CONCRETE CUTTER Journal of The Drilling and Sawing Association
UNDERWATER WIRE SAWING AT TYNE TUNNEL Cover story page 6 DIAMOND HELPS TO BRIDGE THE GAP A RECORD FLOOR SHOW CUTTING UP A STORM Vol 6 路 Issue 2路2011 WWW.DRILLANDSAW.ORG.UK
Why Specify a DSA Member?
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2VBMJUZ Quality lies at the heart of the DSAâ€™s philosophy and members exercise the highest standards of business practice and workmanship at all times. DSA membership is not automatic, and applicants are subject to strict vetting procedures. Not only are members vetted on application, they are continually monitored to meet the high standards demanded. Vetting comprises of a detailed documentary and financial review. On being accepted, members agree to abide by the Code of Practice and conditions of membership.
&OWJSPONFOUBM$PNNJUNFOU Sustainability and environmental impact are major considerations when specifying, manufacturing and installing products in the workplace. DSA requires its members to confirm their commitment to protecting the environment, and is proactive in providing information and guidance on how best to achieve this. Its supplier members in particular are leading the way in seeking techniques and developing systems that provide high environmental and social value. 4VQQPSU DSA members operate with the benefit of vast resources of business and technical information and support from the Association. DSA is keenly involved with industry standards, training and health and safety, to promote a safe working practice and information sheets on topics relevant to our sector. The National Specialist Contractors Council assists in this support with a variety of advice helplines. The Website supports by providing information such as members directory, current affairs and access to documents and links to these. %SJMMJOHBOE4BXJOH"TTPDJBUJPO Unit 3, Brand Street, Nottingham NG2 3GW, United Kingdom Tel: +44 (0) 115 986 7029 Fax: +44 (0) 115 985 0341
CHAIRMAN’S CASE HISTORIES MESSAGE
ain contractors may often ask why should they use drilling and sawing companies who are members of the DSA? The question I always put back to them is why should they use drilling and sawing companies who are not members of the DSA. The DSA was established in 1984 with the objectives of improving standards within the industry by establishing better codes of safe working practice, education and training. One example of this is our official Code of Safe Working Practice, which lays down guidelines for safe operation. This document provides a basis for safe working by the members who supply professional diamond cutting and controlled demolition services to clients in construction. We have also developed, in conjunction with the CITB, a Certification Scheme for accrediting existing experienced operatives. Furthermore, we also joined with ConstructionSkills to provide a national vocational qualification in drilling and sawing, and with the CITB to create an Apprenticeship Training Programme in drilling and sawing. This scheme has now been in operation for over six years and is currently responsible for training over 150 apprentices in a wide range of skills. This means that all member companies have operatives who have not just CSCS cards but specific DSA Certificates of Competence based on specialist knowledge and the highest standards. By employing a DSA member company, therefore, contractors and consultants can rest assured that the firm subscribes to accepted safety standards, codes of practice and carries adequate insurance cover. Additional member benefi ts include support in terms of HSE policies, risk assessments/ method statements, working tolerances, marketing, insurance and many more. In summary, therefore, the DSA represents all that’s good about the industry. WOULD YOU USE A COMPANY WHO COULD NOT DEMONSTRATE THE APPROPRIATE STANDARDS AND TRAINING? Should you wish to receive more information or a list of DSA members in your area then please do not hesitate to contact us at www.drillandsaw.org.uk
Graham Fawcett DSA Chairman
CONCRETE CUTTER 2·2011 | 1
ASSOCIATION SERVICE Lectures on Drilling & Sawing If you are an architect, consulting engineer, contractor or public utility that requires more information on the benefi ts of specialist diamond cutting and allied techniques, we can organise a talk at your premises. The DSA can provide an informative session that may be of interest to both your staff and to clients. This presentation covers the following topics: Illustrations of the various cutting techniques and their applications The advantages of drilling and sawing techniques compared to more traditional methods The DSA Members commitment to a professional… The importance of trained, competent operators with skills cards Variety of case studies undertaken by DSA members Contact Joel Vinsant for further information on 0844 879 3452 or email email@example.com
The DSA Board Joel Vinsant (Secretary) Peter White (President) Graham Fawcett (Chairman) Anita Dervey Colin Walker Dave Swanwick Finlay Crocker Jerry Hare Jim Weaver Julie White Mike Hetherington Paul Bancroft Shayne Major
D-Drill (Master Drillers) Ltd Diacutt Concrete Drilling Services Precision Drilling 2000 Ltd John F Hunt Demolition Ltd East Midlands Diamond Drilling Ltd Core Cut Ltd J Hare Diamond Drilling Ltd ICS Blount D-Drill (Master Drillers) Ltd Tyrolit UK Ltd Access Drilling Services Ltd Major Diamond Supplies
