from the council and started on a three-year project to build his own house. “I built the house from scratch completely on my own,” said George. “I never had a labourer and managed without scaffolding. I put the plumbing in, and the central heating, and I did the plastering.” Afterwards he built up the back garden of the house by 2m by using soil and rubble, surplus from the works site next door. Now George plans to excavate the garden area before putting in a lawn and paving. “I’ve taken delivery of the new JCB digger using my old one as part-exchange,” he said. “I’ve got all sorts of bricks and boulders, which I need to move, and these days I need a bit of help with the lifting. Landscaping the garden is the latest example of the way I like to do things myself. I don’t smoke and I only drink the occasional glass of lager on special occasions and it’s the outdoor life that I love.”
New Caterpillar media contact for EAME regions Caterpillar Trade Press Relations announces that Francine Shore has joined the company to serve their trade press needs in EAME (Europe, Africa, Middle East). Francine is replacing Mia Karlsson who left the company earlier this year. Francine brings more than 10 years of experience in the trade press communications and marketing arena, having been with Terex Aerial Work Platforms representing the same EAME region. In addition to her industry knowledge, she brings much enthusiasm, positive attitude and passion to promote the products and services she represents to our many trade press associates. Francine is located in Leicester, England.
Breaking news at World of Concrete.
Are you visiting World of Concrete at the Las Vegas Convention Center, January 24 — 27 2012 ? Be sure to stop by at Husqvarna’s booths C 4313 (indoor) and O 30370 (outdoor) to check out what’s hot and new in the construction business! A few of our latest releases – live at World of Concrete: DCR 300 and DCR 100. Crushers for our demolition robots, making them even more productive and versatile. TS 60. A lightweight, highly efficient tile saw with many smart features. AD 10. One of the fastest automatic drill feed units in the world. DM 220. Handheld wet/dry core drilling with electronic positioning system. K 3000 Vac. Electric power cutter with unbeatable dust control.
HUSQVARNA CONSTRUCTION PRODUCTS www.husqvarnacp.com Copyright © 2011 Husqvarna AB (publ). All rights reserved.
Recycling Contract of the Year
ing and stockpiling of 20,000m3 of concrete rubble on-site so as to allow the material to be reused during the facility’s redevelopment. Other material such as wood, scrap metal and plastics were segregated and recycled at dedicated facilities thus ensuring a recycling rate in excess of 97%. Commenting on Downwell Demolition’s success company director Matt Philips re-
Downwell Demolition scoops top industry recycling award In the UK demolition and dismantling specialist, Downwell Demolition has won the Construction Recycling Alliance’s (CRA) prestigious ‘Recycling Contract of the Year’ award. The company’s impressive recycling performance whilst demolishing at number of structures at the famous Leavesden film studios formed the basis of its successful entry. For the CRA’s first annual award scheme, submissions were invited in a variety of categories with the Recycling Contract of the Year being one of the most fiercely contested. Downwell Demolition’s successful entry focused solely on its six month contract at Warner Brothers’ Leavesden Studios in Hertfordshire. The project entailed strippingout and dismantling the world-famous studio buildings where the entire series of Harry Potter films together with the James Bond film Goldeneye were produced. A total of seven stage set buildings were stripped of their ceilings, roofs and existing sound-proofing to allow the creation of new structures that can be used to produce forthcoming blockbuster movies. Downwell Demolition was able to demonstrate high levels of reuse and recycling whilst carrying out the various activities during the project, which included dismantling the scaffold framework housed in the high ceilings of the film sets, thus allowing it to be reused elsewhere on site. The company also successfully completed the crushing, screen-
marked, “I am really pleased to accept this prestigious award on behalf of all the entire Downwell team. The Leavesden project was challenging in many respects and our team of operatives and labourers not only worked hard on completing what was asked of them on time and on budget but also excelled at reusing and recycling waste materials arising from the work. The award also acknowledges Downwell Demolition’s on-going investment in recycling equipment with our latest machine, a Scavik jaw crusher, used to good effect throughout the project. Director of the CRA, David Barnes, summarised Downwell Demolition’s success, “Downwell is one of the demolition industry’s up and coming companies, so it was reassuring to see their commitment and determination in reusing and recycling as much of the material on site as possible. The company fought off some strong competition to win this award and they should be justifiably proud of their success.”
Volatile environment and currency effects call for enhanced structural measures Despite encouraging sales growth in local currencies, the result of the Hilti Group has been severely impacted by currency effects and higher costs for materials and logistics. As a consequence of the strong Swiss franc and higher material and logistics costs, Hilti is expecting a 2011 result, which will be markedly below last year’s performance. By implementing an action plan, which will also drive the strategic orientation of the company towards stronger growth in emerging economies, Hilti will adapt its structures, cut costs and significantly enhance profitability over the next few months.
PDi • Issue 5 • Dec 2011 - Jan 2012
A new hub for the London building industry
In the UK a new trade park currently in development, located in the London Borough of Hounslow, aims to create over 500 new jobs and provide a boost to the local economy. The development, which will be up and running in early 2012, will hopefully lead to much needed regeneration of the Hanworth area through the creation of local employment opportunities as the scheme aims to become a hub for building supplies and other trade companies, who are keen to utilize the unique attributes of the site. The Hanworth Trading Estate Development is situated on the site of the previous 106,000 sq. ft. (9850 m2) Marlin Lighting Factory which dates back to WWII, but became derelict in the 1970’s. This “brown-field” site is now proving to be a perfect example of urban regeneration that not only uses land that to all intents and purposes has become derelict, but through commercial development uses the attributes of the site to create new opportunities for the local community. This in turn will hopefully provide a badly needed boost for the local economy. The site is owned by Sisk Marlin Develop-
ments, managed by Korine Property Partners, and is set to be fully up and running in early 2012. The first stage has already seen premier builder’s merchant, the Grafton Group owned Selco, acquire a new 50,000 sq. ft (4650 m2). trade only builder’s warehouse. This is particularly good news for the locality as Selco possess a reputation for making long term commitments to areas where they establish their stores, and will bring much need employment to the area. Selco have been searching for the right site for a considerable time and are said to be “genuinely excited” by the site and the potential it displays. James Measures, Property Development Director for Korine Property Partners Ltd (part of the Sisk Group of companies) states: “The location of the site is ideal for the construction industry, and using the locale as a hub will allow us to develop a complimentary tenant mix that will allow Hanworth to be a one-stop-shop for the construction and building trades industries. The benefits to the community are enormous with employment being created by the tenants, as well as establishments servicing their requirements, and those of their staff.” The aim is to have each tenant being able to service a different part of the industry. “Our focus will be to have a tenant who is able to service a particular need of the industry, and thus the tenants will possess complimentary, rather than competitive main product focus. Currently we have Selco on board, and are in discussions with representatives from the Plant hire, plumbing, tooling and associated industries,” says James. “Nothing is finalised as yet, and we welcome enquires from businesses who feel that this development can aid them in servicing their customers’ requirements through using this excellently located, 7 day week, site.” The Hanworth Trading Estate development is a perfect example of urban regeneration bringing benefits to all. The local economy receives a boost through job creation and trade for local businesses; a derelict site is put to good use; construction and building companies are presented with a hub to serve their needs; and companies such as Selco find the perfect location for their operations. www.hanworthtradingestate.co.uk
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This is our industry 2011 This year’s Concrete Cutting Survey looks at the international concrete sawing and drilling industry involving the international umbrella association IACDS, and an outline of the history of this industry. We also share the opinions of several suppliers about the industry and its future.
Professional concrete sawing and drilling methods are widespread around the world, but still have their domination in Western Europe, USA, Japan and Australia.
The strongest nations In Europe the German speaking countries of Germany, Switzerland and Austria, have the strongest presence of manufacturers of diamond tools and concrete sawing and drilling equipment and concrete cutting contractors. Germany, for instance, has approximately 1200 professional concrete cutting contractors and half are members of the German concrete sawing and drilling association. No other nation has such a large share of membership in the branch association. Other larger markets in chronological order are Sweden, United Kingdom, France, The Netherlands and Spain. The US is the biggest concrete sawing and drilling market in the world, with about 2500 professional concrete sawing and drilling firms. The number of manufacturers is also quite high, supplying mainly the North American market with tools and equipment. Two other nations that represent an extensive amount of concrete cutters are Japan and China. Still it is hard to make a statistical overview of the Chinese market as the country does not have a national association for concrete sawing and drilling contractors. However, reliable sources estimate the number of contractors to be about 1000. Most of the Chinese concrete cutting firms are very small with mostly one or two employees. The country though has a fast growing manufacturing industry with hundreds of new companies producing synthetic diamonds, as well as concrete sawing and drilling machinery. Neighbouring Japan has more or less the same number of confirmed contractors. About 50 of these are members of the national association. On the contrary to China, Japan has the biggest concrete cutting firms in the world with between 500 and 1000 employees in some cases. Japan’s concrete cutting market is also the second biggest in the world, after USA, with a turnover of US$ 1.2 Billion in
PDi • Issue 5 • Dec 2011 - Jan 2012
2009 compared to the US turnover of US$ 5 Billion the same year. The Asia Pacific region with Australia and New Zealand is also strong dominated by Australia. It is estimated that Australia has well over 600 professional concrete cutting firms and about 220 of these are in the national association. New Zealand has about 120 concrete cutters and about 40 are members of the national association. During the last decade there has also been a significant growth of new concrete cutting firms in Russia as well as in Eastern Europe. Russia has about 250 concrete cutting contractors, Poland about 70 and the Czech Republic about 50. There is also growing activity in countries like Bulgaria, Romania and Hungary. New national associations for concrete cutters have been established in some of these countries. The development of this industry in other countries of the world is in general at an earlier stage then the markets mentioned, which have a long history of concrete sawing and drilling since the 1950s.
Emerging markets Countries like Singapore, Thailand, India, the Arab Emirates, Israel, the states of North Africa, South Africa, Brazil,
Argentina and Chile, all have young, but successfully growing concrete sawing and drilling industries. Few of these nations have national concrete sawing and drilling associations. Instead this type of contracting is usually a section of a larger building and construction association. The international umbrella association IACDS is trying to help nations to build up and start their own independent national associations.
Our valuable manufacturers One reason why concrete sawing and drilling technology has experienced such fast and widespread development is due to the manufacturers in this field. There are close to a thousand manufacturers of diamond tools for professional contracting. Most of these manufacturers work locally, providing tools and machinery to local projects. Besides this there is a handful of all round manufacturers working multi-nationally, with production plants on several continents. The biggest manufacturer in this field is Husqvarna Construction Products producing diamond tools, sawing, drilling, grinding and milling equipment for sawing and drilling, demolition and grinding. Other large multi-national manufacturers include Tyrolit, Hilti, Saint Gobain and Cedima as examples. If talking just
2010 Concrete Sawing and Drilling Worldwide Market Survey
Concrete Sawing and Drilling Market 2010 - Worldwide Market Survey All colums: only sawing & drilling contractor companies
Country/Association Australia Austria Canada China (5) Czech Republic Denmark France Germany Ireland Italy Japan Korea Netherlands New Zealand Poland Portugal Russia Spain Sweden Switzerland United Kingdom United States Totals
Association Members by country (1)
Total number of companies (2)
Average revenue or turnover per company in US$ (3)
Estimated total country market in US$ (4)
220 38 19 34 35 608 32 100 110 40 20 25 102 86 75 290 1'834
620 130 350 1'000 50 150 250 1'200 70 220 900 730 400 120 70 30 220 200 350 300 220 2'300 9'880
860'000 653'846 500'000 300'000 275'000 300'000 1'400'000 500'000 350'000 550'000 1'200'000 1'000'000 250'000 300'000 300'000 300'000 500'000 400'000 1'000'000 1'000'000 300'000 1'700'000 Ø 914'924
533'200'000 85'000'000 175'000'000 300'000'000 13'750'000 45'000'000 350'000'000 600'000'000 24'500'000 121'000'000 1'080'000'000 730'000'000 100'000'000 36'000'000 21'000'000 9'000'000 110'000'000 80'000'000 350'000'000 300'000'000 66'000'000 3'910'000'000 9'039'450'000
Most recent date info provided 03. May 08 07. May 11 02. Jun 05 03. May 08 07. May 11 07. May 11 03. May 08 06. Dec 05 07. May 11 02. Jun 05 07. May 11 22. Jun 05 24. Jun 05 02. Jun 05 07. May 11 26. Apr 10 07. May 11 07. May 11 07. May 11 07. May 11
(1) Total number of sawing and drilling contractor members in the individual country association. (2) Estimated total number of sawing and drilling contracting companies in the individual country (includes members and nonmembers). (3) Estimated average annual Notes: (1) Total number of sawing and drilling contractor members in the individual country association. revenue (or turnover) for sawing and drilling contracting firms. (4) Column 2 x column 3 to arrive at total estimated contracting volume (2) Estimated total number of sawing and drilling contracting companies in the individual country (includes members per (5) Estimate as there are many one-man companies. and country. nonmembers). Compiled by IACDS (3) Estimated average annual revenue (or turnover) for sawing and drilling contracting firms. (4) Column 2 x column 3 to arrive at total estimated contracting volume per country. (5) Estimate as there are many one-man companies
Compiled by IACDS
S&DMktgData99-11.xls 2011 E_public
diamond tools the South Korean manufacturers EHWA Diamond and Shinhan Diamond Tools are two very large manufacturers and EHWA is the biggest.
Current market situation Even though the concrete sawing and drilling industry has experienced tremendous growth, it has been a difficult journey and hard work for contractors and manufacturers. But due to the recent global economic crisis the international concrete sawing and drilling industry has suffered tremendously, particularly in 2009. What was built up over many years was lost in a few months for many players in this field. In 2007 and part of 2008 there was fantastic growth for both contractors and manufacturers in the field of concrete sawing and drilling. But towards the end of 2008 things changed rapidly due to the overall economic crisis. Annually the umbrella organization IACDS gathered statistics from 22 markets. Even though a few nations have not completely updated their figures, the global revenue was estimated to be approximately US$9,04 Billion for 2010. The 22 nation members of IACDS have estimated the revenue of their national markets. But there are at least 10 nations with considerable concrete cutting activity that are not included in these figures. Due to the global recession revenue of the 22 nations dropped from a level of US$10.18 Billion in 2007 to US$9.67 Billion in 2008. For 2010 only Germany showed an increase from US$495 M to US$600 M. Sweden had a strong increase from US$175M in 2009 to US$ 350 M in 2010. Austria picked up from US$ 81M in 2009 to US$ 85 M in 2010. Japan showed a slight decrease from US$ 1.2 B in 2009 to US$ 1.08 B in 2010. Both Spain and United Kingdom had dramatic drops. Spain has had the biggest reductions, down from US$168M in 2007 to only US$18M in 2009. But for 2010 things looks better with about US$80 M in revenue. United Kingdom fell from US$180M in 2007 to US$90M in 2009 and has continued to fall down to US$ 66 M in 2010. Also the US market has reported serious drops in revenue having US$5 B 2007 and are down to US$3.9 B for 2010. Some markets have not submitted new figures since 2008 and these are Australia with US$553M,
PDi â€˘ Issue 5 â€˘ Dec 2011 - Jan 2012
Denmark with US$45M and Ireland with US$24.5M in revenue. Russia is reporting a drop from US$125M in 2009 to US$110 M in 2010 while Switzerland has shown a tremendous growth from US$103M in 2009 to US$300 M in 2010. Even though some markets have shown very good recovery in 2010 the total is still under the 2009 revenue figures, which were US$9.67 B. But as the 2009 report contained a high degree of non-updated figures it is thought that the real revenue for 2009 was about US$8 B. In that case the global market has picked up with around 13%.
History of the sawing and drilling industry It is difficult to give an accurate overview of the history of the professional concrete sawing and drilling industry, where it started and how it has developed. The fact that diamonds are efficient in different types of tools goes back to the Greeks a couple of thousand years ago. But the stone producers were well ahead of the concrete cutting industry to use diamond tools and sawing machinery for stone. It is believed that the development of the professional concrete sawing and drilling industry started in the US and Europe more or less simultaneously.
Maybe the cut off saw was the start It started probably with some sort of cut off saw for masonry equipped with a diamond disc. In that time the cut off saw was perhaps mounted on a rebuilt wheelbarrow or some sort of trolley and the first flat saw was created. But we cannot be sure about this information. It is believed that this happened some time in the late 1930s early 1940s. But it took at least another 20 years before the core drill appeared. All sorts of openings for windows, doors, water connections and plumbing in construction were made with handheld pneumatic tools, leaving a rather ugly and uneven edge. This created a lot of extra work to make the edges of the openings smooth. It was from this situation that the very first drilling machines with diamond core drills evolved, probably around the late 1950s. Diamond core drilling systems became very popular during the 1960s and the 1970s and dominated concrete
cutting. Flat saws or floor saws also grew in popularity for outdoor cutting and the first wall saws appeared in the 1960s. They were rail mounted and electrically powered. The method was developed in the US using high frequency motors. During the 1970s electric wall saws also appeared in Europe and some years later hydraulic systems were also developed. Hydraulic systems where much stronger and also considered much safer and more reliable to work with. The only problem was that hydraulic systems were much heavier. The new hydraulic systems fitted US contractors very well and the new technology established a strong foothold in the US for many years. Until the mid 1980s the professional concrete sawing and drilling industry was considered a small sector with not many global players. There were also only a few national associations besides some well-established ones like the CSDA in the US, which will celebrate its 50th anniversary next year. But from the late 1980s this industry has seen a strong and fast growth in the number of players as well as the development of techniques and products.
Booming and growing What happened during the 1990s was that the equipment became more efficient. As the method was developed concrete cutting equipment was used in more applications. The variety of options where the equipment could be used broadened. Staff became better trained, thanks to the associations. The status of a concrete cutter also improved, which lead to better rates and income. During the second half of the 1990s wire sawing equipment became more common in construction applications. The saws were easier to set up, lighter and smaller. Each manufacturer had their special wire sawing system for construction, often it could be converted to a wall saw and all equipment was hydraulically powered. But manufacturers did not forget about the electric powered equipment, as it was much lighter to work with. However, the lack of power and electricity made these systems hazardous. If these problems could be solved electric equipment was a better solution. At the German
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special survey show Bauma in the early 2000s several new electric high frequency devices were introduced, bringing completely new thinking to the market. The HF equipment, mainly wall saws, was just as powerful as hydraulic saws, very easy to mount, safe and most of all less then half the weight of a hydraulic wall sawing system. The HF equipment is now dominant, leaving the hydraulic devices only for special tasks. During the last two to three years the market has also seen the introduction of a growing number of high frequency core drilling systems. There has also been fast development of diamond tools. The price for diamond tools has dropped dramatically since the 1980s. The quality and assortment has also widened dramatically and in terms of efficiency and fast cutting current diamond tools cannot be compared with the tools of the 1980s. Starting with large and few diamonds in the segment, continuing with random placed smaller diamonds, sandwich segments with several layers of diamonds, and now lately the new technique that enables to position the diamond according to a special pattern, has really taken the diamond tool technology far. This has been achieved while prices have been dropping by 70% and more, but the volumes have been increasing by many hundreds of percent since the 1980s.
Future technical developments Even though this industry has received a strong hit due to the recession in many countries, the industry as a whole is on a very strong path. The concrete cutting method can be used in many more applications then before and is due to refining the technique. It is believed that the high frequency technology will continue to increase and be further developed. When designing new concrete cutting systems the modular thinking is very prioritized among manufacturers, making life easier for contractors. This means that contractors will take fewer components to site, but be able to do the same job and even better and more efficiently then before. The trend is clearly lighter, lesser, faster and more profitable. But what comes with this development is a stronger demand on the contractors that they are properly trained. Already and to a much greater extent in the future is the need for comprehensive training by the associations and manufacturers. A poorly trained operator will not be able understand and to operate current and future concrete cutting systems properly. This is already the case and will be even more important for competition between contractors.
Switzerland and Austria. The UK and the Nordic region will increase by about 2-3%. Also Italy is expected to pick up slightly by 0.5 -1%. For construction spending during 2010 and 2011 it is in particular Eastern Europe that is leading that European race with an increase of 4%. But the big construction spenders are South America with 8.1% increase. Asia is also strong and not much behind and varies between 6.8-8%, depending on region and not counting Japan. Western Europe had just a slight increase of 0.3% and US with 1.6%. The world’s total construction spending has increased by 3%. The professional concrete sawing and drilling industry will of course follow the general development within the construction industry. But a rather good recommendation is to look towards South America and in particular countries like Brazil that is now experiencing tremendous growth.
Some views of manufacturers and suppliers For our Concrete Cutting Survey we sent five questions to a large number of manufacturers of diamond tools and concrete sawing and drilling equipment. Only a few responded, but provided valuable input to the following questions:
What is your opinion about the current international market situation divided by continent, -booming, picking up, slowing down, falling or maybe even free falling? President at Ashine Diamond Tools Co.,Ltd Richard Deng says that Asia is clearly picking up together with South America, Eastern Europe and CIS. While North America and Western Europe is falling. On the other hand he considers Africa and Australia booming. Managing Director Thomas Schwab at Maschinenfabrik Otto Baier GmbH in Germany says that as Otto Baier is a company working in a niche market and purely solution oriented, the variations based on economical external influences are less important. “Even though, there are markets like Spain and Portugal, which are heavily hit. All the other countries in Europe are picking very much up. South America is increasing strongly. North America is not served by our company. Arabic countries are picking up as well and the Asian market seems to be more stable by now,” says Schwab. Bruno Beech working with sales and marketing at British Diaquip thinks that in Europe most countries Future market developments are static, apart from the obvious ones, which are free Large parts of the world are still strongly affected of the falling. He then mentions Italy and Greece. He thinks global economic crisis. Markets are now much more that Asia and Middle East are in growth. “Overall Asia is vulnerable then before, the situation developing. In Australasia we have not can change quickly. But in Europe noticed much change in sales either Germany finally started to show up or down. In North America we strong growth also in concrete cutdon’t have much knowledge of selling. ting. But how the construction For us South America appears to be industry will develop in the future is developing well,” he says. very hard to predict and a lot is just Lloyd Williams, president of speculation. In general the estimation Traxx Construction Products in Ausis that economic development for tralia says that the company mostly the construction industry in Europe works with Australia and New Zeebetween 2010 and 2015 would land and to some extent also China increase, except for Spain, Portugal, and India. Ireland, Luxemburg and Greece. “The Australian market remains Those countries will face a decrease somewhat subdued compared to the of between 0.5 and 1.5%. The UK norm. Major contractors are movwill slowly come back on track, but ing to contracts interstate and even the biggest change will be in Finland overseas to keep their larger teams with about a 6% increase. The strong busy. Companies with contacts in the development in Finland is closely at- Richard Deng, Ashine Diamond Tools. mining industry, which is booming in tached to the construction of a numthis region, are doing well,” says Lloyd. ber of nuclear plants. There has been an average increase of General Manager at Heger GmbH, Stefan Haag around 2% in countries like France, Benelux, Germany, says that Heger is mainly busy in Europe only with a
PDi • Issue 5 • Dec 2011 - Jan 2012
focus on Germany and Benelux. “In Germany we see that the general economy is still booming, but the investments in infrastructural construction is slowing down. We also have the impression that certain market’s nervousness is hammering the price levels. With increasing costs it will be tough in 2012,” says Stefan Haag, Heger Diamond Tools. Stefan. Stuart Wilson president and owner of Marathon Diamond Tools in Spain says that he does not think that any market is in free fall now. “Certainly southern Europe has been in free fall, which has left many casualties in terms of bad debts and bankrupt companies,” says Stuart. Some of the emerging markets are China and India. What is your opinion about the current concrete sawing and drilling market there in a contractor perspective? “Regarding China and India I really do not know. I would suggest that India will have a long time to go, but maybe room for foreign contractors,” says Stuart. Bruno Beech said that Diaquip is not active there, but he would guess that opportunities for contractors would be good. “And the same with India,” he said. “We are not represented in China, but India is an upcoming market and we have some very prosperous issues in this emerging markets,” added Thomas Schwab at Otto Baier. “We are not active in those markets. So I do not have any foundation for any estimation,” said Stefan Haag. Lloyd Williams has more comments on this subject though with great experience from both markets. “Having been there at the start of the modern era in China in particular, it is clear to see major change happening in sawing and drilling as with everything else that is going on in China. Old methods of stitch drilling almost everything are Stuart Wilson, Marathon being replaced Diamond Tools. with the latest wall and wire sawing techniques, particularly on the East Coast where labour costs are now skyrocketing. As major spend on roads and airports increases daily, the demand for sophisticated road saws increases also, along with signs of runway grooving, highway grinding and modern techniques of concrete pavement restoration. Demand in India is also increasing, but not with the speed of China. The roll out of fibre optic cable in India got the trend moving with supply of hundreds of high powered ride on style road saws, a couple of years back. What is most interesting in China is the fact that several major diamond tool manufac-
special survey turers have now either set up or are in the process of setting up manufacturing in other Asian countries, such as Thailand, to enable them to compete in both local and export markets. Who would have thought we would have reached this threshold so soon,” says Lloyd from Traxx in Australia. Richard Deng from Chinese diamond tool manufacturer Ashine says that China is still a big market for them, but business is a bit slower in 2011 Thomas Schwab, compared to 2010. “India Otto Baier GmbH is still a small market for us but we see clear tendencies that it can be increasing fast,” says Richard. But what do these industry professionals feel are the new trends in building modern concrete sawing and drilling equipment? “In times like this customers are demanding the very best for every dollar they spend and sometimes the budget does not match the demand,” says Lloyd Williams. “There is a definite major trend towards speed of completion of jobs as labour becomes the single biggest cost, typically, in contracting. This places more and more demands on manufacturers to provide equipment that is faster, more powerful, more efficient and automated wherever possible. The same trend is clear with diamond tools, where speed remains the greatest asset. Life of tools remains important but not to the extent of a few years back and certainly not at the expense of speed. The request for customising of equipment is increasing. Discerning customers are now requiring more ‘add ons’ with sawing machines in particular, with demands for hydraulic PTOs to enable sawing machines to be used for powering standard hydraulic tools such as breakers, saws and drills. Two useful machines for the price of one and a bit makes sense.” Stuart from Marathon as a mainly a diamond tool maker and thinks that the trend for equipment seems to be high frequency machines, but always room for traditional hydraulic machines. “We are convinced that dry drilling in concrete with rebars is the upcoming technical request from all over the world. Baier has no shares in concrete sawing. Thus, for us the main issue will be dry coring in concrete with rebars with diameter 40mm,” says Thomas Schwab. Richard Deng at Ashine thinks the most important trend now is easy to operate with better economy. “My opinion is that in terms of machines the servo motors are pushing out high frequency. In consumables the positioned diamond hype is still very dominant where we see no proof that this is more than marketing. The manufacturers who invested in this expensive technology are forced to get the output on lower prices, which makes economic productivity very difficult,” adds Stefan Haag from Heger. “We feel the Aero concept is catching on quickly. Positioned diamond has been well established, as well as in combination with high frequency equipment,”
PDi • Issue 5 • Dec 2011 - Jan 2012
says Bruno at Diaquip.
“I can only speak for the UK, but they are certainly becoming more professional and more environmentally aware. There is also a great uptake in training,” says Do you believe that the number of applications where Bruno Beech. concrete cutting equipment is considered an option “Although the training efforts of the associations, has increased or decreased, and why? speaking for the German Bohren und Sägen Fachver“In my opinion, the number has increased. And band, show results that the common level of operators this is because more and more construction repairs still can be improved. Many small start up companies need more machine and need less personnel and people working as a one man operation show that they still have do not like to do heavy jobs by hand anymore,” says to learn basic economics to realize what is the cost and Richard Deng at Ashine. the value of their own work and of the equipment and “We are convinced that the number of applications, consumables they are using,” says Stefan Haag at Heger. the requests of applications and the usage of treatment “This is a big subject,” says Lloyd Williams. “The concrete has been increasing steadily, partially because professionalism increases definitely, of the reduced price levels in but perhaps not every contractor diamond products and also in complies. Most operators well and the more appropriate equiptruly understand the need for safety ment,” says Thomas Schwab at and environmental matters, but Otto Baier. serious operators remain frustrated Stefan Haag at Heger says when they invest in equipment only that so far he has not see any mato find others cut corners, hence jor changes during recent years. price, to win jobs. Our associaLloyd Williams has another tions need to play a much stronger opinion and says: “It constantly role in having authorities enforce increases and in my opinion will existing legislation or introducing continue to do so. Demolition legislation where loopholes exist. As practices alone lend themselves a manufacturer and supplier, huge very much to modern sawing and opportunities remain for scanning, drilling techniques. We see more safety and slurry control equipment and more major demolition comto name just a few.” panies investing in equipment Thomas Schwab believes that for their own needs, something the upper level of contractors bethat sawing and drilling associaLloyd Williams, Traxx Construction came much more aware of these tions need to Products. issues. On the other hand, the numaddress with ber of less highly quality oriented contractors increased vigour perhaps. The demand for even though their lifetime in the market is limited. softer and quieter methods of deRichard Deng at Ashine finishes by saying that it is molition is always increasing. The time that all contractors must care for the environment more concrete that is essentially and safety of the workers. poured in any style of construction, will inevitably lead to increases in demand for such techniques. And we know well that despite the recession in many countries, the demand for cement products increases regardless, particularly in Asia.” “Clearly concrete breaking is one market and concrete cutting is another. Many contractors have the two methods, which compliment each other. The use of cutting has increased and always will depend on property values and labour costs. Tool prices have effectively been dropping in recent years and also general contractor rates per square metre have been driven down as well. So the pressure to supply faster cutting tools has been increasing. Diamond cutting has certainly been increasing and is the norm for many more applications,” says Stuart Wilson at Marathon. Bruno Beech thinks that there would be an increase as compliance on health and safety and environmental issues mean that concrete cutting is chosen for demolition, but there would also be some decrease due to cost saving demolition methods. We would like your opinion about contractors’ professionalism, awareness of environmental and safety issues when operating concrete sawing and drilling equipment? “I think that in general Spanish contractors are operating well within reasonable safety standards although maybe with some exceptions. The environment may be an area which could be improved,” says Stuart.
Contact details of contributors Ashine Diamond Tools Co.,Ltd. Richard Deng email@example.com www.ashinediamondtools.com Maschinenfabrik OTTO BAIER GmbH Thomas Schwab firstname.lastname@example.org www.baier-tools.de Traxx Construction Products Ltd Lloyd J Williams email@example.com www.traxxcp.com.au Heger GmbH Stefan Haag firstname.lastname@example.org www.heger.com Diaquip Concrete Cutting Solutions Ltd Bruno Beech email@example.com www.diaquip.co.uk Marathon Diamond Tools SA Stuart Wilson firstname.lastname@example.org www.marathondiamond.es
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29 electronic speeds, easily adjustable during drilling.
Can easily be upgraded with Autofeed Module.
Very high power on the spindle: 3 kW (4 HP) on 1-phase power and 9 kW (12.5 HP) on 3-phase power.
Discover Pentruder MCCS! Discover true modularity in the powerful Pentruder Modular Concrete Cutting System. Use the same light weight HF-motor, power pack and track system for wall sawing, wire sawing and drilling and more products to come. MCCS components are compatible with current and future Pentruder equipment. With Pentruder you can always expect top quality, highest performance and reliability. Try a Pentruder you too A safe investment in a machine which is built to last! Pentruder MCCS Universal Drill Rig with Pentruder MDU3065 and CEL-TS Carriage for Line and Corner Drilling
Tractive AB I Gjutargatan 54 I 78170 Borlänge I Sweden Tel: +46 (0)243 221155 I Fax: +46 (0)243 221180 E-mail: email@example.com I www.pentruder.com Please visit our homepage www.pentruder.com for more information about our products and contact details to the Pentruder distributor in your country.
Castle and Pryor take to the sky during water tower demolition In the UK demolition and concrete cutting specialist Castle and Pryor has assisted with the demolition of a defunct water tower in East Sussex. The project involved lifting one of the company’s Brokk remotely controlled demolition robots into the air so that it could access and demolish the top portion of the structure. The unconventional approach to demolishing the water tower was due to its location. With a busy road on one side of the building and residential dwellings on the other, it was deemed safest to surgically remove the top portion of the tower using a Brokk robot and then fell the remaining section with a conventional demolition excavator. With the aid of a Tadano mobile crane, Castle and Pryor’s Brokk 180 was initially suspended above the tower’s water tank. From this position the machine utilised its hydraulic hammer attachment to break out the roof and sidewalls of the structure. The 2t Brokk was then placed on top of the structure so it could demolish the remaining sections of the water tank protruding for the tower. During the process the Brokk was remotely operated from
a telescopic access platform erected nearby. In total, the Brokk machine spent 10 days demolishing the water tower’s tank, reducing the 20m high structure by 5m. By removing the tank, more conventional techniques were applied to the remaining structure with a 40t excavator used to level the tower and make good the site ready for a future housing development. “We are regularly called upon to deploy our remotely controlled robots on challenging applications in unusual locations such as airports, railways and power stations,” says
Castle and Pryor representative Graham Pryor. “Providing a safe and cost effective means to remove the top portion of the water tower is a good example of this. A large fleet of Brokks and many years experience operating them means we are well versed at finding solutions to the construction industry’s problems.”
Underground construction in Manhattan gets high performance with dust suppression
Workmen set up the DB-60 at the beginning of their shift. The carriage-mounted unit can be easily relocated wherever it’s needed on a given day. One of New York’s leading heavy construction firms is smothering dust from underground blasting operations by using a network of highperformance suppression equipment for the 2nd Ave. Subway Project in Manhattan. The series of four DustBoss machines has been credited with suppressing dust during execution of the $469 million contract awarded to SSK Constructors a joint venture of Schiavone, Shea and Kiewit. The company has to demolish existing buildings to allow construct of the station entrances and ancillaries, mining of the 72nd Street Station Cavern, as well as shafts and adits for the entrances and ancillaries, and mining the G3/G4 tunnel to connect the station to the existing stub
tunnels at 63rd Street. The work is all part of a planned $4.45 billion expansion of the New York City Subway System. “The technique we’re using is drilling and blasting,” says SSK Project Coordinator Frank Townsend. “The potential drawback is that it creates dust and smoke, and since this is one of the busiest sections of the city, we knew we had to find an effective control method.” Most contractors had relied primarily on manual spraying with fire hoses to keep dust down in the past. “That’s a labour-intensive approach, often requiring several workers at a time, and it’s not as efficient,” says Townsend. He estimates that at a $100,000 annual cost
PDi • Issue 5 • Dec 2011 - Jan 2012
per worker in New York City, counting benefits and insurance, the company may have been expending as much as $1 million per year for its attempts at dust management. After investigating several options, SSK decided to purchase four machines from Dust Control Technology. The suppression equipment is positioned to maximize droplet exposure to airborne dust particles and increase hang time. “When we blast, a tremendous amount of energy is released,” says Townsend. “The force carries the dust away from the shot, and if not contained, it would find its way out the tunnel and up the shafts, which could take it out to the street.” To accommodate the conditions, crews set up the DustBoss machines pointed in the same direction as the blast force travel, with two stationed at each of the vertical shafts. “By aiming the DustBoss units along the path that the dust will travel, we give the atomized mist more time to collide with dust particles and drive them to the ground,” says Townsend. Three of the machines purchased by SSK are DustBoss DB-60s, the largest model in DCT’s fleet. The DB-60 employs a series of 30 specially designed brass nozzles to atomize the water into droplets 50-200 microns in size, the optimum for effective particle attraction. Launched by a
SSK 2011-09-29R: The suppression equipment is strategically positioned to maximize droplet exposure to airborne dust particles, pointed in the same direction as the blast force travel. 25 HP motor that generates nearly 850 m3/min, the atomized spray has a range of more than 60 m, yet the carriage-mounted device is completely portable, allowing it to be located wherever it’s needed most on a given day. The other machine is a smaller DustBoss DB-30. Also mounted on a wheeled carriage, the DB-30 capture dust particles more effectively than many larger machines. “The DustBoss units have had a big impact on this project,” says Townsend. “Our air monitoring systems confirm the significant dust reduction. The equipment has been so successful that we’re in the process of purchasing a fifth unit to use for demolition.”
The wait is over.
INTROdUCING BROkk 100 – ThE NExT STEP IN dEMOLITION vERSATILITy This little power packed sequel to our best-selling Brokk 90 has 35 percent more hitting power (!) a more energy-effective engine, 32 and 16 ampere mode at the touch of a switch, reduced weight and transport height and the same jaw-dropping reach and flexibility as its predecessor. In addition, all the existing Brokk 90 attachments are fully compatible with the new machine! Yes, this is the upgrade you’ve been waiting for.
Brokk AB | P.O. Box 730, SE-931 27 Skellefteå, Sweden | Tel: +46 (0)910-711 800 | Fax: +46 (0)910-711 811 | firstname.lastname@example.org | www.brokk.com
Rhino solutions for a In the last year and a half the Spanish grinding company Rhino Tools SL has consolidated a wide range of floor grinding and polishing tools. The ability to manufacture products adapted to customers’ requirements, has turned this family company into one that is progressing at a good pace.
From its foundation in June 2010, Rhino Tools has demonstrated a serious attitude towards the method, the users, the tools and the service in a market, which is still in a state of consolidation. “The success of Rhino is that we believe a little of everything, understanding our customers requirements with an ability to select a tool from our standard range or design and develop a special tool to suit the application and requirement,” says founding partner of the company Stuart Wilson.
25 years of Spanish tool knowledge For this task Rhino Tools founding members count on an experience of 25 years in the diamond industry. The Spanish company was created to strengthen and expand a complimentary existing market that started to grow little by little in its sister company Marathon diamond tools, where their members have worked since 1995. “Having served the construction industry for many years with performance diamond tools and solving many special problem cases with custom built solutions, we felt it was time to turn our hand to concrete floor grinding applications,” says Stuart Wilson.
An understanding of the fundamentals related to the function and application of synthetic diamond has allowed the Rhino Tools team to design and develop diamond segments for grinding in almost any application.
New polycrystalline range The company has recently invested in developing a range of polycrystalline diamond (PCD) tools. A range of defined edge PCD tools for epoxy resin removal uses the most advanced grade of PCD. According to the partners, the key to high quality tools is the retention properties of the PCD insert. Here Rhino has developed its own technology. This, coupled with the use of highly abrasion resistant backup segments, results in aggressive and efficient floor grinding tools. For PCD non defined cutting tools, a novel form of sintered segment, can be used that utilizes a form of non uniform shaped PCD pieces, which are randomly orientated within a sintered metal bond matrix. Conventional synthetic diamond abrasive is also blended to assist the cutting ability and abrasion resistance. Results have demonstrated outstanding stock removal rates whilst achieving excellent efficiency. Rhino Tools has decided to use and refer to their tool range
Delivery of new Scanmaskin machine with full technical backup in Oviedo Asturias, Spain.
24 PDi 26 PDi••IIssue ssue55••D Dec ec2011 2011--JJan an2012 2012
any floor application Above some typical diamond tool products.
with US mesh diamond sizes. Therefore customers can understand the actual abrasive size used and relate this to something practical such as general conventional abrasive products, which also utilize the US mesh grading system. The coarsest abrasive size is 16 mesh and the actual size is approximately 1mm diameter. The design of tool utilizes the carat weight of diamond dispersed throughout the segment. For each carat of 16 mesh diamond used, approximately 100 particles are available for cutting. If the mesh size is changed to 40 there are about 1000 diamond particles. A further change to a finer 80 mesh results in about 10,000 particles available for the cutting application. The understanding of these factors allows the tool to be designed to best meet customer requirements. However, design and development does not stop in Rhino Tools facilities. Field trips are also made to assist customers providing a full backing and technical support for the product range. Rhino Tools focuses on the European Union with the aim of extending and consolidating its presence in this area. Between their future projects, the company is considering to penetrate the American market through a strategically located distributor network. Their intention is to continue creating a commercial and service infrastructure adapted to the requirements and needs of each territory.