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CONCRETE CUTTER Journal of The Drilling and Sawing Association Vol 6 · Issue 2·2011
CASE HISTORIES CONCRETE CUTTER Published by The Drilling and Sawing Association Managing Editor Martin Jennings Lamda Publicity Limited, Odeon House, 146 College Road, Harrow, Middlesex, HA1 1BH, UK. firstname.lastname@example.org
Underwater diamond wire sawing cuts new Tyne tunnel openings Diamond helps to bridge the gap A record floor show Cutting corners saves time and money Diamond provides the right angle Diamond cutting deep Cutting up a storm
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Design and Production Robin Giddings email@example.com
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Thank you to all advertisers and contributors of information. We welcome editorial contributions and encourage advertisements, but acceptance is at the discretion of the Committee of the Association. If you require REPRINTS of any article, please contact the DSA Office. Magazines, newspapers and private individuals are welcome to reproduce articles, in whole or in part, provided that acknowledgement is made to Concrete Cutter, no addition or other alteration is made to the text or illustrations of any article, and no reproduction is made where the copyright © symbol appears. Opinions and views expressed in the Journal are not necessarily those of the Association or the Editor, who shall be under no liability in connection with any article published herein. Official Journal of The Drilling and Sawing Association. Visit our website at www.drillandsaw.org.uk or email email@example.com
INTERNATIONAL NEWS Annual General Meeting of the IACDS Diamond Award winners announced
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CONCRETE CUTTER 2·2011 | 3
JOEL VINSANT DSA Secretary
here has been a time during the last two years when it has been impossible to remain positive with all the endless flow of bad news for the specialist sector. However just maybe we have reached the bottom of the trough and are starting to climb up. Certainly reports from some members are indicating a increase on last year, some are saying it couldn’t have got much worse than 2010. The association have been and are being pro-active to support it’s members with new benefi ts being added such as the GAP deal for plant & equipment hire. The apprenticeship is only now starting to suffer with lower intakes than predicated, this only reinforces my last report, which stated that recruitment for our sector would
be cautious and employers would have experienced workers on-hand to fill any gaps. However this is only a short term fix. The investment for the future is surely to reduce the average age of a company workforce; certain members are recognising this and are seeking younger personnel with the view of an apprenticeship. The DSA was the first in the specialist sector to start apprenticeships, and now after 7 years there are some 18 specialist apprenticeships. We are indebted to the members who have supported this initiative and are seeking new trainees for the future. The Scheme is grant aided and supported by industry as a pathway to careers. Recently ConstructionSkills undertook filming of an apprentice on a live site,
Husqvarna Construction Products is the world leader when it comes to equipment and diamond tools for the construction and stone industry. We provide users all over the world with the most efficient and reliable equipment there is. By doing this we ensure that our professional users will be proud of a job well done. And proud professionals are our best reward.
HUSQVARNA CONSTRUCTION PRODUCTS
Tel: 0844 8444 570 • Email: firstname.lastname@example.org • www.husqvarnacp.com 4 | CONCRETE CUTTER 2·2011
which will be used to promote interest to our industry. Never before have we been put forward as a career. How many people in this industry have fallen into drilling and sawing? I myself was a qualified butcher before my sister talked to me about her work as a secretary for a diamond drilling company. This roused my interest because of the diversity of locations and work applications, and it still does to this day. How often do we hear, “I’m getting too old to carry out this physical work, it’s a young man’s game”. Generally, for a new start, training takes place on-site with an experienced operator who trains and guides the trainee. However is this always the right way? I recently had a conversation with an apprentice who explained a disagreement with a
highly experienced operator over the correct way of fi tting and tensioning a ring saw blade. The apprentice had been taught as per the operator’s manual and had passed our practical fi tting test. The experienced operator however had never seen the manual and had been fi tting the blade incorrectly. Over the years this experienced operator must have cost his employer a lot of money on replacement blades and parts. Currently we are working on several ventures such as Training DVDs, which will assist in training using the latest equipment and techniques. We are also revamping the Generic Method statements and risk assessment and also New Toolbox talks designed specifically for our industry. All of this is funded by Construction skills development grants.