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Brazing a special grinding plate.
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Den Hoek 10 • 5845 EL St. Anthonis (NL) •Tel. +31(0)485 442300 • Fax +31(0)485 442120 • email@example.com Issue 5 • Dec 2011 - Jan 2012 •
Why bolt when you can clamp? To anchor concrete drilling equipment can be done in two ways, the complicated way by bolting down the equipment or by using a stand with a clamping device. The company DIBO from Katrineholm in Sweden has been making drill stands since the 1970s and now plans to increase the use of their systems in Sweden and abroad. To clamp a drill rig stand instead of bolting it to the material is something very Swedish. The method was developed in Sweden a long time ago and has been used by almost every Swedish concrete cutter ever since. Clamping rigs are to some extent also used in other This is how a rigged clamping rig from DIBO look like.
An excellent example of successful cooperation between supplier and contractor are DIBO’s application for sword cutting with a chainsaw from ICS. Pictured from left, DIBO Production Partner AB Marketing Manager Lars-Erik Rundqvist, former designer at DIBO Production Partner Borje Widén, retired since last summer, Hovets Entreprenad Håltagning AB’s Lenny Andersson and Mikael Wallgren.
Nordic countries. But it is still rare on other markets in Europe, in USA or other parts of the world. It is quite strange that this principle didn’t breakthrough in other countries as it makes the fastening much more stable and safe. Plus the fastening is much easier and quicker to move to another location. Clamping stands are more expensive, but they offer quite a lot in return and bolting damages the material more.
What is clamping? But what is a clamping rig, the device that can be found with every Swedish concrete cutter. In short it is a rig that is clamped either between the roof and the floor or between two walls or any parallel surfaces. No bolting in the concrete is involved. The rigs are very steady and are easy to set up. A feeding head is fixed on the clamped stand. From the feeding head a boom is fastened between the feeding head and the surface to be drilled. On the boom there is a drill attachment where the drill machine is mounted. The set up is a very simple operation for a concrete cutter and offers 100% stable and accurate drilling. In Sweden there are several manufacturers making these clamping rigs but the oldest producer is DIBO Production Partner in the city of Katrineholm in mid Sweden.
PDi • Issue 5 • Dec 2011 - Jan 2012
DIBO was founded in 1978 by Ove Gustafsson. Besides making the DIBO clamping stands the company also worked as a manufacturer of different types of parts. When the DIBO system was launched it quickly became very popular among concrete cutters in Sweden. Rather quickly other manufacturers in Sweden started to produce similar systems, including HRA Scandinavia, now owned by Husqvarna Construction Products. Later Jerneviken Maskin developed their own clamping system. But DIBO invented the clamping principle. The biggest advantages with the DIBO clamping rig is that it provides extreme stability. It is ergonomic and designed to be set up and used by only one person. It is light, thanks to the stand, boom, feeding head and drill motor attachment being made of aluminium. It can be clamped up to 4 m in height and leaves no marks or damage in the material it is clamped to. The system is built up with exchangeable components, which makes it easy to work with. It is versatile thanks to a large number of accessories for different applications and it can be positioned in any angle and can accommodate all drill motors. DIBO clamping rigs are made in two sizes: DIBO 75, which is suitable for small up to heavy duty drilling applications and the small and smooth DIBO 50.
OilQuick - for efficient demolition!
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Irvator Group and sister company to Momento that make power sockets. Lars-Erik Rundqvist, marketing manager at DIBO, says that the company has decided to go into a higher gear to market the system worldwide. “We have known for a long time that we have a great product that emphasises the daily work for the concrete cutter by making the work more profitable, more efficient and safer,” says Lars-Erik. The DIBO systems are a bit more expensive than traditional bolted rigs but on the same price level as the other Swedish manufacturers of clamping rigs. “Swedish contractors have no problem with seeing the benefits with our clamping systems and the small additional cost they have to pay comes quickly in return thanks to better efficiency and a more accurate job procedure,” says Lars-Erik. The set up is made almost in no time and the contractor can quickly get moving with the drilling. When finished with the first hole, dismounting the clamping rig is fast and he can quickly moved to the next hole. “The quality of the drilling is also increased as the drill machine is steadily fixed and locked thanks to the DIBO system. The system can also be easily adjusted thanks a tilting mechanism that puts the drill in the exact position before drilling. Complicated under-up drillings become very smooth with a DIBO rig,” says Lars-Erik. Powerful drill diameter of 750 mm and clamping equipment from DIBO.
Picture is showing negative wire sawing with a wiresaw from Hilti and two DIBO 75 stands with columns equipped with rubber wheels where the wire runs. With the help of DIBO’s equipment the wire is fed into the pre-drilled hole and the negative wire sawing is performed. DIBO 75 can take drilling diameters up to 750 mm and DIBO 50 up to 360 mm. DIBO 75 weighs 75 kg and DIBO 50 39 kg. The base plates are equipped with wheels, which makes it easy to move.
More efficient, more profitable and safer DIBO was first to develop the clamping rigs and business was good from the start. But DIBO was never a large company and this was its only product for the concrete cutting industry. Now DIBO is part of the
PDi • Issue 5 • Dec 2011 - Jan 2012
The two pictures above and left showing a new DIBO application for chain saws. mainly work on complicated and special concrete cutting solutions and has carried out several spectacular concrete cutting projects in the centre of Stockholm. They have developed a special solution for negative wire sawing with DIBO equipment. With two parallel DIBO clamping rigs and a vertical boom between them and some other accessories developed by DIBO a difficult wire sawing job became very easy. Recently DIBO with Hovets tested a new application where an ICS chain saw was used in conjunction with the DIBO 75. This appeared to be a smooth solution for deep cutting with a chain saw without risk for over cuts. The set up time is kept Tougher abroad short and the stability was excellent. Thanks to the DIBO To implement the advantages with the DIBO system’s design the sawing can be carried out system in Sweden is quite easy but abroad it in all directions in the floor, roof or wall. “I is harder to convince contractors about the think this application can attract many ICS excellence of the DIBO system. “You just users and it works of course with other brands have to travel to Denmark to meet a bigof chains saws,” says Lars-Erik. ger reluctance towards clamping. They are Lars-Erik Rundkvist is optimistic for the very afraid to try something new even if the future. In Sweden the company already has benefits are so clear. Moving more south in a market but it can be much bigger. Then Europe the reaction is the same, they continue Roof plate. he sees great potential abroad. “We need to using the old method by bolting the rig to the communicate the advantages with our system concrete making the work more complicated, and start to demonstrate our products. But I time consuming and damaging the material,” remember some tough years in the beginning says Lars-Erik. of this century. “Momento bought DIBO in DIBO has been trying to sell their sys1999 from its founder. We saw immediately tem abroad. The company has exhibited at a great potential for the product. We were at World of Concrete the last three times. The that time mainly competing with Husqvarna US market has showed interest but the real and used the former company Hagby as our break though has not yet occurred. DIBO is distributor. But then Husqvarna bought now actively looking for distributors all over Hagby and was of course not interested in the world. “We don’t give up easily. We have a Tensioning device for selling our system when they had their own. great product and now we need to start com- clamping operation. This fact put us in a rather difficult situation municating the advantages with the system to for some years. But now we are back full of the market. We just need a few contractors on confidence and we are now slowly building each market to take up the system and see the up a network of distributors. But we need advantages and the implementations will go more distributors all over the world,” says much smoother,” says Lars-Erik. Lars-Erik Rundqvist.
Satisfied customers One Swedish concrete sawing and drilling Base plate. contractor that cannot be without clamping rigs from DIBO is Hovets Entreprenad Håltagning AB in Stockholm. “We have used the DIBO systems for decades and there is no alternative. We would never go back to bolting the drill rigs. The DIBO system makes our work so much easier, flexible and more efficient. The DIBO stands never break and are very easy to work with,” says Lenny Andersson who owns the company. Lenny and his company have also been an important sounding board for DIBO. Together with Hovets new products and applications have been tested. Hovets
Below the DIBO swivel bracket.
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Read more at www.greygrinder.com PDi_4_half-page2011.indd 1
12/1/11 11:11 AM
In the rotary oven with Nasum’s Conny Lundqvist, operator of the Husqvarna demolition robot DXR 140. Conny thinks the robot is terribly strong for its size and is much more efficient than their older machine even though it weighs about half a ton less.
The Södra Cell’s pulp mill in Värö, Sweden, sometimes needs to clean the brick lining in their kilns. This usually happens with planned downtime, when the factory’s entire process is closed for about ten days for inspection and preventive maintenance.
Such large, planned downtime is now scheduled every 18 months, but will extend to every two years in the near future. In the Värö plant the paper producer Södra Cell produces around 430,000 t/year of bleached pulp. Most of the products are exported. At full production about 300 t/day of lime is produced the kiln. The rotary inclined lime kiln is 113 m long and 3.4 m diameter and the material to be heat treated takes place in the cooler end. There is a burner in hot end and a device for transporting the material when it has been treated. The oven’s interior is lined with refractory bricks and 240mm think when new. The bricks are torn as the input material shuffles around in the kiln. At the planned outages the thickness of the brick lining is measured by ultrasound or by drilled to check thickness. The parts that are worn are to be removed and replaced with new. The job of taking out the worn bricks went to Nasum Concrete Cutting, specialising in heavy interior demolition. The old bricks are chopped out using a demolition robot.
Exotic environment One small problem emerged when Södra Cell mounted a ringshaped threshold in the oven, close to the burner. The threshold is designed to delay and prolong calcium carbonate staying in the oven. Nasum’s existing demolition robot turned out to be too large to access the brick beyond the threshold, so a new, more compact model had to be bought. The choice fell on a Husqvarna DXR 140. Conny Lundqvist, concrete cutter, robot driver, asbestos removers and truck driver at Näsum enjoyed working with the new machine when he got to try it. In just a few hours, Conny Lundqvist got through almost the entire furnace. He has done similar work before, and says that cleanup can take anywhere from 4-5 hours to several days depending on the thickness of the brick to be removed. “The Husqvarna robot is terribly strong for its size. It demolishes better, but still weighs about half a ton less than the company’s existing demolition robot. I am very satisfied
A robot in a rotar Text and photo: David Ehrenstråle
PDi • Issue 5 • Dec 2011 - Jan 2012
with this machine,” says Conny Lundqvist. He is the only on Nasum employee that operates the Husqvarna robot and thinks it is better in view of maintenance and reliability. Boom lubrication is recommended by the manufacturer and the operator should inspect and lubricate it with grease daily. During weekly inspections cleaning with water or compressed air is recommended, and also inspection and lubrication of rotary bearings and legs. Apart from this, there are preventive maintenance and service schedules after 100, 250, 500 and 1000 hours.
The oven as seen from the input end, the colder end. This is where raw materials are added to the heating process. At the far end, about 100 m away is lighting from the demolition robot.
The end product in the kiln is cleaned out before maintenance.
Lime kiln at Södra Cell in Värö is a 113 m long rotary kiln with an external diameter of 3.4 m to burn limestone to a temperature of about 1100 ° C.
Issue 5 • Dec 2011 - Jan 2012 •
Introducing Brokk 100 - the next generation Brokk has done it again. Just a few weeks ago Brokk introcued the new Brokk 800. Now the company is launching another, Brokk 100, which will replace Brokk 90. Over the past two years Brokk replaced all existing models with new ones.
Brokk AB is introducing the new Brokk 100, the next generation of demolition machines in the compact below 1000 kg segment. With 35% more breaking power, increased versatility and an even more compact design, the Brokk 100 is a successor to the best selling Brokk 90.
Completely new machine “Brokk 100 is a completely new machine that will enable our customers to take on even more challenging projects with increased profitability,” says Brokk AB CEO Martin Krupicka. “The machine has been designed from scratch, making full use of Brokk’s 30 years of experience in building demolition robots. The result is an outstanding machine.” Under the hood, the Brokk 100 features a new load sensing hydraulic system with improved hydraulic capacity, providing for a 35% increase in power using the 150 kg SB152 breaker. The Brokk 100 also features improved driving properties, a lower profile, advances in serviceability and additional improvements to an already industry leading cooling capacity.
steel covers, improved rubber pads and LED lights. “With the introduction of Brokk 100, Brokk is now several machine generations ahead of any competition in all sizes of machines in the remotely controlled demolition machine market,” says Martin Krupicka. “Needless to say, the new Brokk 100 is another great leap forward in fulfilling Brokk’s promise to deliver maximum power and flexibility to solve our customers’ complex and confined space demolition needs.” The Brokk 100, which weighs 990 kg, is 780 mm wide and 1147 mm tall. The recommended maximum weight of attachments, such as breakers, crushers, shears and drills is 150 kg. It was displayed for the first time at the Batimat exhibition in Paris, France, on 7-11 November, and then at open house events around the world from December. The machine will be available for delivery starting February 2012.
360° working performance On site Brokk 100 is the first in the industry to deliver the flexibility of true 360° working performance in this size range, without compromising stability, productivity or reliability. When electric power supply is limited, the machine offers the option to gear down and work using only 16 A. Other new features include impact resistant Below a photo from Brokk’s premices in Stockholm. Way out on both sides Leif Pettersson (left) and Adam Afarin working at service center in Kista. From the left Martin Burström, after marketing manager, Michael Gardell, sales manager for Sweden, Eva Skinner, marketing communications manager and Brokk president Martin Krupicka.
The Brokk 100 is loaded with smart features and solutions that feature the lower, denser, more durable and 35% stronger robot. A smart detail is that the cable can be folded to the side to protect from injury.
The new control system with the new control box has been made smarter and easier to work with.
PDi • Issue 5 • Dec 2011 - Jan 2012
HTC introduces a new innovative dust extractor HTC now introduces the new revolutionary HTC 80 iD. This new dust extractor increase the productivity with up to 15% compared to traditional dust extractors. The HTC 80 iD is equipped with a unique pre-separator that, despite its compact size, removes up to 95% of the dust. With HTC 80 iD the productive time for a flooring contractor will be increased. All companies looks for ways to make their business more profitable. The core focus for HTC is to keep developing the ultimate flooring system and with the new HTC 80 iD they take the next step towards that vision. HTC believe in a system where all parts are made to match. HTC 80 iD is a dust extractor designed for high capacity floor grinders, such as HTC 950, 800, 650. The HTC 80 iD can be used in various ways depend-
ing on your setup. For maximum efficiency and output, a remote controlled grinder from HTC is recommended. The unique bypass valve leads to continuous operation, something that with conventional dust extractors has been impossible. However, a traditional grinder without remote control still benefit greatly from the double Longopac®, the high performance integrated pre-separator and the ability to use the remote control, an optional feature, to turn the dust extractor on & off from a distance.
Atlas Copco’s new Bulk Pulverisers Atlas Copco Construction Tools has introduced two new hydraulic Bulk Pulverisers, which are ideal for secondary demolition and reduction of reinforced concrete elements. The broad jaw makes it easy to feed in demolition material on the ground, which enables the clean separation of rebar and concrete and reduction into grain sizes suitable for crushing or use as backfill. An optional hydraulic rotation device also makes it possible to use the BP Bulk Pulverisers for primary demolition of ceilings and walls. High and constant power at the jaw tips, even when the jaw is almost closed, helps
to demolish structures with fewer bites. The huge jaw dimensions enable high throughput. Speed valves deliver more speed and shorten the opening and closing cycle time and reduce fuel consumption during pulverizing. “Our new bulk pulverisers follow our concept of lower cost of ownership,” says Silent Demolition Tools Product Line Manager Wolfgang Hohn. “And the robust design of the moving jaw and the housing extends the service life even under extreme stresses.” Bulk Pulverisers are available for carriers of 18-35 t.
BP 2050 BP 2050 R BP 3050 BP 3050 R Carrier weight class, t 18-27 22-27 25-35 30-35 Service weight, kg 2050 2600 3050 3850 Jaw opening max, mm 875 875 1000 1000 Jaw depth, mm 610 610 650 650 Blade length, mm 190 190 190 190 Cutting force upper blades, t 290 290 365 365 Crushing force jaw tip, t 90 90 115 115 Operating pressure, bar 350 350 350 350 Oil flow, l/min 150-250 150-250 250-350 250-350 Opening/Closing, sec 5.4 5.4 5.6 5.6
New model of Holer’s hydraulic handsaw Holer Diamond Tools have been manufacturing the revolutionary 21” (534mm) hydraulic hand saw since 2008. The machine features a 535mm blade capacity to give 210mm cutting depth. Two piece blade guard to provide flush cut capability on walls and floors. It has automatic water ON/OFF feature via blade trigger as well as a build-in pressure relief valve providing correct oil flow & pressure for operator protection. The Pressure /Flow recommendation are 140-160bar / 35-40liters. New 2012 model available now Holer is releasing a new model now with several new and improved features like a simplified belt tensioning system. The Poly Chain Carbon drive belt system has been improved with a new belt system which eliminates slip and is guaranteed not to stretch. All aluminum components are now anodized for better resistance to concrete slurry and distinguishes the 2012 model with the electric blue look. The reduced blade speed give better cutting performance and more torque. All existing machines can be upgraded to the 2012 spec. Issue 5 • Dec 2011 - Jan 2012 •
Creating Airport Link is a new 6.7 km toll road and tunnel under construction in Queensland, Australia. It is the country’s largest privately funded transport infrastructure project to date, and is expected to open to the public in the middle of 2012. Part of the AUD $4.8-billion project required the core drilling and sawing of concrete structures to expose tension piles and facilitate the inclusion of reinforcing slabs. Some of the core holes created needed to be 1m diameter and 1.2m deep. In addition, large amounts of wall and wire sawing were also required.
When complete, the new Airport Link toll road will connect the city’s central business district to Brisbane Airport, the Australia Trade Coast industrial district and the rapidly growing northern suburbs. It will provide several entry and exit points to alleviate traffic on some of the city’s other commuter routes.
Massive number of large holes drilled
As part of the project, two massive concrete boxes, approximately 65 m and 12.5 m tall have been placed under Queensland’s busiest railway line without disruption to train passengers. These jacking boxes formed part of a tunnelling operation under one of the railway line’s embankments. Hydraulic jacks and steel strands pushed and pulled the boxes under the embankment, while excavators inside the boxes dug out the earth to keep the boxes slowly moving forward into position. Thiess of South Bank, Queensland entered into a joint venture with John Holland of Brisbane for the Airport Link project, forming the Thiess John Holland Joint Venture. The joint venture needed to enlist a specialist concrete cutter that had the experience and Lubricant smoothened the operations equipment to handle a range of tasks along the link, Traxx Construction Products representative, Stuart and chose CSDAA member Fast Cut Qld Pty Ltd of Holes were core drilledSmith was brought on site to review cutting progress 1m in diameter. Brisbane to complete the work. and suggested the use of the TraxxCFQ diamond The most significant portion of the contractor’s tooling lubricant. A small amount of the lubricant was work was to drill 52 large holes of 1m diameter and 1.2 m deep mixed with the water supply, between 2% and 4% of the total through 80 MPa concrete and 40 mm reinforcing bars. These quantity of the mixture, to extend the life of the diamond segments core holes were required to expose tension piles for concrete slab on the core bits and increase drilling speed. Operators found that tie down. Another task included flat sawing through an 800 mm after applying the lubricant, drilling time was reduced from 36 thick slab to expose the earth below, and creating around 9,500 to 12 hours per hole. In addition, the life of diamond segments small-diameter core holes to provide the key for a reinforcing was increased an average of 30% while drilling speed increased an slab. This slab was to be installed to prevent sideslip of the tunnel average of 200%. The load on the power pack and hydraulic drill section as the slab was moved into place. In addition, the ends motor was also reduced by 40%, saving fuel, wear and tear and of jacking boxes, measuring 1.5 m wide by 17 m tall, were to be CO2 emissions. In addition, water consumption was reduced as cut and removed. less time was spent drilling. Core drilling with diamond tools was the most efficient way The contractor then went on to complete approximately to access the tension piles. As the project was to run in 24 hour shifts and ran through a suburban area, noise restrictions were put in place to protect workers and nearby residents from excessive noise levels. Using core drilling techniques with diamond tools produces less noise than traditional demolition methods. In addition, this technique made sure the contractor stayed within critical dimensional tolerances, as deviations from these tolerances would have led to extra restoration work after the completion of the project. The non-destructive nature of core drilling also minimized vibrations that could have compromised the structural integrity of surrounding buildings and structures. “We had considered all the options available to us, like plunge sawing, but core drilling was the ideal choice,” says Rex Scoles of Fast Cut Qld Pty Ltd. “This technique met all of the criteria set by the joint venture, so we began looking for a company that could supply us with the equipment we needed.” Scoles contacted a representative from Traxx Construction Products to procure the necessary core bits and rigs.