My next news relates to the robotic plant that we use. Construction Plant Certification Scheme Cards will be available under Demolition Plant Pedestrian 360. This means that all operators will require this card for site. For those who already have this card for skid steer loader or dumper truck it means there will be a two part test, theory and practical. At present we are in discussions with CPCS and the NFTG to produce guidelines for testing. I will keep all our members informed on this matter as it unfolds. On a final note the next AGM will be held at the Concrete Show in Coventry next February, We have booked a contractors’ stand and several of our supplier members are exhibiting. Hope to see you there.
CONCRETE CUTTER 2·2011 | 5
CASE HISTORIES Underwater diamond wire sawing cuts new Tyne tunnel openings Remotely controlled Tyrolit SB wire sawing machines were operated from on top of the walls of the river Tyne, above high water mark
Scheduled for opening at the end of this year, a second Tyne tunnel is being built to accommodate the increased traffic that is now overloading the original 1960s built tunnel. As part of the construction of this new Tyne tunnel, underground approach roads on the north and south sides were built using cut and cover techniques up to the river walls. The roads then had to be linked to the tunnel, which is of immersed tube design comprising four prefabricated caisson structures set into a deep trench in the river bed. To allow this work to take place, main contractor Bouygues Travaux Publics constructed transition shafts on both banks of the river. Controlled demolition and diamond cutting specialist, Robore, along with other firms, was asked to devise a method for cutting an opening in the walls on the north and south sides down to the river bed, up to 26 m below high water mark, to allow the tunnel connections to be completed. The complexity of the work deterred many companies from making a bid, but Mitcham-based Robore was both willing and able to fulfil this exacting task and consequently was awarded the contract. Realising that diamond wire sawing would play a major part in this project, Robore contacted its regular suppliers of diamond wire sawing equipment. Of the companies that were interested, Tyrolit emerged as the successful candidate. Not only did the company have considerable previous experience of underwater sawing, but, during trials, its sawing machines proved very reliable and the latest electroplated diamond wire delivered good sawing speeds and cost per cut. When the job commenced, it was decided that the south and then the north concrete walls would be removed in nine sections, each being cut full height and removed by sea crane, with the largest central key stone weighing in excess of 175 tonnes. Initially, Robore diamond drilled all the wire feed holes and lifting holes, some up to 2 m deep. This was done from within the transition structure in dry conditions. As each hole penetrated the wall below the water line, it was plugged to prevent the shaft from flooding. Once the river bed had been excavated down to the level where the cut across the bottom of the walls was required, wire sawing commenced using four remotely controlled Tyrolit SB wire sawing machines positioned on top of the south wall, above the level of the water at high tide.
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A key element in the construction of the new Tyne tunnel in Newcastle was cutting openings in the prefabricated concrete tunnel caissons to connect the new approach roads. In the event, underwater diamond wire sawing – at depths of up to 26 m – proved to be the only way to do this. Robore used specially constructed deflection pulleys designed by Tyrolit to transfer the direction of wire travel from the vertical plane to the horizontal, enabling the bottom cut to be executed. A dive master and two teams of 10 experienced divers, one on days and one on nights, were employed to locate and clear each of the wire feed holes and to thread the wire through the pulleys accurately in virtual darkness. Tyrolit’s DWM-C wire achieved above 1 m2 /hr cutting speed and typically completed 21 m2 in a 24-hour period, allowing for time spent making adjustments and monitoring the cut. This was despite having to saw through concrete containing reinforcing bars ranging from 16 to 55 mm in diameter. To overcome the initial problem of the wire drawing debris from the river bed into the cut and stopping the saw, the direction of drive was reversed to pull the wire out into the river, forcing the debris away. Up to 86 m of wire was used to complete the cuts on the deeper south bank. Vertical cuts were pulled up to within 2 m of the top of the wall, after which a sea crane was positioned and all lifting plant attached before the cuts were completed – seen here are preparations to remove the 175 tonne keystone from the south bulkhead
CASE HISTORIES Another of the wall sections on the south bank being lifted away by sea crane
Next, Robore completed the vertical cuts, with the central keystone removed first so that the other eight could be lifted free without jamming. When cutting the centre section, the saws were set at a 45° angle from inside to out to enable easy removal of the key stone by river crane. Each subsequent vertical cut was a straight pull, with divers used at regular intervals to verify cutting positions and move temporary supports as required. Over the course of a week, all of the remaining eight sections on the south side were similarly removed. Work was carried out in severe winter conditions, with snow driven by winds of over 50 mph and temperatures during the night dropping to minus 7 °C. The project was therefore not only technically difficult but physically demanding as well. With dismantling of the south side involving work up to 26 m under water, the north bank at a mere 17 m deep at high tide was straightforward for Robore and was completed well within the scheduled contract period. The new, £139 million Tyne crossing, one of the biggest transport infrastructure projects in the UK, provides a second vehicle tunnel linking Jarrow on the south bank of the river with North Shields and Howdon on the north. The original tunnel entered service in 1967 and was designed for a daily traffic throughput of 24,000 vehicles, although 38,000 customers per day now use it during peak hours. It is currently being refurbished and from December 2011 the two tunnels will work in tandem, providing capacity for the 43,000 vehicles that are expected to cross the Tyne each day by the end of the next decade. Capping beam to be removed prior to the blocks 1000 1200
Waling beam to remain
Contacts: Tyrolit Ltd, Eldon Close, Crick, Northants, NN6 7UD. Tel: 01788 824500 Fax: 01788 823089 Contact: John Willis, Managing Director email@example.com www.tyrolit.com Robore Group, Unit 16, Mitcham Industrial Estate, Streatham Road, Mitcham, Surrey, CR4 2AP. Tel: +44 (0)20 8646 4466 Fax: +44 (0)20 8646 4046 Contact: Jeff Lawrence, Contracts Director firstname.lastname@example.org www.robore.com
Wgross = 157 t Wgross = 144 t Wgross = 144 t Wgross = 149 t Wgross = 148 t Wgross = 154 t Wgross = 151 t
North and south transition shaft bulkheads were sawn using diamond wire and removed in nine sections to create openings in the river walls – this dimensioned diagram is of the south bank bulkhead
CONCRETE CUTTER 2·2011 | 7
Diamond helps to bridge the gap Renovation work to the famous Forth Road Bridge involved around 17,000 m of diamond drilling to facilitate the placement of steel reinforcement bars for strengthening of the bridge’s foundations.
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From around 1130 onwards, pilgrims travelling to St. Andrews crossed the Firth of Forth using the “Queens Ferry”. That all changed in 1964 with the completion of the construction of the Forth Road Bridge, which at that time was the 4th longest suspension bridge in the world spanning over 2.5 km. Today, this elegant and hard-working Scottish icon of engineering provides a safe crossing for more than 24 million vehicles each year and links the capital, Edinburgh with Fife and the North East of Scotland. As part of a regular maintenance programme, work commenced on site in May 2010 to replace all the bearings on both approach viaducts on the north and south of the Forth and will continue until the end of 2012. The approach viaducts are supported by reinforced concrete piers with steel bearings to allow the bridge deck to move to compensate for changes in temperature and traffic loading. The project involves jacking up the bridge deck to allow removal and replacement of the existing bearings, with the concrete being strengthened at the jacking points by the addition of reinforced concrete corbels added to each side of the piers. Corecut Ltd, based in nearby Broxburn, are carrying out a package of subcontract works on behalf of main contractor, Balfour Beatty Civil Engineering having worked together previously on similarly technically demanding contracts. One of the main aspects of Corecut’s work is the drilling of holes in the existing concrete piers to accommodate the placement of new steel reinforcement bars that would ‘tie’ the new corbels to the existing structure.
CASE HISTORIES The scope of work involves mapping the depth and location of the existing reinforcement within the bridge piers, drilling holes up to 5.5 m deep and inserting new resin-bonded rebars into the cored holes. Corecut chose Hilti as its tool and equipment supplier since it was one of the few companies that offered a complete range across all these activities.