Safety and method paramount Before the team from Fast Cut could start cutting on the Airport
Link site, a full job safety analysis and work method had to be completed and submitted to the joint venture. On approval, the contractor set up and began creating a test hole. As the operator drilled, it was discovered that the steel reinforcement in the concrete was greater than the client initially thought. In consideration of this discovery, modifications to the work method were made. Each hole had a top layer of 200 mm thick steel with only 50 mm of cover. The first layer consisted of 27 bars of 40 mm diameter, followed by various numbers of 40 mm diameter bars at 200 mm spacing down the length of the core. Finally, there was a bottom layer of another 27 bars of 40 mm diameter. This meant that initial projections for completion of the drilling work were not achievable, so a second drill rig was brought onto site. Initial targets for the job were to complete one to two holes every 24 hours, so the addition of a second rig helped maintain this pace. However, some holes were taking up to 36 hours to complete so Fast Cut had to come up with a new plan.
PDi • Issue 5 • Dec 2011 - Jan 2012
The Airport Link project will provide much-needed transport links to Brisbane.
the Link Core Drilling Helps Form New Airport Link Road in Australia
Issue 5 • Dec 2011 - Jan 2012 •
Holes were core drilled 1m in diameter.
The core drilling produced cores 1.2 m tall and weighing 3 t. Cores were heavily reinforced. The TraxxCFQ diamond tooling lubricant was mixed with the water supply to improve cutting performance.
10,000 m of flat sawing on reinforced concrete slabs to a depth of 800 mm. This was to cut through the slab and allow the general contractor access to the soil below. The tails of the jacking boxes were then to be removed by wire saw. Fast Cut wire sawed four bottom sections and two tops sections, each measuring 1.5 m by 17 m, before the cut sections were removed by crane. Pre-start meetings were held before each shift change to discuss activities and address any safety concerns. Working around several other contractors, supervisors from Fast Cut had to make sure that their operators were aware of restrictions in the work area. The contractor was working to strict time constraints and timing had to be closely monitored. Due to the size of the 1 m diameter, 1.4 m tall core bits and the drilling rigs, the contractor had to ensure that the work area was free from any incumbents and strictly followed all health and safety standards set for the project. The general contractor placed safety barricades around the work area so no vehicles or unauthorized personnel could access the area. To run the two drill rigs on site, Fast Cut modified its own diesel-powered hydraulic power pack by setting up two hydraulic circuits. The remainder of the tools and equipment needed to complete the job, including drill rigs, core barrels, core bits and diamond tool lubricant, were either manufactured or supplied by
Traxx Construction Products. Representatives from the manufacturer were also on hand to provide on-site service support while the cutting work was done.
52 holes and over 3 t of cores In total, 52 holes were drilled on the Airport Link toll road, which produced concrete cores each weighing over 3 t. As a result of the cutting these cores, 156 t of concrete was cut and removed by Fast Cut. In addition, the contractor performed 10,000 m of slab sawing, drilled 9,700 small diameter holes in a reinforced slab and wire sawed six jacking box tail sections 1.5 m wide by 17 m. The job completed on time in the allotted two months, having three crews of operators work alternating 8 hour shifts on a 24 hours/day, seven days/week schedules. The job remained on budget throughout, and as a result of Fast Cut’s performance, the joint venture has awarded the contractor more wall, floor and wire sawing work on the project. “I’m really satisfied with our work,” said Scoles. “The project was completed on time without any major issues, thanks to the continuous commitment of my operators and the help provided by my suppliers. I have skilled, trained operators in every discipline who have been able to show the joint venture their experience on several parts of the Airport Link project.” The Airport Link toll road is set to open in June 2012 with the aim of improving Brisbane’s road system. The work completed by this CSDA member has helped to keep the whole project on schedule and shown general contractors the benefits of cutting and coring with diamond tools. The contractor has helped create the Airport Link while forming important links of its own with general contractors.
The concrete was heavily reinforced with rebar, which made cutting difficult.
PDi • Issue 5 • Dec 2011 - Jan 2012
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Husqvarna wire sets new standards In 2005, Husqvarna started developing a diamond wire using vacuum brazed technology for high demanding applications such as heavily reinforced concrete and steel cutting and now the technology is ready to hit the market. The main challenge in steel cutting is creating cutting chips in order to be able to finish the cut. Contrary to other conventional technologies the Husqvarna technology allows the use of extremely big diamonds that not only guarantee a smooth cutting process, but also gives customers peace of mind. Vacuum brazed wires are developed specifically for demanding applications like dry and wet cutting in reinforced concrete, and in solid or hollow steel. The vacuum technology enhances durability and performance. Vacuum technology uses active welding, one of the strongest welding methods, making for extra hard bonds and excellent diamond retention. Vacuum brazed wires cut faster and last longer than standard electroplated/sintered wires. They are ideal for both dry and wet cutting. The possible fields of application are numerous, but there is a strong focus on cutting in the offshore and the nuclear industries.
In both cases the reliability of the wire is the main issue. As far as the offshore is concerned, the costs of having a vessel with divers available all the time is huge, and breakage or malfunctioning of the wire has to be avoided at all costs. In the nuclear sector the operation can be more critical. Not only does a breakage require intervention from an operator in a hostile environment, but the clear demand in the nuclear industry has been that the cutting operation has to be performed without any cooling water. Wire without joints is common knowledge in the wire sawing business that the only weak link in the diamond wire is the connection or joint. Regardless of how good the joint has been made,
• • • • •
SAFE FAST SINGLE PHASE 21 cm CUTTING DEPTH EASY TO USE
PDi • Issue 5 • Dec 2011 - Jan 2012
it still cannot take the same forces and/or impact that are inherent in the cutting process. Therefore Husqvarna offers on the full cobra range a closed loop or spliced wire. This is a wire without a joint. The wire is continuous hence the weakest link has been eliminated. Husqvarna supplies closed loop wires to the major players around the world in the offshore and nuclear businesses. The range of cobra wire has two types of beads of 10.5 mm and 9.5 mm. Depending on the application different type of wires are offered. The C1000 is the universal cobra wire for heavily reinforced concrete and steel, both dry and wet cutting. With 44 beads/m of 10.5 mm diameter the C1200 is the high demanding application wire for solid and hollow steel structures, both dry and wet cutting. The C950 has 53 beads/m of 10.5 mm diameter and is the general wire, for heavily reinforced concrete and steel, both dry and wet cutting. For higher cutting speed and 40 beads/m of 10.5 mm diameter is the C900 versatile wire, for finishing difficult or making small cuts, for heavily reinforced concrete and steel, both dry and wet cutting.
New Holer dust shroud Holer Diamond Tools has added the Holer Dust Shroud 180 Premium*** to its line of Floor-Pro Concrete Grinding Equipment. The new Dust Shroud for angle grinders has been designed to give operators full control while hand grinding. The need to make adjustments to fit different cup wheels and diamond segment heights is a thing of the past, thanks to the custom made rubber diaphragm, which automatically adjusts the shroud to the cup grinder body. Edge Grinding is made easy thanks to the
moveable mouth piece, which when opened without tools can grind right up to concrete walls, but still gives the operator 99% dust free productivity. The adjustable air vent allows the operator to adjust the vacuum pressure of the vacuum cleaner, giving the operator full control to ensure dust free grinding, but preventing the shroud from bogging down. Different angle grinder collar sizes are available to suit different makes and models. The Holer Floor-Pro Range now consist of its 300 mm Single Phase 2.2kw Concrete Grinder, Fast Fix Concrete Shoe Grinding Segments, Dust Shrouds for angle grinders and Deluxe Spanner.
DEMCON 2012 A Show Worth Waiting For. 6-7 September, 2012 InfraCity, Bredden, Stockholm, Sweden
An Integrated P art of DEMCON 201 2.
First a big THANK YOU to all exhibito continuation of the original demolit this folder as a reminder that the d next edition of DEMCON will be on 6 previous show. DEMCON represents all the play distributors and professional contra recycling, concrete cutting, hydrode dust and slurry and diamond tools. folder. As with the last DEMCON the will be a fully integrated part of DE The reservation of booth space to m also and
ors and visitors at DEMCON in September 2010. It was a successful premiere and tion show, which was held at InfraCity in the 1990s. DEMCON is here to stay and demolition show at InfraCity, Stockholm, Sweden will be held every two years. The 6-7 September 2012 at InfraCity, Bredden north of Stockholm, the same venue as the
yers gathered under the collective name of demolition, such as manufacturers, actors. In demolition there will be several different sectors, including demolition, emolition, cleaning, grinding and polishing of concrete floors, unloading, handling and . A more detailed summary of the fair segmentation can be found on the back of the e rental show ExpoRent will be held in parallel with DEMCON. But this time ExpoRent EMCON as ExpoRent exhibitors will be mixed with the DEMCON exhibitors. at DEMCON 2012 and ExpoRent 2012 has already started and the easiest way make your reservation is through the dedicated website www.demcon.se, which o goes for ExpoRent booths. At the website you can also pre-register as a visitor print your entrance tickets.
you at the DEMCON and ExpoRent ws in September 2012.
“This is DEMCON” •
All forms of demolition and demolition equipment, such as remotely controlled demolition robots, excavators designed for demolition purposes using long reach demolition booms, booms for heavy duty demolition, implosion techniques and equipment, special dismantling equipment, like wire saws for complex demolition tasks and hydrodemolition equipment.
Various attachments and tools for demolition, recycling, sorting, handling and crushing, like hydraulic breakers, crushers, pulverisers, sorting grabs, milling heads, crushing buckets and steel shears.
Concrete sawing and drilling equipment for drilling, wall sawing, wire sawing, chain and plunge sawing and power cutting.
Diamond tools for professional concrete sawing and drilling, scarifying, milling, grinding and polishing.
New technologies and methods behind demolition, concrete cutting, recycling and concrete floor preparation, grinding and polishing.
Professional equipment for taking care of dust and slurry on worksites, both indoors and out doors, as well as cleaning the air.
Machines and equipment for recycling different types of demolition waste using mobile recycling crushers, mobile screeners, crushing buckets, steel shears and shredders.
The show also covers all types of additional equipment related to the above product sectors.
“Book your booth and pre-register at www.demcon.se”
DEMCON 2012 6-7 September, 2012 InfraCity, Stockholm, Sweden S.C.O.P. AB P.O. Box 786 • SE-191 27 Sollentuna, Sweden Tel: +46 (0)8 585 700 46 • Fax: +46 (0)8 585 700 47 email@example.com • www.demcon.se
clearance • recycling • concrete floor grinding • concrete polishing • hydrodemolition • dust extraction • aircleaners • dust cannons • power cutters • wall sawsPLATINUM • pulverisers • concrete crushers • wire saws • high frequency equipment • high reach demolition • compact loaders • mini excavators • demolition robots • wrecking balls • cranes • steel shears • drill stands • powerGOLD packs • diamond tools • sorting grabs • mobile recycling machines • hydraulic breakers • mobile screens • grinding tools • quick couplings • floor saws • retipping equipment • wet cutting blades • mini excavators • mini dumpers • chain saws • ring cutters • cracking devices • suchtion systems • core drills • jack hammers • crushing buckets SILVER • magnets • circular saws • diamond wires • drilling machines • demolition • diamond tool • concrete cutting • clearance • recycling • concrete floor grinding • concrete Supporters• dust extraction polishing • hydrodemolition • aircleaners • dust cannons • power cutters • wall saws • pulverisers • concrete crushers • wire saws • high frequency equipment • high reach demolition • compact loaders • mini exHiB, Håltagningsentreprenörerna Riv- & Saneringsentreprenörerna cavators • demolition robots • wrecking balls • cranes • steel shears • drill stands • powerpacks • diamond tools • sorting grabs • mobile recycling machines • hydraulic breakers • mobile screens • grinding tools • quick couplings IACDS International Association of Concrete Drillers & Sawers • floor saws • retipping equipment • wet cutting blades • mini excavators • mini dumpers • chain saws • ring cutters • cracking devices • suchtion systems • core drills • jack hammers • crushing buckets • magnets • circular saws • diamond wires • drilling machines • Official Show Magazines demolition • diamond tool • concrete cutting • clearance • recycling • concrete floor grinding • concrete polishing • hydrodemolition • dust extraction • aircleaners • dust cannons • power cutters • wall saws • pulverisers • concrete crushers • wire saws • high frequency Official equipmentOrganiser: • high reach demolition • compact loaders • mini excavators • demolition robots
The rental show ExpoRent will be organised together with DEMCON. But this time the ExpoRent exhibitors will be integrated among the DEMCON exhibitors.
No more skirt adjustments with the custom made rubber diaphragm Adjustable built-in air vent allows vacuum pressure control Unique removable edge grinding mouth piece
Holer Dust Shroud 180mm Premium Various collar models available to suit grinder brand
Unique removable mouth piece
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Optional recommended accessory for easy removal of cup wheels
Introducing the latest development for optimum dust control on angle grinders. The New Angle Grinder Dust Shroud 180mm Premium made by Holer. Our custom made dust shroud has been carefully developed to satisfy the Pro Concrete Grinders with no compromises in design or materials used.
Head Office / PO Box 3464 / 65 Main Road, Richmond 7050 / New Zealand P:+64 (03) 543 9750 / F:+64 (03) 544 0110 / E: firstname.lastname@example.org
High-rise demolition with w Näsum Concrete Cutting was hired to demolish a 50 m high concrete and brick chimney at Blekinge Hospital in Karlshamn, Southern Sweden. The company used a combination of concrete cutting with demolition robots. Text and photo: David Ehrenstråle The old chimney at Blekinge Hospital in Karlshamn is located just off the E22. The 50m high chimney was used for the boiler room for heating the hospital, but has been replaced by district heating. The chimney is close to other buildings, so demolition by blasting and high reach excavators were excluded. The chimney was built using the continuous concrete casting slipforming process with four internal brick lined channels. The bricks had been heavily polluted by soot and exhaust gases and classified as hazardous, requiring special care during demolition and disposal as landfill fees are 10 times higher than for non-hazardous materials.
A massive crane lifted down each section.
Customer: PEAB Chimney: 50 m high with four channels Material: Concrete with brick lined channels Age: 50 years
A Brokk BM110 used for walls and foundations of the bunker. saw used in the demolition is surprisingly quiet due to sound absorbing blades. The sawn sections are about 2-2.5 m high and weigh about of 5-9 t/section. The top section of chimney crown weighed 9 t, while the subsequent section, weighed 5 t. During the initial demolition a 180 t capacity Grove mobile crane with 70m boom, was used for lowering the sections.
Södra Cell pulp mill A few kilometres away there is another project carried out by Näsum Concrete Cutting at Södra Cell’s pulp mill in Mörrum. Näsum has demolition projects for Södra Cell in Mörrum and Värö in the province of Halland. Näsum had to demolish a bunker inside a factory building, which after would be converted to a flat floor for storage of tanks and similar. The concrete from the bunker was estimated to about 300 t and demolished with the help of an electric wall saw from Husqvarna and a Brokk demolition robot BM 110. The production at the mill could not be disturbed. Näsum cuts off the wall sections, which weigh about 3-4 t. They are lifted onto a trailer three floors down with the help of the factory overhead crane. The sections are then transported to a landfill. Mattias Karlsson, Näsum Concrete Cutting in front of the 50 m high boiler house chimney in Karlshamn.
PDi • Issue 5 • Dec 2011 - Jan 2012
Main focus: Concrete cutting and demolition Turnover 2010: 1.8 M EUR/2.4 M US$ Employees: 13 people CEO / owner: Matti Karlsson Founded in: 1994 Home www.nasumbetonghaltagning.se
Facts: The demolition at Blekinge Hospital in Karlshamn
Chosen for its method “We received the order from PEAB and expect 4-5 weeks to implement our part of the demolition project,” said Matti Karlsson from Näsum Concrete Cutting AB, which received the contract for the demolition of the chimney and disposal. “I understand we were not the lowest bid, but PEAB had confidence in our plan of works and safety. It is not always about price, but about the client’s overall cost for the various options offered,” says Matti Karlsson. After cleaning the bricks Näsum made horizontal cuts with an electric wall saw WS440 from Husqvarna Construction Products. “This wall saw is very easy to work with when you do not have to mess with hydraulics at high altitudes or other tricky places. We brought a new wall saw in reserve in case something unexpected should happen. Such redundancy is required on these kinds of projects where nothing can go wrong,” says Matti Karlsson. The unused saw is Husqvarna’s property until Näsum needs to use it. “We appreciate Husqvarna fine back up,” added Matti Karlsson. The water-cooled wall
Facts: Näsum Concrete Cutting
The rails are in place for the electric wall Husqvarna WAS control by radio. Sound-absorbing blade makes the sawing in a hospital district or other sensitive environments.
The crown of the chimney and the four chimney ducts. This part weighs about 9 tons.
S 440 HF. The operator Roland Itkonen controls the saw with a remote g silent. A clear benefit to staff working environment and when working
A good year 2010 was a good year for Näsum and 2011 seems to be ending the same. Matti Karlsson is preparing an expansion of the company to be able to have all the equipment in one place. When he started his own company in 1994 Matti Karlsson had 10 years of experience as a concrete cutter, but had also been an excavator operator for several years. He started with three employees and shareholders. Matti took over from his partner in 2010 and has since been sole owner. The company currently has 13 employees and each has a service vehicle with most of the equipment needed for site visits. Matti Karlsson likes to buy machines that facilitate the employees’ work. “When I get home after a tough day I do some carpentry for a while as it makes me really relax, “ he says.
The electric wall saw got stuck at one point when the weight of the entire wall section jammed the blade. Issue 5 • Dec 2011 - Jan 2012 •
ROBOTICS in Demolition Remotely controlled demolition robots are becoming increasingly popular in the demolition industry around the world to protect operators from hazardous working environments and to reach in narrow and confined spaces. Since the 1970s and until just a few years ago there was just one manufacturer of these machines. Today the number of manufacturers has started to increase slowly. PDi’s Mikael Karlsson takes a look at what is new with remotely controlled demolition robots.
Two new machines from Brokk The Swedish company Brokk, the early pioneering manufacturer of these machines, is launching two new robots, the new Brokk 100, the next generation of demolition machines in the compact below 1000 kg segment. With 35% more breaking power, increased versatility and an even more compact design, the Brokk 100 succeeds the Brokk 90. “Brokk 100 is a completely new machine that will enable our customers to take on even more challenging projects with increased profitability,” says Brokk AB CEO Martin Krupicka. The Brokk 100 features a new load-sensing hydraulic system with improved hydraulic capacity, providing for a 35% increase in power using the 150 kg SB152 breaker. It also features improved driving properties, a lower profile, advances in serviceability and additional improvements to cooling capacity. On site the Brokk 100 is first in the industry to deliver the flexibility of true 360° working performance in this size range, without compromising stability, productivity or reliability. When electric power supply is limited, the machine offers the option to gear down and work using only 16 A. Other new features include impact-resistant steel covers, improved rubber pads and LED lights. The Brokk 100 weighs 990 kg and is 780 mm wide and 1147 mm high The recommended maximum weight of attachments, such as breakers, crushers, shears and drills is 150 kg.
World’s largest Earlier in 2011 Brokk also announced the new Monster Brokk 800, which is the most powerful demolition robot ever, according to the manufacturer. It is, in fact, more than twice as big as the previous top model Brokk 400. It meets customers’ demands for longer reach and higher capacity, especially
within the tunnelling, mining and metal process industries. The Brokk 800 weighs 11 t and has a reach of approximately 10 m. It has more than twice the hitting power of the Brokk 400 and can also carry twice as heavy equipment, like buckets, beam-grapples and drilling equipment. It is a very compact machine for its power with the same capacity-to-size ratio as the rest of the Brokk machines. The Brokk 800 is available in two models as the Brokk 800 Standard and Brokk 800 Process, where the latter is especially designed for complicated demolition jobs in hot environments. The Brokk 800 Standard version features Brokk’s signature 3-arm system, exceptional reach, and delivers a phenomenal punch equipped with a MB1000 breaker. The Brokk 800 Process version features an arm with a specially designed breaker with 360? rotation, making it possible to work at a perfect angle, regardless of where the demolition power is needed. The breaker has a clever hit-bend-and-break function, enabling perfect control when cleaning out ladles and furnaces. It also has special heat protection for work in hot environment, advantageous for the process industry where short process downtime is essential.
Robot from Hong Kong The Hong Kong based construction equipment manufacturer HD Engineering offers a remotely controlled demolition robot for heavy-duty demolition, the HD50-RB that was first shown at Conexpo 2011. The HD50-RB robot is driven by a 37 kW electric motor. It weighs around 5 t and has a reach of approximately 8 m. The radio remote control is already set up for the drilling work, without the need for another control box for the drill. “Apart from the HD50-RB robot (37 kW), our company can build and has built other sizes of robot to customers’ needs, such as a 2 t, 15 kW robot,” says Lawrence Ng at the Below a Finmac F16 in operation in Paris.
Left picture: Brokk AB is introducing the all new Brokk 100, the next generation of demolition machines in the compact below 1000 kg segment.
PDi • Issue 5 • Dec 2011 - Jan 2012
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Below Finmac F16 from Finmac Demolition, today part of the Avant Group in Finland.
The large picture above: HD Engineering from Hong Kong offers a new remotely controlled demolition robot for heavy duty demolition, the HD50-RB, that was first shown at Conexpo 2011.
HD Engineering sales department. “And as a partner company with the Casagrande Group in Italy, our resources in product development and manufacturing have been increased dramatically, as well as international marketing channels for our products being greatly enhanced.”
Finmac and Avant Tecno merger The Finnish manufacturer of the remotely controlled demo-
lition robot F16, Finmac Demolition Oy, was acquired by the Finnish compact loader manufacturer Avant Tecno Oy in July 2011. Finmac founder, Paavo Salonen, is working with Avant Tecno to support the operation and says: “We are in the process to make some changes in the old machine, and an updated version will come out in early 2012.” Avant Tecno’s business unit director, Jukka Karjalainen, sees the demolition sector as a very interesting business arear
The new versatile remotely controlled robot, DXR 140, from Husqvarna with the concrete crusher DCR 100. More info on the crusher on page 56.
Issue 5 • Dec 2011 - Jan 2012 •
the operator to utilise up to 100% of the breaker’s force. The 11 kW motor can be run on a 16 A fuse. The demolition robot was developed with a focus on making the user’s work more efficient and simpler. Its compact design, with a width of only 770mm, makes the robot agile to manoeuvre and transport. The DXR 140 passes through most doorways and fits in a lift or onto a trailer. Its low-slung body gives a free view over the machine, making work both more efficient and safer.
A hybrid robot from Norway
The prototype RC 950 demolition robot in action. Yet a bit similar to the rumour about the Loch Ness monster. Several have heard about it but never seen it. The market is waiting anxiously for the official launch.
for the company in the future. “We consider this acquisition as an excellent way to expand our product offering due to the fact that we also have customers that are in the demolition business,” he says. “We are also consolidating the dealer network to see where we are going to sell the demolition robot through the former Finmac distributors and use our established Avant dealers, starting in Europe.”
Husqvarna DXR 140
Two pictures above with the HD Engineering robot.
The DXR 140 is the latest addition to Husqvarna’s range of remotely controlled demolition robots, which has been available for some time. This is the smallest and lightest member of the family. Despite its compact design, it is a powerful machine for demolition work in cramped spaces where the substrate requires a lightweight machine. The DXR 140 weighs only 967 kg and has an output of 11 kW. It is also available with a 15 kW motor that allows
PDi • Issue 5 • Dec 2011 - Jan 2012
Hansen Engineering A/S in Lillehammer, Norway, has developed a brand new remotely controlled demolition robot, the RC950, which has 360° rotation and a boom swing of 115° making it a versatile and productive demolition robot. The machine is built with a view to serviceability and has a body composed of steel and vacuum moulded carbon fibre. “This is the very first model on the market equipped with the unique hybrid engine system,” says Rune Hansen who has developed the new robot by himself. The hybrid system is based on the Kubota E-TVCS 10,2 kW diesel engine with low emission and noise and the 11 kW electric engine ABB G3AA 400V that is equipped with 24V soft start/stop. No mechanical operation is needed to change from electric to diesel. The Norwegian robot has integrated stabilizers in the dozer blade, hydraulic operated from the remote control to increase width from 700 to 1700mm. The digital and analog radio remote control unit has a reach of 300 m and special ergonomic design that allows easy use either in the carrier belt or when carried by hand. Unit weight is only 2.2 kg and has an operating time of 10 hours. “A prototype of the demolition robot has been in operation here in Norway since we built it in 2006. And it has worked superbly. We are currently looking for investors to go into full-scale production,” says Rune Hansen.
Rumours about a new demolition robot brand? What you have just read is about all the existing brands of remote controlled demolition robots besides that the Chinese manufacturer Giant Breaker. The manufacturer was though very reluctant to leave any information about their products when PDi contacted them. There is also a rumour spread in Sweden, Finland and Germany that a large global manufacturer has started to develop a remotely controlled demolition robot. This is just a rumour and PDi takes no responsibility what so ever for if it is true or not. This is just something we overheard and we prefer not to mention any names before we get the rumours confirmed.
New Aqua Cutter 710 V Classic to debut at World of Concrete 2012
Aquajet Systems AB, the Swedish specialist manufacturer of hydrodemolition technology, will be introducing the latest generation of Aqua Cutter 710 V Classic at World of Concrete 24-27 January 2012, in Las Vegas on booth S11455. The new model is ideal for working on bridges, tunnels, roads, walls, parking garages or ceilings. Working with a typically 1000 bar water pressure and flow of 250 l/min, the robot handles removal depths down to approximately 1000 mm of concrete if required. Aquajet has recognised that there is frequently a demand for its hydrodemolition systems with reduced computer control allowing manual handling with, for example, flow control valves for oscillating speed, roller speed, lance-angle speed and mechanical stops for operation widths and lance angles. Facilitating operator comfort and convenience new improvements have been made to the settings of programmes with several parameters easily selected and adjusted on the colour display with multilanguage operator instructions. Built to operate in tough conditions, the system has been designed with the operator in mind and is easy to operate.
WALL & WIRE SAWS I POWER PACKS I HAND HELD SAWS I DRILLING EQUIPMENT I SURFACE PREPARATION I ROADSAWS I DIAMOND TOOLS
Issue 5 â€˘ Dec 2011 - Jan 2012 â€˘
Two new crushers from Husqvarna Powerful and the widest jaw opening on the the user can do his job both easier and faster. market. The new crushers DCR 300 and DCR “This is a welcome addition to the demoli100 take Husqvarna Construction’s robots to tion machines. Our robots equipped with our even bigger heights when it comes to demolition own crushers is the most powerful solution machines. on the market,” says “ O u r p o w e r f u l Husqvarna’s new robotic Lars Gustafsson. Both crushers widen the uscrushers – the fastest the DCR 300 and the age range for our rocrushers in their class DCR 100 are typical bots,” says Husqvarna Husqvarna products with Construction Global Product Manager, Construca thought through, robust design and innovation Equipment Lars Gustafsson, Husqvarna’s tive solutions. Both crushers have an excellent demolition robots have, in a short period of power-to-weight ratio. The crushers can be time, become very popular in the construction equipped with crushing tips in the middle of industry. Now the company launches robotic the crusher, grinding the concrete even more crushers that further enhance the machines’ effectively. The metal cutters in the back of the usability. The crushers DCR 300 and DCR 100 jaw makes it possible to cut thicker rebars. The have a crushing force of a massive 45 and 34 crushers are easily serviced, for example, the tonnes, respectively. Husqvarna’s crushers are tips on the DCR 300 are detachable. The DCR also equipped with a deep and wide jaw opening 100 has two pre-sets for the jaws, thus giving and the capacity to get through walls of 430 or it an even wider range of use. 425 millimetres respectively. This means that www.husqvarna.com
Fact Husqvarna DCR 300 • Fits Husqvarna DXR 310 and Husqvarna DXR 250 • The most powerful crusher in its class • Crushing force: 45 tonnes • High power-to-weight ratio • Weight: 274 kg (incl. adapter plate and hoses) • Robust design • Depth: 195 mm • Maximum jaw opening: 430 mm
Fact Husqvarna DCR 100 • Fits Husqvarna DXR 140 • Weight: 192 kg (incl. adapter plate and hoses) • Crushing force: 34 ton • Capacity to cut through 400 millimetres walls • Two jaw opening settings: 320 and 425 millimetres. • Depth: 185 mm
PDi • Issue 5 • Dec 2011 - Jan 2012
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Atlas Copco’s new demolition cutter CC 950 Atlas Copco has introduced the new hydraulic demolition cutter CC 950 with a hydraulic rotation device. With an operating weight of 920 kg, the CC 950 fits onto carriers between 9 and 16 t. “There is much that changes in this excavator class,” says Silent Demolition Tools Product Line Manager Wolfgang Hohn. “We are seeing a clear trend towards increasingly more versatile carriers, which are ready equipped with couplers for a wide range of different attachments.” The hydraulic rotation device ensures continuous 360º rotation, thus allowing attachments to be placed in position quickly and easily and has 55 t crushing force. “The combination of low weight with optimum crushing force is important in terms of cost-effective usage. If I can use a smaller crusher and, consequently, a smaller
excavator for a specific task, then I save on investment and operating costs,” adds Wolfgang Hohn. This also applies to the wear part concept where the attachment cutting blades can be rotated, so replacing them on site is possible without much time and effort. The CC 950 can be used for light demolition work and joins the CC 650, launched at Bauma 2011 as an addition to Atlas Copco‘s Light Combi Cutter line.
Upgrade for Bobcat mini excavators
A new feature on the panel is a sound indicator, which produces a series of beeps to indicate the fuel level when refuelling. The shorter the intervals become, the nearer the fuel tank is to being full. Another new feature switches off the lights automatically when the machine has not been operated for 10 minutes, preventing the battery from going flat in the event of the operator forgetting to turn off the lights when leaving the machine. An additional feature allows the operator to push a button on the instrument panel to scroll through the data on ‘hours’, ‘rpm’ and ‘job’. An optional keyless ignition feature makes it
A new instrument panel is now standard on all new 2 to 5 t Bobcat mini-excavators and offers a variety of new features, including a selectable auxiliary hydraulic flow function. This function allows easy adjustment of the auxiliary flow according to the type of attachment being used, improving the control and productivity of the application. There are three pre-set modes for various types of attachments. The panel is also available in kit form for upgrading older models, except for the E26.
Technical details: Operating weight, kg Carrier weight class, t Oil flow rate , l/min Operating pressure, bar Clamping force, t Jaw opening, mm
CC 950 920 9-16 90-180 350 55 650
possible to secure the excavator without a key. This provides multiple operators, each of whom can have a unique code, with the ability to operate the excavator and acts as a useful deterrent to theft.
Complete package for mobile lighting The Wacker Neuson LBM 1 light balloon brings together all components for mobile lighting in one unit, thereby offering great flexibility on construction sites. The LBM 1 is easy to assemble and dismantle, extremely sturdy and robust in use and safe in application and quickly and simply provides necessary lighting. “What makes the LBM 1 light balloon stand out is that it is immediately ready for use at any time as all the necessary components are integrated in the system,” says Wacker Neuson
utilities product manager Robert Brauneis. “Thanks to the sturdy transport cart the light source, tripod and generator can quickly be moved by one person to the place on site where lighting is needed. This allows work to continue without restrictions even in the dark and in poor visibility.” The HQI lamp of the LBM 1 light balloon generates 99,000 lumens. At up to 3.70 m high, its tripod can provide light over large areas. The translucent textile cover diffuses the bright light and disperses it uniformly and without glare over
the surrounding area, preventing shadows and contrasts. “This is particularly important for use near busy roads,” adds Brauneis. The LBM 1 also provides particular flexibility through its integrated generator, which not provides the power supply for the lighting and an additional earthed “Schuko” socket (230 V, 16 A) for connecting additional equipment. If needed, the generator supplied (GV 2500A) can also be removed and either used separately or replaced with another generator. The LBM 1 is equipped with a frame and wheels, which also make it suitable for transport over uneven ground. As an alternative, the LBM 1 can
Jenny Products offers duplex compressors In the US Jenny Products, Inc. has completed its line of single and two-stage duplex compressors. Each unit is equipped with two pumps and two electric motors, which can be operated separately or at the same time. This allows the second pump to serve as a back up or complement the first pump in order to accommodate greater airflow needs. The duplex compressors are powered by industrial-duty electric motors and come with ASME-certified air tanks. also be moved using its solid jack ring. Three height-adjustable support legs give the system its stable base. These can compensate for sloping surfaces and also give the system excellent stability in windy conditions. The lighting unit is fastened to a tripod that is conveniently and safely extended and retracted with a crank.
Diesel engine improvement on Hinowa lifts Hinowa has introduced the new Hatz diesel single cylinder rpm control called Hinowa Diesel AutoRev. The current tracked aerial platform models, Goldlift 14.70, Goldlift 17.80, Lightlift 14.72 and Lightlift 19.65, can be fitted optionally with a Hatz single cylinder with manual rpm setting of 1600 and 3000 rpm. At the last Apex Show the new
HD AutoRev was shown with three rpm steps of 1800, 2200 and 3600 rpm. On the grounds of the selected movement by the operator, the engine regulates automatically the rpm rotation. Advantages of the HD AutoRev model include, more speed on movements, less consumption, noise and pollution and long life of the engine due to lower usage at maximum range. Issue 5 • Dec 2011 - Jan 2012 •
Back to The countdown for World of Concrete 2012 has begun. Although it will be a slightly smaller exhibition, due to the market conditions in the United States, a lot of new equipment is expected to be launched at the show.
World of Concrete has long been an important
Exhibitors in the field of demolition, concrete cutting, floor grinding, recycling, etc at World of Concrete 2012
benchmark particularly for concrete cutting, demolition and grinding and polishing of concrete floors. Although the show is primarily intended for the US market it is visited annually by a high proportion of international visitors. Few other trade shows can match WOC in terms of equipment for demolition, concrete sawing, drilling and concrete floor preparation and recycling.
However, WOC has been suffering because of the current economic situation in the US and throughout the world. The number of exhibitors and visitors has declined dramatically since 2009 when it had 1,800 exhibitors and around 65,000visitors. In 2011 there were about 47,000 visitors and around 1300 exhibitors. Prior to the show in January the number of exhibitors is expected to be about 1,160, and all of the key manufacturers will be present.
Emphasis on drilling As usual, many US, European and Asian manufacturers of demolition equipment, diamond tools, equipment for sawing and drilling, floor grinding,
Bosch Power Tools & Accessories O30204 Diamond Pauber SRL S11751 Brokk Inc O30018 Diamond Productions Canada, Ltd. S11252 Carhartt Workwear At Rugged Outfitters S12614 Diamond Products O32002 Case Construction Equipment C5771 Diamond Products O32150 Caterpillar Inc C5371 Diamond Products C4889 CDC Larue S10349 Diamond Speed Products, Inc. S13007 CDC Larue O31654 Diamond Tec, Inc. S12607 Chicago Pneumatic C4349 Diamond Tools Technology, LLC C5921 Comet Breaker C6597 Diamond Vantage C4663 Concrete Polishing Association of America S12355 DITEQ Corporation C5191 Concrete Polishing Technologies O31327 Dixie Diamond Mfg Inc C5483 Concrete Products N246 Doosan Infracore Construction Concrete Raising of America S12523 Equipment America C5594 Concrete Reinforcing Steel Inst N2937 Dust Control Technology S10801 Concrete Sawing & Drilling Association C4457 Dustless Technologies S12700 Concut Diamond Products O31568 Dynamic Diamond Tooling S12323 Conjet AB S10501 Eagle Industries S11820 Contec North America S12747 EDCO & Contrx Systems S10115 Astec Inc. N727 CS Unitec Inc O30652 EDCO & Contrx Systems O31418 Blaklader LLC S13239 Diamond Blade Depot S11855 Ermator LLC S10215 Blast It All Mfg Inc C6555 Diamond Blade Depot S12512 Everdigm Corp C6659 BlastPro Manufacturing, Inc. S11527 Diamond Blade Warehouse/Diamond E-Z Drill Inc C5355 Blastrac Diamatic S10123 Chain International S10727 FLOORChef S12011 Bobcat Co C5389 Diamond Chain International O31002 Genesis Attachments C4229
This is the line of exhibitors booked for World of Concrete 2012 when PDi went to press i December, 2011.
PDi â€˘ Issue 5 â€˘ Dec 2011 - Jan 2012
o Vegas polishing, recycling and dust extraction will exhibit. There will be a number of new tools and equipment for concrete sawing and drilling as well as concrete floor grinding and related equipment. There will also be several new brands of diamond tools with the diamonds positioned in the segment. For several years now, WOC has been a Mecca for equipment for grinding and polishing of concrete floors. There are strong rumours from several manufacturers in this segment is that a lot of new products will be on display.