The surface is scanned to locate the rebars prior to diamond drilling of 57 mm diameter holes up to 5 m in depth
Prior to commencement on site, a “mock pier” was built at nearby Rosyth in order to gauge the accuracy of the diamond drilled holes. Using a core bit guide previously developed by Hilti, a tolerance of ±10 mm was achieved whilst drilling horizontally to a depth of 5.5 m, the maximum for the job. Mapping the depth and location of the existing reinforcement within the bridge piers is being carried out using Hilti’s PS 200 Ferroscan. In this way, Corecut operatives work alongside Balfour Beatty site engineers to determine where best to drill holes for the post-installed reinforcing bars. A Hilti PR 25 Rotating laser is then used to transfer levels around the pier at the required height and aid in setting the location of the holes to be drilled. Once this is agreed, Corecut then uses Hilti’s DD 200 diamond drilling system to core out the 57 mm diameter holes to the depths and accuracy specified. On completion, the total distance drilled will be in the region of 17,000 m. When the holes are drilled, the additional reinforcing bars are installed using Hilti HIT-RE 500 resin, which the company claims has high load values over a wide range of bar diameters backed up by extensive test data. Using a Hilti HIT-P8000 pneumatic dispenser and long lengths of hose with piston plugs attached ensures the resin is installed from the base of each hole – a precise volume of resin is used to ensure the design loads are achieved – up to five 1400 ml tubes are used on the larger diameter holes and a total of 5,500 litres will be used on completion of the project. Contracts Supervisor for Corecut on the project, Peter Ferguson said, “Our initial trials were critical to ensure every bar is installed correctly, our operatives are well trained and know exactly what is required.” Every detail of the installation process was thought through even down to keeping the resin at a constant temperature in insulated crates at the workface to ensure easy and cost efficient use. Alongside the strengthening works, Corecut are also employed by Freyssinet UK to cut grooves for the installation of a cathodic protection system to reduce corrosion rates of the reinforcing bars within each pier. 12 m long grooves are cut at a 45° angle into the structure using a Hilti TS 20-E track saw to a depth of 45 mm. Once again, accuracy and a precise depth of cut are needed to ensure the existing reinforcing bars are not damaged.
Resin is pumped into each hole and a reinforcement bar inserted
Project Manager for Balfour Beatty Civil Engineering, Alan Brisbane speaks highly of the relationship built with Corecut on this project, “Finlay Crocker (MD of Corecut) and his team have helped in making an awkward and challenging job run smoothly and it is a pleasure to work with such a professional and conscientious contractor.”
Contacts: Corecut Ltd, Bankhead, Broxburn, West Lothian, EH52 6PP. Tel: 01506 854 710 www.corecut.co.uk Hilti (Great Britain) Limited, 1 Trafford Wharf Road, Trafford Park, Manchester, M17 1BY. Tel: 0800 886 100 www.hilti.co.uk
View showing new reinforcement in place for the new concrete corbels, which is tied to the post-inserted bars
CONCRETE CUTTER 2·2011 | 9
A record floor show Each night a minimum of 1,300 linear m of concrete is cut to a depth of 65 mm
Contacts: Saint-Gobain Abrasives Ltd, Albert Drive, Burgess Hill, West Sussex RH15 9TN. Tel: +44 (0) 1444 259444 www.nimbus-diamond.com Corecut Ltd, Bankhead, Broxburn, West Lothian EH52 6PP. Tel: 01506 854 710 www.corecut.co.uk
An ongoing floor sawing contract involves cutting around 250,000 linear m of concrete to a depth of 65 mm. The work, which can only take place at night, has to be achieved within 12 months, so correct choice of sawblade at the start was crucial. One of the largest floor sawing contracts ever to be undertaken in Scotland is currently taking place at the Eastgate Centre multi-story car park in Inverness. The work involves the removal of the top 65 mm of the concrete floor in preparation for a new layer of structural concrete to be applied. The floor saw is being used to make 65 mm deep grooves in the surface at 60 mm intervals, thus enabling the concrete to be more easily broken out. As the car park is fully operational during the day, all work has to be carried out at night when it is closed. The 12 month contract involves cutting 250,000 linear m of concrete, with a minimum of 1300 m of cutting to be achieved during each night shift. Main contractor, Volker Laser Ltd appointed Corecut Ltd as the specialist diamond drilling and sawing contractor. Prior to commencing work, Corecut carried out trials to find the optimum diamond sawblade specification that would complete the task most efficiently. In the event, Corecut chose a combination of the new Vortex and Titan-X diamond blades from Norton Nimbus, as these gave the best performance in terms of both speed and life, thus enabling the company to achieve the desired output at the most economical and cost effective rate. The 600 mm diameter blades are mounted on a 66 hp turbo diesel floorsaw. Finlay Crocker, Managing Director of Corecut commented, “The tight schedule and sheer size of the job meant it was essential to hit the ground running to ensure we obtained the right balance between production output and cost as quickly as possible. The Norton Nimbus blades proved to be the best solution, enabling us to be on course to complete the contract efficiently and on time.” The sawblades themselves are part of the Norton Nimbus premium diamond range, for use on concrete containing the toughest aggregates, as was the case here. The sawblade being used for the majority of the work is the Titan TX40, which is achieving a life of over 2,000 linear m for a 65 mm depth of cut.