Jubilee Travel to Las Vegas The US Concrete Sawing and Drilling Association will be represented at their home fair again. In 2012
the association is celebrating its 40th anniversary and will start at WOC. The Swedish Concrete Sawing and Drilling Association, HiB, is celebrating its 25th anniversary next year with a trip to the WOC. PDi will again be covering the show and will also have its own booth in the Central Hall, number C6391. A full report of the exhibition will be published in the PDi 1-2012. www.worldofconcrete.com
Short Facts About World of Concrete 2012 Where: When: Öppettider:
Las Vegas Convention Center, Las Vegas, Nevada, USA Tuesday 24 - Friday 27 January, 2012 9.30-17.00 Tuesday to Thursday 9.30 - 13.00 Friday
Monday 23 January 3-hours seminars: 8.00-11.00, 13.00-16.00 90-minute seminars: 8.30-10.00, 10.30-12.00 13.30-15.00, 15.30-17.00 Tuesday 24 January - Thursday 25 January 3-hours seminars: 8.00-11.00, 13.00-16.00 90-minute seminars: 8.30-10.00, 10.30-12.00 13.30-15.00, 15.30-17.00 Friday 27 January 3-hours seminars: 90-minute seminars:
Organiser: Hanley Wood www.worldofconcrete.com
General Equipment Co S10715 SASE Company Inc. S10515 Jetstream of Houston LLP S10913 Glacier Diamond, Inc O31562 SPE - USA S11750 Jiangsu Huachang Tools Manufacturing S12829 Golz, LLC O31746 Jiangyin Likn Superabrasive Co., Ltd. SSAB C6927 S12529 Hammelmann Corp S13014 Stihl Inc C4645 John Deere Construction & Forestry C5970 Hanson Diamond Tools (Danyang) Co., LTD. S12931 SUNGSIM CO., LTD O31056 John Deere Power Systems N2427 Hilti Inc O30900a Justcut Inc S11339 S12211 Superabrasive, Inc. Hilti Inc O30808 K2 Diamond Superabrasive, Inc. O31229 O31005 Hilti Inc O30900 Klindex SRL Sysdyne Corp. N951 O30648 Terrco, Inc. O30422 HTC Professional Floor Systems S11227 Multiquip Inc O31840 Texas Demolition Products Inc S12156 HTC Professional Floor Systems O30936 Multiquip Inc O31846 Tru-Cut Inc. N1249 Hilti Inc O30808a Multiquip Inc C4813 Tuf-Tite, Inc N657 Huskie Tools Inc. N3115 National Surface Preparation Equipment S10955 US Saws S11007 Husqvarna Construction Products O30370b New Holland Construction C4877 US Shotblast Parts & Service Corp S10453 Husqvarna Construction Products O30370 Nilfisk-Advance, Inc O31235 Volvo Construction Equipment NA Inc C6170 Husqvarna Construction Products O30370c Norton Construction Products C4841 VTN Rotobec C6316 Husqvarna Construction Products O30370a PDi Magazine C6391 Wacker Neuson Corporation O31708 Husqvarna Construction Products C4313 Pearl Abrasive Co. S12339 World Diamond Source Inc S12725 ICS Concrete Chain Saws O31102 Pentruder Inc. O32132 Wyco Tool Co - The C5627 ICSSAWS.COM N1321 Pullman-Holt S12606 Xingyi (China) Polishing Machine Co., Ltd S13030 IHI/Compact Excavator Sales LLC O31520 Putzmeister America, Inc. C5636 Xtreme Engineered Floor Systems, Inc. S11453 International Concrete Repair Inst S11139 RB Abrasives O31752 Zoomlion America C5223 International Grooving & Ready Jet N248 Grinding Assn (IGGA) C4237 Ritchie Bros Auctioneers C4245 Jet Inc N2756 SANY Heavy Industry Co., Ltd. C6148
Issue 5 • Dec 2011 - Jan 2012 •
Indian contractor buys second Rockster Recycler
The Indian construction company M/S Popular Construction bought its first Austrian Rockster R900 Impact crusher with Duplex system in November 2010 and ordered a second Rockster crusher at the exhibition BC India in Mumbai. Rockster Austria has a direct presence in India with their subsidiary Rockster Recycler India PVT. Ltd. in Bangalore. M/S Popular Construction is a division of Popular Infra Resources and says that Rockster offers the only mobile crusher in the world having the Duplex system, which allows the company to switch over from Impact to Jaw crusher or vice versa in less than three hours in site conditions. Since November 2010 they have worked with the Rockster R900 with Duplex system. The hydrostatic drive allows clockwise as well as left-handed rotation of the crusher and the impact and jaw can be exchanged on the same base frame. This guarantiees a quick and efficient adaptation to individual material requirements. “Additional to the experienced service experts in India, the experts from Austria are also available on call at short notice to support our operation as well when required,” says M/S Popular Construction director Mr. Mayur. “Therefore we have the technician of Rockster Austria here together with his local engineers to guide and train our staff on the new machine. We have found the right partner for our crushing and screening equipment for a long term business relationship, as we are highly satisfied with the service and after sales offered by Rockster and the high quality and performances of the machines”.
Sandvik crusher helps Offerton development Offerton Sand & Gravel in the UK has been recycling soils and aggregates since 1986. Based at their 63 acre quarry in Stockport, Cheshire, the company supplies high quality materials to the construction industry throughout the UK. To assist with recycling Offerton has bought a QJ241 tracked jaw crusher from Sandvik Mining and Construction. All recycling activities are fully authorised by the Environment Agency. The current waste management licence covers the treatment up to 150,000 t/year. Offerton’s commitment to maximising the re-use of recycled construction materials, whilst minimising their own negative environmental impact, led the company to invest in the Sandvik QJ241 tracked jaw crusher. This compact crusher is based on the design of the world leading series of Sandvik machines. Highly productive, yet self-propelled, this machine brings the revolutionary features of the Sandvik QJ341 to the smaller quarry or demolition site, where operating space is limited, yet high performance demanded.
veyor has a hydraulic raise and lower facility to give increased clearance for rebar, and has also been extended to give an increased discharge height enabling enhanced stockpiling capacity. Thanks to new design features such as a jaw level sensor, speed wheel on the main conveyor, together with an improved load control system,
CEO of Rockster Recycler India PVT. Ltd., Niyogi Subhash together with the customer Mr. Mayur and the supervisor from Rockster Austria, after the successful start up of the R900.
Arrival of the first R900 with Duplex system, screenbox and return belt, easily done in one transport.
The return belt can also be used as stock pile belt.
The QJ241 is powered by a Stage 3B CAT 7.1 Acert engine that complies with all current and proposed emission standards reducing operational emissions by 45%. It also has improved fuel economy, ensuring a low cost of ownership and reduced carbon footprint. “We wanted a modern jaw crusher to work throughout our site. It has to be designed to increase production, reduce our operating costs, and produce a consistent product from virtually any material it encounters. There is no doubt that the QJ241 matches our aims,” says Offerton representative Martin Ridgway.” The QJ241 possesses many new features that have been developed specifically for the recycling industry, and based on feedback from customers. The QJ241 is proving ideal for Offerton’s recycling requirements as the main con-
PDi • Issue 5 • Dec 2011 - Jan 2012
the machine is able to monitor and regulate material feed. This provides continuous uninterrupted crushing, resulting in higher productivity. Furthermore, the unit is now a much more user-friendly, easier to operate machine due to its advanced PLC electrical control system, and is easier to maintain due to increased access to service points. Through the use of the QJ241 and the existing processing facilities, Offerton is now able to produce and supply such products as recycled MOT, 6F2/6F1 crushed aggregates, coarse granular fill and pipe bedding. Offerton has developed a material merchandising arm, The Stockport Stone Company, which acts as a premier supplier of recycled construction materials throughout the northwest. This retail merchandising has enabled them to become an
established supplier, not only to the construction industry, but also to the landscaping trade. They are now able to supply materials such as York stone paving, granite sets, cobbles, sandstone sets, natural walling stone, block pavers and many other items reclaimed from the quarry.
Flex-Mat® Vibrating Wire Technology Celebrates 15th Anniversary In Canada Major Wire Industries is celebrating the 15th anniversary of Flex-Mat® independently vibrating wire technology, now in its third generation with Flex-Mat 3 Tensioned and Modular versions. Flex-Mat technology is made of crimped wires assembled sideby-side and held together by lime-green polyurethane strips. Each wire vibrates independently, increasing material screening action and material throughput, virtually eliminating blinding, pegging and clogging and reducing downtime spent cleaning or replacing screen media.
Metso’s new Lokotrack LT120 jaw plant Metso’s new Lokotrack LT120, with its world premiere at the Steinexpo exhibition in Germany, combines crushing performance and user friendly design in a new, revolutionary way. For the first time, the same Lokotrack model is now available in a hydraulically or electrically driven version. The Lokotrack LT120 uses the same fieldproven technology seen in Metso’s tracked units for over 26 years. Every detail of the new jaw plant has been designed for reliability and long life. The main targets have been energy efficiency, good performance, reliability and product safety. Field tests have demonstrated its good fuel economy and high crushing capacity. The Lokotrack LT120 is also available as an electrically driven unit, the Lokotrack LT120E, which can take energy from an external power supply or a 420-kV onboard diesel generator. Having the possibility to use an external power supply enables a highly economical and ecological crushing process. The Lokotrack LT120 is built around the new C120 jaw crusher. The Lokotrack LT120 is designed to be safe to operate, move and service. “A safe operating environment is created by
practical solutions. When service points can be reached easily, the possibility of dangerous situations diminishes,” says Product Manager Timo Nakari. “Good examples of safety built in to the Lokotrack LT120 include sturdy, easy-to-open composite flywheel guards and hydraulically folding and locking feed hopper sides.” The Lokotrack LT120 can be fine-tuned to suit customers’ applications by selecting the required options, from a long main conveyor and hammer and boom to a water spraying system
and rubber lining for the feeder and hopper. The Lokotrack LT120 features a Caterpillar C13 310 kW engine and is 16 m long, 3 m wide and 3.9
m high and weighs 57 tons. The LT120E version weighs 63 t.
Lokotrack LT120 combines user-friendly design and good crushing performance in a new way.
Lokotrack LT120 is the latest and most advanced of Metso’s track-mounted jaw crusher plants. Issue 5 • Dec 2011 - Jan 2012 •
Market Success For CRS Kinetic Flow Screen
Blue Group is experiencing success with the CRS KF 44-18 Kinetic Flow Screen. The flip flow technology of the KF 44-18 allows waste management and recycling specialists to extract even greater volumes of recyclable fines material from waste streams, after primary screening, for blending or further separation as single size saleable material. This also reduces tip-to-landfill volumes. Blue Group has delivered numerous units to recycling companies in the past few months, especially the recently introduced mobile version. Kinetic Flow technology is specifically targeted at the waste recycling industries. It is versatile and spans many sectors and materials, including fine screening in gypsum, compost, coal, soil, ballast and woodchip screening, separating fines material of 0-70mm size and most difficult sticky materials. Based on the kinetic flow principle, the patented design produces a unique and aggressive pitch, throw and action, which results in clean fines material, no matter how wet or sticky. Screening area is 1.80m X 4.4m and the self-cleaning polyure-
thane screen elements are easily replaced. The crawler mounted model provides site mobility for moving the unit to the material. Maximising recovery of useable material, the CRS KF 44-18 Kinetic Flow Screen has a range of applications, including fine mixed construction and demolition waste, mixed organic waste, damp and sticky materials, such as powders, soils and sand; shredded mulch or organic materials.
Ramtec launches new Robi Multi Master Screening Bucket The Finnish company Ramtec is complementing the Robi Multi Master product line with the new MM062 screening bucket. MM062 is designed for 10 to 16 t excavators. Bucket volume is 0.6 m 3 and with the operating weight of 1250kg it is a robust bucket for its size. Robustness enables the bucket to screen great variety of materials from recyclable
waste to topsoil. Two screening axels are driven by two efficient hydraulic motors. Direct gear drive makes the bucket reliable and highly productive. Drive without the traditional chains makes it almost maintenance free and improves also the fuel economy of the carrier machine.
Metso’s SmartTag - next generation and beyond SmartTag™ is a Radio Frequency Identification (RFID) based technology designed to allow tracking of ore from its source through blasting, run of mine pads, crushers, intermediate stockpiles and finally into the concentrator. A SmartTag™ RFID tag travels through a mine and mineral processing plant in a series of simple steps. Initially, the tag and insertion location is logged using a hand held computer, and then it is inserted into the ore, for example a blast hole. The tag travels with the
ore through digging, transport and processing, before being detected at detection locations, such as conveyor belts, when the time and specific tag is recorded. The RFID tag data is then loaded into a database and analysed as required.
Top innovations for diamond tools – drill longer, cut faster! Arranged for performance
High-strength, high-tech +43 (0) 662 424248-0 · www.eurodima.com At the bauma in Munich: hall A1.405/500
PDi • Issue 5 • Dec 2011 - Jan 2012
Silent Demolition Tools: powerful, fast and cost-efficient
Silent demolition tools cover the whole process from breaking and crushing to downsizing, sorting and loading. These powerful low-noise, low-vibration attachments turn mechanized demolition into a fast, cost-efficient and precision process. Atlas Copco Construction Tools www.silent-demolition.com
Rellok zooms in on micro-trenching tailor-made machines Last year, Celle-based Rellok made its presence known in the floor sawing segment by marketing an impressive four-piece line of machinery. From that moment on, the company has been busy promoting the Rellok brand worldwide and expanding its product offering. In the below interview, Reno Schroeder, the marketing manager at Rellok, talks about the latest products and shares his outlook on the floor sawing business.
PDi. Rellok came on to the market well prepared. However, little is known about the company’s background. So, where did Rellok come from? R.S. This know-how was brought into the company by people who had many years of experience in the drilling and sawing industry. It’s no longer a secret that the constructors and technicians came from Koller. The company has developed and constructed floor saws and bump cutters for over 25 years for another large Celle-based company in the same sector. Most of our sales and marketing people come from there. The only thing that’s really new is the RELLOK company itself. PDi. What are the personalities behind the company? R.S. Via several levels of corporate hierarchy, RELLOK is a subsidiary of MB Holding Company LLC. Having its headquarters in Oman, this group is a global player with over 6,500 employees and over a billion USD annual turnover. MB is mainly operative in the oilfield service sector. RELLOK’s direct parent company in Germany is MB Petroleum Deutschland GmbH with its headquarters in Salzwedel/Germany. PDi. Rellok appears to be a very niche company, specializing strictly in floor and road sawing equipment. Is this a correct Reno Schroeder. impression or Rellok’s interests, in fact, extend beyond this niche? R.S. Yes and no. There’s no doubt that it’s the market for mid-range and fully-hydraulic floor saws and surface grinding machines for bump cutting and grooving with which we mainly identify ourselves. This is where our core competence lies. It’s here that we possess the know-how to react swiftly and flexibly to customer demand to offer solutions for specialist applications. However, we now also have various products in our range which are at home in other business sectors. This ranges right down to the diamond saw blade for dry cutting. But you’re right to suggest that we don’t offer the same depth and width of product range as some competitors do. PDi. Floor saws are Rellok’s core product. What are the latest technical and marketing trends you are seeing in this sector? R.S. In our opinion, micro-trenching will be a dominant topic over the next few years. We’re already present with 2 solutions in the market. Both are based on the fully-hydraulic floor saws. A variant which has the standard, side-mounted cutting shaft which can be discharged relatively quickly from the standard machine, and a very special machine in which the saw blade motor is mounted in a box frame behind the machine. As well as these application-driven innovations, there are also those which are legally required. The ever-stricter European exhaust gas norms are an example of this. I think
PDi • Issue 5 • Dec 2011 - Jan 2012
that purely standardized solutions are ever-more difficult to sell, not least due to the technological progress in the Far East. Today, customers demand very special solutions which are aimed precisely at the specific current application. And for this we are very well prepared. PDi. How big was the demand for the floor sawing equipment in the last couple of years and what markets drove it? R.S. Looking back over the last few years, 2007 was the year in which there was the highest demand for floor saws. If my memory serves me well, this level of demand was hard to keep up with for suppliers at the time. This dreamlike state ended abruptly in 2008. In my opinion, it is pointless to gaze back into the past. From our point of view, and according to VDMA statistics, 2011 has been a very bad year for floor saws. The sales figures just announced for the big machines are disastrous. This fact is down, in a large part, to the fear of crisis. New acquisitions have been postponed or even cancelled. RELLOK has fared rather well, in comparison. If the politicians could create a climate which provided a feeling of future security for enterprise, demand would also rise. There are enough building sites around. PDi. Did you take on any new personnel since 2010? R.S. Yes, of course. The number of employees has practically tripled since the company was founded in 2010. This growth in numbers has been spread through all of our departments, and at present, RELLOK has 28 employees. PDi. The ghost of a new economic meltdown is haunting Europe. How will the situation be developing, in your opinion? R.S. This question can only be answered subjectively. The long-term media bombardment with political and economic tales of woe hardly permits an objective viewpoint. I think that the crisis-afflicted EU states should continue on their rigid austerity course. The attempt to boost the economy by printing fresh money is an unsustainable method. The effect of this will evaporate quickly. This is, of course, only my opinion. I’m not an economist or an expert in finance. PDi. Does Rellok have any “survival strategy”, if the worst comes to worst? R.S. If the worst case scenario actually comes to pass, i.e., the breakdown of the international currency and economic systems, I would be very surprised if anybody has an efficient strategy to hand. Because our main outlets currently lie within the EURO Zone, we hope very much that our communal currency remains stable. However, I do not currently think that we will have to deal with the worst case. PDi. Since Rellok’s arrival on the market, the manufacturer has introduced a number of new products. Could you tell us a few words about them?
R.S. Since 2010, various products have arrived on our palette. Both mid-range floor saws, the RSF 330 and 420 are particularly worth mentioning as cured or green concrete machines, as well as the micro-trenching machines. But aside from the floor saw technology, a lot has been happening. There’s probably not enough time to tell you about everything. I recommend that every prospective customer check our website regularly, and read PDi, of course. PDi. What are the bestselling items in Rellok’s catalogue? R.S. In spite of the moderate market situation in the area of mid-range and large floor saws, we have achieved our highest single turnovers with them. Overall, however, diamond cutting discs for professional applications are our best-seller. PDi. Last year PDi wrote about Rellok’s partnership with Dr. Schulze. Is Dr. Schulze still acting as a Rellok agent in Eastern Europe, Asia and Africa? And how big is Rellok’s network of dealers and distributors at the moment? R.S. Our distribution partnership with Dr. Schulze is not a short-term agreement, and of course, it still exists. In the German customer care department we have meanwhile a rather efficient distribution team. In Sweden we have an exclusive partner in RELLOK Diamond Tools Sweden AB. We work in France and Switzerland with our own branch; RELLOK France SARL, with its headquarters in Bordeaux. As well as this, there are many countries in which retailers sell our products without exclusivity. We are, of course, always in search of distributors or agents. PDi. The BRIC countries are often seen as the biggest drivers of the global economic growth in the future. In your estimation, how big is their potential? And how important are those markets for Rellok? R.S. Approximately 43% of the world population lives in the BRIC states. Ambitious industrial nations with impressive growth rates are now driving the world economy. For RELLOK, the situation currently presents itself in such a way that
Russia, India and China are covered by Dr. Schulze. Brazil is, of course, dominated in the area of construction machines by North American suppliers. We’re keeping the BRIC markets under observation but proactive action is not currently being planned. There is enough potential in more easily accessible markets to be worked on. PDi. What are the company’s plans for the immediate future? Any new products in the pipeline? R.S. First of all we will seek to establish our existing program at a deeper level in the market. In focus is also the job of raising the profile of the RELLOK brand. With regard to new products, I can only say that in Celle, a whole team of designers are constantly working on new, market relevant solutions. PDi readers will be the first to benefit from the latest information as it arrives.
Issue 5 • Dec 2011 - Jan 2012 •
Faced with uncer tool makers bet o As economic uncertainty deepens amidst the ongoing European crisis, businesses go into the waiting mode by the score. This partly explains why players in the diamond tooling industry have busied themselves this year with selling the existing solutions, rather than developing new products. Still, PDi has some interesting news to report.
New plants In 2011, two major players – the Korean Widecut and German Dr. Schulze - have announced the expansion of their production facilities. Launched in August, Widecut’s new plant has the capacity three times as much as the old factory. The manufacturer says that the increased capacity and fully automated assembling lines have allowed it to reduce production costs and, consequently, prices for diamond wires, which remain Widecut’s core product. Dr. Schulze has recently commissioned a new plant in the Eastern Germany that houses all necessary equipment for development and production of all types of diamond tooling under one roof. According to Alexey Levin, the facility has its own metallographic laboratory to control the quality of raw material and develop new tool specifications, a few presses for cold and hot sintering, an automated laser welding system and a testing ground. It is at this plant that Dr. Schulze has developed and is now testing its new line of patterned tooling. The patterned range is expected to hit the market in early 2012.
Following the pattern Undoubtedly, pattern technologies remain all the rage in the diamond tooling business. Tyrolit, for instance, focuses on the promotion of its PREMIUM*** core bits for wet drilling equipped with TGD®-technology. According to the manufacturer, the new line is outstanding in terms of versatility. Two types - CDL*** and CDM*** - cover the range of drilling tasks from 47 to 1,000 mm. This leads to a reduction in storage and transportation costs. Although the new core bits are compatible with most of the existing drill motors, a system solution, optimized for TYROLIT Hydrostress machines, is also available from the manufacturer. ‘Silent’ wall saw blades equipped with TGD®-technology are another focal point for Tyrolit. The level of noise emitted by these blades is measured at just 10 db which makes them a perfect solution for jobs in noise-sensitive areas like airports and hospitals. The reduction in noise levels is achieved by using sandwiched steel cores in blades. TYROLIT has combined this feature with the TGD® patterned technology to create a tool for the most demanding cutting applications. The Belgian Carbodiam has developed a ‘silent’ version of the popular Alligator VX saw blades. It consists of two steel sheets with a copper foil in between. As a result, noise level is cut to 8 to 11 dB. Celle-based Rellok which is mostly known for its microtrenching and floor sawing equipment also has the pattern technology of its own. Rellok offers patterned blades for powerful 15 kW wall saws under the brand name of WSCC5. The
PDi • ISSUE 5 • DEC 2011 - JAN 2012
blade is available in the silent modification as well.
Trimex adds the third dimension UK-based Diaquip has devised a technology which is said to have taken the idea of patterned tools to a new level. The process called Trimex allows production of tools with diamonds arrayed in alternating lines to maximize the concentration of diamonds on the cutting surface. The manufacturer feels that offering tools with standard patterns is not longer enough to meet the everincreasing requirements for speed and efficiency. Diaquip believes that Trimex adds a third dimension to the existing arrayed technologies. The Trimex? concept has been applied to a large range of products, including segments for core drills, floor saw blades, wall saw Blades and hand saw blades. Standard diamond position is being replaced by the specific diamond positioning of the Trimex Third Dimension.
“Cobalt-free philosophy” and “green tools” Reducing impact on the environment and operators’ health remains an ongoing concern for the industry. Last year, Heger introduced a new HECO drill line which is completely cobalt-free. The application range covers all construction materials from regular concretes to heavily reinforced concrete with hard aggregates to abrasive masonry and asphalt. The HECO cobalt-free philosophy extends to Heger’s professional dry cutting range as well. The metal bonds for the Heger VIP and PRO ranges are fully devoid of cobalt. In early 2012, Heger will launch a new series of Titan Xflow wall saw blades that combine the proven Titan maX technology with the patented dot structure of the segments. Short segments and reduction in side friction account for a very good speed, whereas the segment height of 14mm provides the required life performance. Carbodiam, too, has prioritized manufacturing of ‘environmentallyfriendly’ diamond tools. In line with the commitment to reducing environmental impact, Carbodiam had its range of sawing, drilling and polishing tools certified by the European Diamond University (EDU). Following the inspection, the Carbodiam tools were recognized as “green” because of reduced levels of noise, dust and water consumption.
rtainty Diamond on performance PCD cup wheels this autumn. The manufacturer started out with 125 mm diameter but promises to top up its range with more specifications. Being laser-welded, Kern-Deudiam’s cup wheels are heat-resistant and recommended for use with 5” angle grinders.
Bits and pieces
Grinding news The Russian Adel continues its research into grinding and polishing tools with positioned diamond particles. Having already mastered production of all types of polishing and grinding tooling, the manufacturer is now looking to increase the efficiency of its products by making consumables with patterned diamond positions. Also, the company keeps adding new specifications to its product offering; the latest additions are the WF 400 C for concretes, the BF M-H for heavily-reinforced concretes, the SG 800 C for hard natural stones, the SR 800 C for dense ceramics and the SC 800 C for monocrystals. Ashine Diamond from China has announced the launch of a new line of tools for grinding hard concrete surfaces. Such grinding tasks are usually very challenging but Ashine says its ‘golden-bond’ tools are able to grind 15 square meters, whereas competitors’ can only do 4. And this is accomplished without compromising the speed of the process. Kern-Deudiam entered the grinding business with laser-welded
The specialist wire manufacturer Widecut keeps extending its line of electroplated wires. The latest addition to the range - the HT9 - is a versatile tool for wet or dry sawing of heavily reinforced concrete and straight steel. The HT9 is complete with 9.5mm beads and 4.8mm inner cable. Usually, a thinner wire requires a thinner inner cable, but the HT9 has been specifically designed that way for more efficient cutting. Kern-Deudiam has recently purchased a drill bit welding machine BSM 300 from Dr. Fritsch to manufacture 8 to 300 mm laserwelded core bits. Dr. Schulze unveiled a new generation of diamond blades for diesel floor saws (up to 150 hp) ‘Asphalt Ultimate’ that combine high cutting speed with long service life. EDT Eurodima is said to be working on a new type of segment but no specifics were provided at this stage yet.
ISSUE 5 • DEC 2011 - JAN 2012 •
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Basement Egress Window Systems If your concrete cutting business is in an area where residential basements are predominant, then you have an excellent opportunity to capitalize on a sawing application involving egress window system installations.
Shim the window from both the interior and exterior sides until it is level, square and flush with the exterior side of the basement wall.
By Kevin Warnecke and Tom Stowell
Egress simply means a direct method of leaving a building. An egress window code is a legal requirement, intended to ensure a person can escape a building through a window in an emergency. Most codes also require egress windows to be large enough for a fully outfitted fire fighter to enter. In general, the egress window code requires installation of an egress window to any habitable space in a basement area. If there are individual bedrooms added to a basement dwelling, then a separate egress window is required for each one. Most communities in the US and Canada have based building codes on the International Residential Codes (IRC) created by the International Code Council, a membership organization that promotes building safety and fire prevention. These codes were developed with input from organization members and the construction industry. A typical basement egress window system consists of an egress style window, a window well and a window well cover. The installation requires an enlargement of an existing window or the addition of a new window. This can be accomplished by sawing into the existing basement block or concrete wall. The windows must have a minimum net clear opening of 20 inches wide, 24 inches high and have a minimum net clear opening of 5.7 square feet. They must be installed so that the sill height to the finished interior floor measures no greater than 44 inches to meet the IRC-2006 code requirement. The preparation for the installation of an egress window system is similar to the preparation of any concrete sawing job. Suitable tools for the creation of an egress window opening include a wall saw, diamond chain saw, circular hand saw or ring saw.
The excess drain tile should be left above the ground to be trimmed later.
Adherences to local code authority and manufacturer’s installation guidelines are absolutely necessary for a watertight and approved installation.
A wood frame is required on a block concrete wall installation. On a poured concrete wall, a wood frame may or may not be used depending on preference.
There are two types of installation; framed and nonframed. Framed installations can be used for both block and poured concrete walls. Non-framed installations can only be used for poured concrete walls.
A helper should be positioned inside the basement to assist with window placement.
Kevin Warnecke is the director of heavy user sales North America for ICS, Blount, based in Portland, Oregon. He currently sits on the CSDA Board of Directors and plays an active role in the association’s committees and training programs. Kevin can be reached kwarnecke@ icsbestway.com. Tom Stowell is a CSDA Past President and retired vice president of sales and marketing with Norton Pro Diamond. He can be reached at thomas. email@example.com. Issue 5 • Dec 2011 - Jan 2012 •
Sima Diamant Sima Diamant, the newest company in the Sima group, is told to boasts the most modern and technologically advanced diamond blade factory in Europe. Located on the Los Llanos industrial estate in Seville, Spain, the factory occupies a surface area of 3,500 m2 and has a team of 14 employees to supervise all production processes.
Antonio García Aguilera, president and founder.
At the head of the Seville factory is Antonio García Aguilera, president and founder of the group, which has celebrated its 40th anniversary. In this interview, he outlines the objectives of the new company and the medium and long-term strategies of the group. He cites innovation as a basic tool for achieving good results.
How did Sima Diamant come about? What was behind the decision to open this new line of business? The idea to create Sima Diamant began to take shape in 2006 and the factory was set up between 2006 and 2008 and 2009 saw the consolidation of the production process. The quality is excellent and the clients are extremely satisfied. Competing in international markets has been a Sima objective from the outset. In those markets, the large cutting machine manufacturers produce their own blades and spread their sales on a 50-50 basis over machines and consumable products. Our aim is to achieve those percentages within a three year timescale. How did your clients react to this initiative? Very positively. It means that we can offer an integrated solution of machine and blade for complex jobs, whilst demonstrating that a machine cannot operate effectively without a suitable blade. We are European manufactures, we manufacture to European quality standards and we are completely familiar with the needs of the Spanish and European markets. If you need to cut difficult material, contact us and we will manufacture the most suitable blade for the task. What differentiates Sima Diamant from the competition? Basically it’s cutting quality and performance. Sima Diamant aims to position itself at the quality end of the market, which represents the future. The deluge of lowquality imported blades is a thing of the past. Nobody wants problems and complaints from clients and we certainly do not. We manufacture blades for demanding markets that satisfy client needs. In addition, we provide the best service and this is what sets us apart.
PDi • Issue 5 • Dec 2011 - Jan 2012
How do you view the recent adjustment in the sector and how do you expect it to evolve? It has been devastating, creating an unsustainable situation for companies, many of which have been forced to close. Almost all these companies have shared a common denominator: they did not export or exported a very small percentage of their production. The first step is to adapt production to current sales, not to become disheartened and to avail of every possible opportunity. Sima has managed to take on board very rapidly the changes arising from the crisis. In the current business climate, what expectations does the company have in the short, medium and long term? Within the current context, we have to differentiate between the world crisis and the domestic crisis. For instance, China is growing at a rate of 11% and the German economy is now growing too. In any case, in broad terms, the short-term strategy is to consolidate and avail of any opportunities that arise in countries where we already have a presence. With respect to the medium term, we now export on a regular and sustainable basis to 43 countries and we aim to consolidate our position in these countries and continue the process of internationalising our company. Internationalisation is no longer merely an option. It is absolutely vital. But internationalisation is not merely selling there. It is having a presence there. This is why we are currently setting up a subsidiary in a European country and next year, we will open another in a South American country for the purpose of marketing our entire product range, including machines, abrasives, diamond core bits and diamond blades. Finally, our long-term objectives include continuously adding to our catalogue of manufactured products and consolidating the internationalisation of the company in more countries. We aim to do this by entering into agreements with other manufacturers or by buying small companies to enable us to position ourselves rapidly in these markets. Sima has shown itself to be an innovative company from the outset. Apart from this, what are the other factors that make the company a strong player? It is true that Sima is an innovative company and that much of its success is based on this. Innovation is having a desire to change throughout all the departments in a company. Innovation is the driving force behind change. If you want to obtain different results, you have to do things differently. We constantly apply innovative thinking, not only for the design of new products but also
for the enhancement of existing ones in terms of design and quality, and the use of new raw materials. Essentially, this is what differentiates us from the competition. We also innovate at a commercial level, with the creation of the product manager figure. The product manager is responsible for positioning the product in the optimum location between the client and the factory. We have also innovated by creating a special division to increase market share in core bits, diamond blades and abrasives. Furthermore, we are pioneers in B2B. All the changes we make are customer-oriented and have helped us to achieve an extraordinary improvement in our results this year. Last year you celebrated the Sima group’s 40th anniversary. How do you feel when you look back over this period? I feel satisfaction because in this period we have diversified and now we are a group made up of a number of independently managed companies including Sima, S.A., Sub.Pyltin, S.L., Inversiones Ejabe, S.L. and DiamanStone, S.L. Forty years is a lifetime and I think of it in the same way as when I look back on my time doing the military service, in the sense that I only remember the good people I have met, the good friends I have made and the good times I have had...between the periods of guard duty. I do not remember the bad moments. But for the time being, I want to continue looking ahead, with even greater motivation, if that is possible. Finally, with your wide experience of this business, what advice would you give to those wishing to enter it? To have dreams and be extremely motivated, to be well qualified and surround oneself with a good team and to work, work, work.
GLOBRAM Steelshear makeover New lighting Euroram-Rockmaster, manufacturer of high quality demolition and crushing attachments and based in the Netherlands, completed its GLOBRAM product range nine years ago with a wide range of steel shears. The worldwide success of these
shears was based on the perfect match the shears made with all carriers from 10 to 100 tons operating weight. Since that time new developments have changed the properties of carriers to such an extent, that Euroram-Rockmaster decided to modify the GLOBRAM steel shear range, in order to match the improved power and productivity levels. After a two-year development period, the first shear of the new 9/5-serie, the GLOBRAM RM 924/5R, was introduced last year. As a result of extra reinforcement of the body, the new model weights about 3 tons, making it 250 kg heavier than the previous model, the RM 924R. Combined with special bending techniques and some design changes, this has made the frame more rigid, enabling an increased jaw opening from 560 to 625 mm, and an increased cutting force from 646 to 715 ton. Throughout 2011, all new models have been introduced in the market, including a small 680 kg shear designed to fit carriers from 3 to 8 ton weight. The complete GLOBRAM steel shear range now includes 8 models, with jaw openings from 290 up to 1050 mm, and a cutting force of up to 1535 ton for the top of the range, the GLOBRAM RM 968/5R.
equipment from Tower Light
In Italy Milan based TowerLight Srl has introduced their very latest development in environmentally sound lighting, the VB9-LED. This is a 9m vertical mast lighting tower fitted with energy saving LED lamps replacing traditional metal halide lights. LED lamps are made from robust polycarbonate, with no glass or bulbs to replace and have a 5 year manufacturer’s warranty, with a high resistance to breakage and explosion. An added benefit of using LED lamps is that unlike metal halide, LED lights will restart whilst hot.
Der Partner für Profis Partner voor professionals The partner for professionals Le partenaire des professionnels Issue 5 • Dec 2011 - Jan 2012 •
Dr. Fritsch MasterTec series
Dr. Fritsch Master Tec series is known on the markets since 2007. The manufacturer is extending the series by now launching MasterTec-3. MasterTec-3 is also a fine, prealloyed material with high sintering activity. It is also an iron based alloy, but different from MasterTec-1 and MasterTec-2, this new version is combined with copper and nickel. Since 2007 Dr. Fritsch has supplied iron based prealloyed materials named MasterTec to its customers in the diamond tool industry. While the first customers were mainly attracted to having an alternative to cobalt powder with favourable and stable prices the view of tool designers today goes much deeper. Fine and homogenously alloyed powders, like MasterTec, having a very low sintering temperature, stand alone as universal base materials for the diamond segment production.
A hydrometallurgical process MasterTec is manufactured by the hydrometallurgical process. These powders have a very fine grit size and a very high sintering activity. Until early 2011 there were four MasterTec variants on the market differing in chemical composition and apparent density. As a result, these MasterTec variants also show considerable differences in wear performance. While MasterTec-1 has a higher hardness and slightly lower impact strength, the MasterTec-2 is a bit softer and more ductile. Consequently, MasterTec-1 does in most applications lead to higher tool life. Free cutting performance of both base powders is rather similar. Since their market entry in 2007 MasterTec-1 and MasterTec-2 are used for more and more applications. A mix of MasterTec-2 and 20 – 30 % bronze powder 90/10 for example, is often used for wall saws, for non-abrasive granite and for drilling reinforced concrete. Pure MasterTec-1 instead is often applied for medium-powered joint cutters and for granite cutting disc with diameters above 800 mm. For smaller granite blades the MasterTec-1 is again blended with bronze powder 90/10. Meanwhile a lot of producers also used MasterTec-1 as base powder for wire saw beads to cut granite. Both MasterTec qualities are perfect base powders to be mixed with other elements, such as bronze, iron, copper, cobalt, to adapt MasterTec for tool specific requirements. At the beginning the same mixing ability was also taken for granted in case of tungsten or tungsten carbide powders. Comprehensive field tests have, however, shown that, when adding tungsten or tungsten carbide to
PDi • Issue 5 • Dec 2011 - Jan 2012
genic, the mixtures made from MasterTec-3 and tungsten carbide are also from this point an interesting alternative.
Free sintering of MasterTec powder
MasterTec-1 and/or MasterTec-2, the measured hardness increases, but not the wear performance. In a few cases even the opposite happened, where the tool life dropped. It could be observed that the effect increases the higher the content of tungsten or tungsten carbide. Examinations and research have revealed that under certain conditions a brittle phase can arise between iron and tungsten/tungsten carbide. This brittle phase forms itself at the contact surface between the two different elements. Under stress this phase can easily break so that the tungsten/tungsten carbide containing grit breaks out of the bond. As a result the tungsten/tungsten carbide is no longer available to fulfil its job and the intended and expected effect to increase tool life is not reached. On top of that the pores created by the loss of the tungsten/ tungsten carbide particles additionally reduce the wear performance and thus even decrease tool life further. In case of high tungsten/tungsten carbide contents the tool life can therefore be considerably lower than the value achieved when using pure MasterTec without any addition.
All MasterTec powders show a very high sintering activity, which can be seen from the very low hot pressing temperature. This low temperature was the reason to examine the sintering ability in a furnace without applying external pressure. Lots of tests were made with different temperatures, dwell times and cold pressing pressures to examine the free sintering behaviour of MasterTec-1 and MasterTec.2. The result taken from these tests is that both powders need a free sintering temperature of approximately 1000 °C and a dwell time of minimum 30 minutes. Under these conditions a closed porosity is achieved when applying a specific minimum compaction pressure of 1,5 t/cm2. The diagrams below show that MasterTec-2 is more sinter active compared to MasterTec-1. This can be taken from the higher density achieved after sintering. The hardness values achieved of approximately 90 – 93 HRB seem to be rather low at the first look, but they are normal in this context. Similar values are also typical when free sintering cobalt. Next are the micrographs of MasterTec-1 and MasterTec-2. The sintering condition is given underneath each. Both show the structure in an x1000 magnification. In that high magnification there are no apparent pores, but a second phase can be seen. This second phase is iron oxide, which is included in the powder resulting from the production process. Also in micrographs of hot pressed segments these inclusions can be found. When processing the cold pressed segment in an atmosphere with higher
Gap’s closed This gap is now closed with MasterTec-3 Dr. Fritsch is introducing. MasterTec-3 is also a fine, prealloyed material with high sintering activity. It is also an iron based alloy, but different from MasterTec-1 and MasterTec-2, this new version is combined with copper and nickel. In MasterTec-3 the copper overtakes the task to saturate the iron, so that it can no longer absorb any tungsten. The formation of a brittle phase is, therefore, no longer possible. The sintering behaviour of MasterTec-3 is next to identical to that of MasterTec-1 and MasterTec-2. However, sintering already starts at a considerably lower temperature of 660 °C. Its hardness is similar to the hardness of MasterTec-2 and also density is at the same level. The material is even a bit more ductile again in comparison to MasterTec-2. Looking to tool life MasterTec-3 reaches the same value as MasterTec-2 based on the standard sawing test done by Dr. Fritsch. Free cutting is at the same level as MasterTec-1 and MasterTec-2. When mixing MasterTec-3 with tungsten or tungsten carbide the earlier described effect does no longer occur. Comparison of wear performance values of MasterTec-3 + 20 % WC and a cobalt sub-micron + 20 % WC have shown same tool life. Taking into consideration, that combinations of Diagram 3: Effect of specific pressure on hardness and cobalt and tungsten carbide are said to be carcinodensity (T=1000 °C, t = 30 minutes, N2/H2 95/5).
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hydrogen content, these inclusions can be removed. These iron oxide inclusions have a lower density. Since they are, however, part of the powders, they reduce the theoretical density of MasterTec. This is proven by the low density achieved and the fact that no pores were found in the micrographs. The densities achieved with the samples shown in the pictures are: MasterTec-1 = 91,9 % and MasterTec-2 = 96,6 %. In case of MasterTec-1, 8 % pores should be discovered, in case of MasterTec-2 is should still be 3.5 %. However, these pores are not found in the micrographs. To increase hardness MasterTec can be blended with copper. Adding 40 % fine copper powder to MasterTec-1 hardness increases from 93 HRB to 100 HRB. Also density increases in our test from 94.5 to 97.9 % under same sintering conditions. Looking at the wear performance the values as shown
real game changer. Quieter, lighter weight and less vibration. That makes us more productive and more profi table.