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CONCRETE CUTTER 2路2011 | 11
Cutting corners saves time and money The chain saw can make cuts flush up to the beams
Finished cuts need little or no remedial work to be carried out
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The old adage that cutting corners can save time was certainly true on a recent job in London, where a concrete chain saw was employed to cut flush up to adjacent beams or walls. But it was not just time that was saved, but more importantly money, as the job was completed well within budget. Britannia Cutting Services Ltd is a well-established concrete sawing and drilling company based in Kent. Specialising in the cutting needs of the construction and renovation industry in the UK, Britannia was recently called upon by Marks Demolition to assist on a project being run by Galliford Try, one of the largest construction companies in the UK, to take on a unique and challenging job in the centre of London at Rathbone Place, City of Westminster. The 60 year old building was being renovated from a conventional office building with many small offices into a modern media office with a more open floor plan. For reasons both of aesthetics and structural support, the decision was made to leave several concrete beams intact on each floor, while removing portions of each wall. Many of the planned cuts had to be made flush to the beam or adjacent wall. The beams measured 300 mm x 200 mm and the walls were 210 mm deep with various diameters of rebar from 12 mm all the way up to 25 mm. There were seven drop beams per floor and six floors to do. In addition to the larger openings, just cutting around the beams would amount to about four linear m of cutting on each floor. All the work was at height so this made the task even more difficult. Britannia would normally have deployed the tried and tested method of stitch drilling around the beams and columns to achieve the severances that were required. However, coring around each beam would have taken eight core holes per beam and there were seven beams per floor. According to the operator, the
CASE HISTORIES core drilling method would have taken three days per floor just to complete the work around the beams. Owner Pat Southin, who in the past had always been sceptical about concrete chain saws, decided this was the perfect job to give the technology a try.
Using the ICS hydraulic powered flush-cutting chainsaw, Britannia was able to complete an entire floor per day and used less than one chain per floor (five in total), so the time savings made this method much more cost effective than coring. Adding to the cost savings, the chain saw cuts required almost no patchwork or finishing, whereas the core method would have left a scalloped cut that would have required grinding or chipping to make flush to the beam. The chief operator on site Jim Evans, said, “I will never core another corner again now that I’ve got an ICS saw.” Owner Pat Southin was also happy about his decision to try concrete chain saws on this job and now said, “The purchase of the concrete chain saw was a great investment for me, and I can now see many opportunities for us to use it. Not only is it quicker than stitch drilling, which saves on our labour costs, but it also leaves a much neater and tidier finish for our customers.”
Contacts: ICS, Blount UK Ltd Tel: 020 3328 0621 email@example.com Britannia Cutting Services Ltd Unit 1, Millside Industrial Estate, Lawson Road, Darford, Kent DA1 5BW Tel: 01322 221533 www.britcut.co.uk
The benefits of concrete chain sawing Concrete chain saws were first introduced to the sawing and drilling industry in the ea early 1990s as a method of achieving perfectly clean, square corners in a concrete wall or floor opening. Regular users of these machines now find that this meth method is both preferable and affordable. ICS has been refining this product concept ffor over 20 years and remains the world leader. In fact, the diamond chain sawing m method is now standard for concrete sawing and drilling professionals in North A America where the product was originally launched, and now over two are specified and sawn with ICS concrete chain saws each year. million corners co UK, however, chain saws have yet to gain the same popularity and most In the U openings are still specified without mention of square corners, thereby op allowing overcutting and/or chipping. The assumption remains that the cost of cutting clean, square corners outweighs the benefi ts of aesthetic appeal and structural integrity. However, by taking a closer look at that assumption, it can be shown that the chain saw method can make square corners easy and affordable. When forming an opening, most professionals use a circular wall saw blade to make the main cut, leaving three options: overcut past the corner, perform the labour intensive task of coring and grinding the corner, or use a concrete chainsaw to cleanly, quickly, and efficiently finish the corner (see Diagram 1). In the UK, corners are typically finished by core drilling out the remaining material left in the opening after the wall-saw cut and then using a grinder to finish the rounded surfaces left by the drill. This process takes on average 40 minutes to an hour per corner, or about 3-4 hours per opening. For highly skilled contractors, the cost for 3-4 hours of labour can be expensive. Diagram 1
Sawing a corner with a concrete chain saw can be done in minutes with lower cost than other methods such as core drilling or chipping. With the concrete chain saw method, the chain saw is inserted into the cut made by the circular wall-saw to clean the corners. Due to the depth and shape of the bar the operator is able to cut only the material remaining rather than overcutting or leaving material to be ground off (see Diagram 2). Each corner can be completed with a chain saw in about 10 minutes, or about 40 minutes per opening. Compared to the core drilling method, a labour saving of about 2-3 hours is achieved. Furthermore, there is no need to finish the corners by chipping and grinding as the chainsaw leaves a nearly perfect square corner. The end result is a cleaner, more aesthetic corner with less time and labour.
Material remaining after circular blade
Concrete chainsaws efficiently “clean the corners”
CONCRETE CUTTER 2·2011 | 13
MEMBERS DIRECTORY WALES
CONTRACTORS IRELAND Supple Cutting Services Ltd Redfield Dromroe Causeway Co. Kerry Ireland firstname.lastname@example.org www.concreteremoval.ie Tel: 00 353 66 7148828 Fax: 00 353 66 714 8672 SCOTLAND Core Cut Ltd Bankhead Greendykes Road Broxburn West Lothian EH52 6PP email@example.com www.corecut.co.uk Tel: 01506 854710 Fax: 01506 853068 Core Drilling Specialists Ltd Unit 3 Inchcross Industrial Estate Bathgate Scotland EH48 2HR firstname.lastname@example.org www.coredrilling.co.uk Tel: 01506 637840 Fax: 01506 652910 CoreTec Drilling 17 Barnton Street Stirling Scotland FK8 1HF email@example.com www.coretecdrilling.co.uk Tel: 0800 068 3837 Fax: 01786 841659 GT Diamond Drilling Services 26 Fairfield Road Dundee Scotland DD3 8HR firstname.lastname@example.org www.gtdiamonddrilling.com Tel: 01382 813399 Fax: 01382 813388 Holemasters Scotland Ltd Block 2, Unit 6 Whiteside Ind Est Bathgate EH48 2RX email@example.com www.holemasters-scotland.co.uk Tel: 01506 653303 Fax: 01506 652991 Lochwynd Ltd 19 Lonmay Place Panorama Business Village Porterfield Road Queenslie Glasgow G33 4ER firstname.lastname@example.org www.lochwynd.com Tel: 0141 781 4477 Fax: 0141 781 4724
Celtest Ltd Trefelin Llandegai Bangor Gwynedd LL57 4LH email@example.com www.celtest.com Tel: 01248 355269 Fax: 01248 360400 Denver Construction Services Construction House Dumballs Road Cardiff Bay Cardiff CF10 5FE firstname.lastname@example.org www.denverconstructionservices.co.uk Tel: 02920 497441 Fax: 02920 436966 Marson Diamond Drilling Ltd 16 Lauderdale Road Tairgwaith Ammanford SA18 1YG email@example.com Tel: 01269 825979 Fax: 01269 825979
Unit 12 Raikes Clough Ind Est Raikes Lane Bolton BL3 1RP firstname.lastname@example.org www.diamanttek.co.uk Tel: 01204 366435 Fax: 01204 366437 Hi-Tec Diamond Drilling Ltd Units 9 & 10 Courtyard No. 2 Maple Estates Wentworth Road Mapplewell Barnsley S75 6DT email@example.com www.hitecdiadrill.co.uk Tel: 01226 388553 Fax: 01226 388553
Crown Cutting Services Unit 5 Queens Drive Industrial Estate Chasetown Burntwood Staffordshire WS7 4QF firstname.lastname@example.org www.crowncutting.co.uk Tel: 01543 682329 Fax: 01543 671622 D-Drill (Master Drillers) Ltd Shilton Industrial Estate Kiln Way Shilton Coventry CV7 9QL email@example.com www.d-drill.co.uk Tel: 02476 612858 Fax: 02476 615425
Holemasters Demtech Ltd Unit 1 Bracewell Avenue Poulton-le-Fylde Lancs FY6 8JF firstname.lastname@example.org www.holemasters.co.uk Tel: 01253 01 012 892890 01253 Fax: x: 01 012 253 892891
East Midlands Diamond Drilling Churchfield House 1 Lockwood Close Top Valley Nottingham NG5 9JN Dave.Swanwick@emdd.co.uk www.emdd.co.uk Tel: 0115 967 9000 Fax: 0115 967 4223
Richardson P C Ri Ric chardson & Co Ltd Courville House Courvil 34 Ellerbeck Court Co Stokesley Industrial Park Stokesley North Yorkshire TS9 5PT john email@example.com firstname.lastname@example.org woodward@pcrichardson co uk www.pcrichardson.co.uk Tel:l: 01642 714791 7147 Fax: 01642 714 714387