– George Cramer, President, Bedrock Concrete Cutting Inc.
We understand what contractors like George Cramer go through every day. So every day, we push ourselves to perfect our tools and technology to make a rough, dirty job a little easier and you even more effective.
See how we’re changing the game at icsbestway.com email firstname.lastname@example.org, or visit a dealer near you. ICS | Blount Inc.
in table 2 are achieved. The lower the removed quantity the higher the wear performance. The results show that the higher hardness of the MasterTec-1 mixture does not lead to a higher wear resistance. The higher tool life, despite lower hardness and
icsbestway.com ©2011 ICS | Blount Inc. All rights reserved. 695F4 pictured. 0211
density, is achieved with pure MasterTec-1. The wear resistance of MasterTec-1 + copper is at the same level as other materials specifically developed for free sintering. The Dr. Fritsch team is working on the next alloy, MasterTec-4, a product, which will be free of cobalt and nickel.
Diagram 4: Effect of holding time on hardness and density (T = 1000 °C, spec. pressure = 2 t/cm², N2/H2 95/5). Issue 3 • July - Aug 2011 •
ACT saving important heritage structures in Chennai
Mohan Ramanathan, President of Advanced Construction Technologies Ltd. in India shares an interesting story about a demolition project and saving heritage structures in Chennai.
In Chennai, India a new Metro Rail project is envisaged by the Government of India. This is the largest public project in Tamilnadu with an investment of Rs 14,600 Crores (US$ 3.20 Billion).
Silent demolition at massive metro project Phase 1 of this project envisages about 44Km of underground and over surface high-speed rail network. Of this about 24 km will be underground. There will be a total of 32 stations in the two corridors planned in phase 1. The main hub of this entire project will be at the Central Station, which is one of the busiest places in Chennai. A huge underground station is being planned here with multilevel platforms and inter mode transport system for metro, bus and railways. This will probably be the toughest station to build, as arterial roads intersect here with continuous traffic. It will be a challenge to keep the traffic flowing during the deep excavation for the station. ACT had already introduced the concept of using silent demolition methods using hydraulic crushers to Chennai Metro
PDi • Issue 5 • Dec 2011 - Jan 2012
Rail Limited (CMRL ) in the demolition of old police quarters for Mannady Station in Chennai earlier in June 2011. This method is new to Chennai and CMRL was convinced in using this method of an excavator based hydraulic crusher for the rest of the project. “The reason why this type of equipment was used is that concrete crushers are silent demolition tools. No vibration and very low noise is produced during the demolition process. This is, according to me, the only method used in all develop countries for urban demolition for primary demolition works within city limits,” says Mohan Ramanathan. “Hydraulic concrete crushers are mechanical tools engaged for silent demolition works. Powerful jaws are used to crush concrete, brick and structural steel. Hydraulic concrete crushers are specified worldwide by leading Institutions and city authorities for urban and industrial demolition owing to its low noise, no vibration, economic and faster execution. Cities like Hong Kong and London use only hydraulic concrete crushers for demolitions. Hydraulic crushers are also perfect for demolition of industrial structures.”
posed to use the hydraulic crusher for the entire demolition of the Hotel Picnic. CMRL approved this method of demolition. Two Volvo machines, one EC 240 BLC fitted with a Doosan hydraulic crusher and another EC 460BLC, UHR fitted with a 26m Kocurek triple boom and a MBI hydraulic crusher CR26R started the demolition work. This is the first time in Chennai, a high reach demolition machine of 26m reach is being used. Dust is controlled by a built-in water spray system in the high reach machine. With the introduction of such safe demolition technologies, ACT believes that the Heritage structures can be saved for posterity and modern buildings can be built in place of old and dilapidated ones. Ripon Building
Ripon Building is the seat of the Chennai Corporation (Madras Corporation) in Chennai (Madras), Tamil Nadu. This is a fine example of Indo-Saracenic style of architecture, a combination of three types of architectural styles - Gothic, Ionic and Corinthian. The Ripon Building is white and is located near the Central station in Chennai. Commissioned in 1913, it was built by Loganatha Mudaliar. The Building took four years to build at a cost of 750,000 Rupees. Ripon building was named after Lord Ripon, Governor General of British India and the Father of local self-government. Earl of Minto, the then Viceroy and Governor General of India laid the foundation on 12 December, 1909. The Municipal Corporation of Madras, after functioning from several other places, settled at Ripon building in 1913, with P.L. Moore as the President of the Municipal Corporation at the time of the inauguration.
Demolition in a sensitive area Now in the Central station area of CMRL, there is an existing multi storey structure called Hotel Picnic, which is a reinforced concrete framed structure 30m high. This structure is sandwiched between the two famous landmark Heritage structures, The Rippon Building, the seat of Chennai Corporation and The Victoria Hall. Hotel Picnic is very close and between both these Heritage structures and hardly 10m clearance is available on either side of these Indo-Saracenic buildings. Organisations like INTACH, who protect Heritage structures all over India, are quite concerned about this demolition since both these structures are more than 100 years old and made of masonry in lime mortar and any vibrations from the demolition will definitely be harmful to these structures. A f t e r c a re f u l study of the structures, ACT had pro-
Victoria Public Hall
The building is located on EVR Periyar Salai near Moore Market and between Ripon Building and Chennai Central Railway Station. Constructed with red brick and painted with lime mortar, the building has an Italianate tower capped by a Travancore-style roof. The two large halls in the ground and the first floors were built to accommodate 600 people, while a wooden gallery in the eastern end has seating arrangements for more than 200 people. The structure consists of arcaded verandas, a square tower that is three storeys high, and a carved pyramid roof. There is also an intricately carved terracotta cornice, which resembles Islamic calligraphy, atop the tower. The hall has four staircases, of which three lead to the hall on the first floor and one to the balcony, and four turrets. The Trevelyan Fountain, a memorial fountain in the grounds of the hall, was raised to mark the contribution of Charles Trevelyan, Governor of Madras during 1859-1860 and the developer of the People’s Park, towards providing the city with adequate drinking water. On one side of the fountain is a basrelief of Trevelyan’s head.
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THE ULTIMATE MOV Mobile Recycling:
In the last episode of this year’s series of ‘Movers & Shakers’, we are featuring Kleemann GmbH: the trendsetter in mobile recycling and a member of the international Wirtgen Group since 2006. A busy and eventful 2011 draws to a close, and PDi magazine wishes everybody a Merry Xmas and a Happy New Year!
Mobile recycling is the ultimate realization of the concept of “moving and shaking”. Moving, crushing and shaking a rock or construction material is exactly what mobile recycling plants are designed to do. And Kleemann GmbH, as the supplier with worldwide capabilities and a track record that dates back to the 19th century, is the perfect example of an international Mover & Shaker.
From a file cutting shop to a recycling giant Now a major force in material recycling, Kleemann did not, in fact, originate as a manufacturer of recycling equipment. Back in 1857 when Ferdinand Kleemann established his firm, recycling, as we know it, was yet to be invented. What Herr Kleemann started was a file cutting shop that manufactured agricultural implements. Significantly, his shop became the first industrial enterprise in the area of Obertürkheim, Stuttgart. By the turn of the century, Kleemann’s range expanded to include circular saws, eccentrics and spindle presses. It was with these products that Kleemann achieved widespread recognition in Germany. However, soon after the new age dawned, the company decided to diversify into rock and stone processing under the name of Kleemann´s Vereinigte Fabriken. The move proved even MR 130 ZS EVO processing asphalt in Australia.
more successful, and in the 50s Kleemann made stone and rock processing its core business. It was also around that time that Kleemann went onto the international level and has remained an export-oriented player ever since. In the second half of the century, the German manufacturer became a driving force in the development of track-mounted crushing and screening plants for mining and construction applications.
Joining the Wirtgen Group In 2006, Kleemann became part of the Wirtgen Group. The merger went smoothly as both companies shared the same values of prompt and reliable customer service. Gaining access to the Group’s worldwide network of 55 sales & service offices allowed Kleemann to further step up its international presence. Three years later, the manufacturer transferred its production to a new state-of-the-art plant in Göppingen. In 2010, Kleemann launched the new impact crushers MOBIREX MR 110 ZS EVO and MR 130 ZS EVO built around an innovative material flow concept.
EVO concept: a new standard in recycling Described in a nutshell, the EVO concept ensures that there is no restriction to the flow of the material; with the possibility of an obstruction eliminated, the performance of the entire plant increases, while reducing the wear of its parts. This is achieved by using the combination of proven Kleemann components and the newly-developed solutions which include the active double-deck pre-screen, the vibrating discharge chute, the innovative inlet geometry and a new rotor ledges technology. The fully automatic hydraulic gap-setting system of the crushing jaw (still unique in the market) substantially improves the quality of the final product. It also serves to enhance, along with an effective overload protection system, the technical availability of the machine.
Global customer satisfaction The customer feedback that Kleemann is now getting from all corners of the world proves the new concept’s
Kleemann Mobirex MR 110 Z EVO recycling rubble in China.
worth. Here are just a few examples of its efficiency and reliability. In Xuchang, China, a MR 110 Z EVO plant is processing demolition debris. The feed material with an average size of 0 - 900 mm (1,000 mm, in some cases) is crushed to a size of 0 - 32 mm. The resulting rubble can be used either as a subgrade filler in road construction or for manufacture of various products like cement and bricks. Performance tests showed feed capacities of as much as 350 tons per hour. According to David Zhao of Wirtgen China, the customer had tried different suppliers but only the Kleemann plant was able to fulfil its demands for reliability and performance. Another Kleemann unit - MR 130 ZS EVO - is being employed on a complex recycling job in Sydney, Australia. The job’s main challenge is diversity of the materials being processed: asphalt, bricks, tiles, concrete and demolition debris. With initial size of up to 700 mm, the material gets reduced to 0 - 40 mm and then used for road construction, gabions or decorative applications. The machine is said to have been chosen for its high average performance of over 300 tons per hour, robust design and the features like the active pre-screen and diesel-electric drive system with direct crusher drive. The EVO plants are equally efficient in stone processing. A MR 110 Z EVO is now recycling up to 3,000 tonnes of bauxite in an 8-hour shift on a project in France. Michael Schwarz, Area Sales Manager with Kleemann GmbH, reports that the customer is particularly impressed by the machine’s hourly capacity and its low diesel consumption. The above examples are a brief illustration of the EVO technology’s capabilities but, of course, its application range is not limited to them. Kleemann’s growing portfolio of the EVO case studies can be found on the company’s website.
PDi • Issue 5 • Dec 2011 - Jan 2012
VING AND SHAKING
Issue 5 • Dec 2011 - Jan 2012 •
Bosch’s Freu In 2009, Bosch Group incorporated Freud, the Udine-based manufacturer of circular saw blades, router bits and cutter heads, into its vast structure. Both parties seem happy with this marriage of mutual convenience, which they speak of as ‘a perfect match’. PDi’s Andrei Bushmarin was given a tour of Bosch’s Italian facilities.
Bosch Group is a worldwide corporation, has a 125year history and a household name in many parts of the world. Bosch’s diverse interests fall under three general categories of automotive technology, industrial technology and building technology and consumer goods. It is Bosch’s position in the latest category that the Group aimed at strengthening by taking over Freud.
Accessories matter Bosch products are known and used by professional
PDi • Issue 5 • Dec 2011 - Jan 2012
builders, DIY enthusiasts and households all over the world. However, the acquisition of Freud, the manufacturer of tools for both professional and DIY applications, allowed Bosch to become the world’s top supplier of circular saw blades and router bits. With this task accomplished, the Group is now looking to break into the top three in industrial cutting tools, another area of Freud’s expertise. All three products of circular saw blades, router bits and industrial cutting tools, belong to a market segment defined as accessories. Having incorporated Freud, the Group increased the number of manufacturing units in the accessories sector to 11. Most of these plants are located in Europe, with the two distribution centres in Slovenia and the US taking care of product packaging, customization and distribution. In 2010, the global market for circular blades, router bits and industrial cutting tools was estimated at some EUR 1.3 billion. Freud is planning to become the Group-wide research and development centre for these products. Freud is a combination of the Italian words ‘frese’ and ‘Udinese’ meaning, ‘cutting tools from Udine’. It was there that three brothers started their manufactur-
ing business more than 50 years ago. Today, Freud has over 600 employees and operates four manufacturing sites, all based in the province of Udine. Each of the plants specializes in one particular type of product. Carbide powder is made at Martignacco, cutter heads at Feletto, which also serves as Freud’s headquarters, router bits at Colloredo and circular saw blades at Fagagna. It is the circular blades that have remained Freud’s flagship product over the years. The Fagagna plant produces an extensive range of them at a fast rate as every five seconds a new blade comes off its production lines. In 2010, the plant’s annual output reached 4.5 million blades. The lion’s share of Fagagna’s production goes to North America, where the Diablo brand has been popular for decades. Unique tooth geometry devised by Freud engineers is one of the features that single out a Freud circular blade from competitors. The others include advanced coating technology and polyurethane filed anti-vibration slots. Freud produces everything in-house from carbide powder to cutting teeth to blade coating and packaging. Such a comprehensive approach to manufacturing allows Freud to exert tight controls over product
Photo: Maija-Liisa Saksa of Puu&Tekniikka magazine. Front row from the left: Debora Costa, Assistent to general manager Eugenio Perrella, information manager Lisa Lüthi, export manager Christian Leschiutta and general manager Eugenio Perrella. Second row from the left plant manager for Tungsten Carbide production Martignacco Stefano Driussi, marketing manager Jörg Seidel, plant manager for the circle saw blade production Steffen Schneider and vice president for spare part Peter Heekenjann.
udian Dream quality at every stage of production. The result of this manufacturing policy is circular saw blades whose high quality and performances are equally appreciated by professionals and DIY amateurs.
Perfect match The Bosch and Freud partnership looks like a win-win situation for both. With one side having something
to offer the other what it lacks, this cooperation is anticipated will generate a powerful synergy in years to come. Bosch Group, one of the industry’s best recognized names, is more than happy to provide Freud with the marketing opportunities, which have previously been out of the company’s reach. That includes access to Bosch’s worldwide distribution network. Freud, on its part, brings its impregnable reputation, as a niche
manufacturer of tools and accessories, half-a-century’s experience in the industry and first class research and development capabilities. The integration is further helped by the fact that Bosch and Freud are said to share the same corporate values. When everything clicks between the two, they are justified in calling it a perfect match.
Issue 5 • Dec 2011 - Jan 2012 •
The Story of
During the autumn the British manufacturer JCB opened its own museum, which tells the story of JCB from the early 1800s until today. The museum, which is housed at the JCB headquarters in Uttoxeter, measures 2500 m2 and will be permanent. It is estimated that at least 20,000 people will visit the museum annually.
JCB has a unique story to tell, especially by being a large, global privately owned manufacturer of products that are still largely owned and controlled by the founding family.
From the smithy to multinational JCB stands for Joseph Cyril Bamford. He founded the company’s current business in 1945 but the family’s
JCB headquarter in Uttoxeter, England. First JCB frontloader. ©JCB.
manufacturing genes goes back to the 1820s. The business began as a blacksmith and at that time tools and machines were produced mainly for the agricultural industry. Over time, the company took the name Henry Bamford & Sons and was also at that time located in Uttoxeter in the middle of England. For decades the company grew and they began to produce machines that were widely used in the growing era of industrialization in England. But the year 1945 changed Joseph Cyril Bamford’s focus on the business or, more correctly broke away from family tradition and started his own business. Post-war England was in a need of everything. In the beginning JCB was to remain in the agricultural machinery sector, but would soon start producing machines for the construction industry. This unique manufacturing tradition in JCB resulted in the establishment of a unique, permanent exhibition on the premises at the head office in Uttoxeter. The exhibition opened in October.
Proud of the Board In connection with the inauguration of the new exhibition JCB Chairman Sir Anthony Bamford said that the new Picture from the permanent exhibition. exhibition would be important to further promote and Visitors will also learn that Henry Cyril Bamford allows, clarify JCB’s value on the world market especially in new through a letter, his nephew, Joseph Cyril Bamford know growth markets. The exhibition is an investment of about ‘that his services are no longer needed at the company.’ It £5.5M. “This is a fantastic company and for the first time is this event that will mark the start of the JCB founded in the history of our company and my family’s roots in in 1945. manufacturing are narrated in the form of a permanent JCB has managed to get the most out of the exhibition,” said Sir Anthony exhibition. Visitors can see Joseph Cyril Bamford’s Bamford. “We are an innovative old office from the 1970s. The exhibition also concompany and our success over the tains detailed presentation of 10 different product past 66 years has been driven by models launched by JCB over the years, such as our innovation and that is what is JCB’s hydraulic tipping trailer, backhoe loaders the essence of the new exhibition. from 1962 and a model of the JCB JS200 tracked Our unique history and our abilexcavator. You can also see where and how the JCB ity to be innovative is something brand has been built and where the products are that we can be proud of. “ manufactured and sold. The exhibition is divided into fourteen different zones that Market leader take the visitor through time, Backhoe loaders are synonymous with JCB and from 1820 until today. It presents the first model was launched in 1953. Since in detail the various inventions that have made JCB known. Joseph Cyril Bamford. ©JCB. then, new models succeeded each other. Then came the wheeled excavators, wheel loaders and crawler excavators. JCB was early with telescopic handlers and the first model came 1981. In recent years JCB has launched a wide range of compact equipment with mini excavators, dumpers, skidsteers and more. The company is market leader in backhoe loaders and telescopic handlers. They also still have comprehensive manufacturing of machinery for agriculture and defence. It is the third largest manufacturer in its sector in terms of number of machines and the fifth largest in terms of turnover. JCB has 18 manufacturing facilities around the world, including China, Germany, Brazil, USA and India. In India it has been operating since 1979. It also has a large number of sales offices around the world. The turnover amounted in 2010 to nearly £2.8 Billion and the company produced 51,600 machines. Compared to 2009 they made a strong increase from 36,000 machines. The company employ 8,000 employees on four continents, it has operations.
PDi • Issue 5 • Dec 2011 - Jan 2012
f JCB Latest model of a JCB front loader.
At the JCB workshop during the 1940s with Sir Anthony Bamford as a child in his mothers arms. ©JCB.
JCB chairman Sir Anthony Bamford and son to the founder Joseph Cyril Bamford. @JCB.
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Impressive attendance at German demolition summit
With approximately 500 delegates and 50 exhibitors in 2011, the Demolition and Dismantling conference has been well established as Europeâ€™s largest event relating to demolition. The next conference will be the 18th and will be held, as usual in Berlin, Germany on 16-17 March 2012. It is open to anyone who is interested in the topic or who wants to expand their personal expertise for professional reasons. With approximately 20 lectures and presentations, the conference will offer a broad topic range, showing latest findings and technical developments. In addition to numerous reports about extraordinary demolition projects and technologies, the programme will this time focus on the dismantling of nuclear facilities, hazardous materials on demolition sites, recycling and environmental aspects, as well as the qualification of employees. The accompanying exhibition is a valuable addition to the professional programme, such as the excursions to demolition
sites in Berlin on the second day of the event. The Come-togetherevening on Friday will, as always, provide participants the ideal ambiance to strengthen existing contacts and build new ones within a relaxed atmosphere. The conference programme and registration forms will be released in January 2012. The documents can then be
PDi â€˘ Issue 5 â€˘ Dec 2011 - Jan 2012
downloaded from the website www.deutscher-abbruchverband. de. Likewise, the documents can also be obtained at the office of the German Demolition Association.
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