G & B Chasing & Drilling Ltd HRS House Garretts Green Lane Birmingham B33 0SJ email@example.com Tel: 0121 680 5003 Fax: 0121 680 7003 Fa Fax
p14 p1 DSA Membs 1 (further edits TBA) NORTH
A19 Drilling Ltd Penine ne Avenue North Nor rth Tees Industrial Estate Esta Stockton-on-Tees Stoc ckton-on-Tees TS18 8 2RJ firstname.lastname@example.org www a19drilling co uk www.a19drilling www.a19drilling.co.uk Tel: 01642 619171 Fax: 01642 613712
Allied Drilling Ltd Unit B5 (6) Moss Industrial Estate St Helens Road Leigh Lancashire WN7 3PT email@example.com Tel: 01942 673066 FFax: 01942 679066 Barton Drilling Ltd Contex Works Station Road Latchford Warrington Cheshire WA4 1LB firstname.lastname@example.org www.bartondrilling.co.uk Tel: 01925 653354 Fax: 01925 230151
Concrete Drilling Services Ltd Unit 4 Waters Meeting Britannia Way Bolton BL2 2HH email@example.com www.concretedrillingservices.co.uk Tel: 01204 382398 Fax: 01204 380625 Diamanttek Ltd
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Precision Drilling 2000 Ltd Wyke Street Hedon Road Hull East Yorkshire HU9 1PA firstname.lastname@example.org www.precisiondrilling.co.uk Tel: 01482 586585 Fax: 01482 223864 Sawcon Plant Ltd Knoll Street Industrial Park Salford Manchester M7 2BL email@example.com Tel: 0161 792 2827 Fax: 0161 792 2800
Jointline Join oin ntline Ltd Airfi Air rfield View Camp Road C Witham St. Hughs Lincoln Lincolnshire LN6 9TW firstname.lastname@example.org www.jointline-group.co.uk Tel: 01522 868636 Fax: 01522 868806 Philmore Contracting Ltd Unit 14 Twigden Barns Brixworth Road Creaton Northants NN6 8NN email@example.com www.philmore.co.uk Tel: 01604 505902 Fax: 01604 505756
MIDLANDS Access Drilling Services Ltd Unit 3 Marsh Lane Industrial Estate New Mills High Peak Derbyshire SK22 4PP firstname.lastname@example.org www.accessdrilling.co.uk Tel: 01663 743201 Fax: 01663 745551
SOUTH EAST A C Specialist Services LLP 96 Broom Road Stanford Bedfordshire SG18 9JE email@example.com Tel: 01462 813666 Fax: 01462 813351 A J Willcock Holeformers Ltd Unit 2, Great Hidden Farm
MEMBERS DIRECTORY Wantage Road Eddington Hungerford Berkshire RG17 0PW firstname.lastname@example.org Tel: 01488 686175 Fax: 01488 683801 Access Diamond Drilling Ltd Clifton House 23 Clifton Road London SE25 6PX email@example.com www.accessgroup.me Tel: 020 8239 1486 Fax: 020 8239 1486 Acudrill Ltd 12 Meadway London SW20 9HY firstname.lastname@example.org www.acudrill.co.uk Tel: 020 8540 5335 Fax: 0208 542 5387 Baker Dougan Ltd Unit 4, Oyster Estate Jackson Close Farlington Portsmouth Hants PO6 1QN email@example.com Tel: 02392 370777 Fax: 02392 371777 Barcol Ltd Oak Lodge Studland Avenue Wickford Essex SS12 0JF firstname.lastname@example.org www.barcol.co.uk Tel: 01268 764642 Fax: 01268 764644 Bardon Contracting Thorney Mill Road West Drayton Middlesex UB7 7EZ email@example.com Tel: 01895 422861 Fax: 01895 422871 Britannia Cutting Services Ltd Unit 1, Millside Industrial Estate Lawson Road Darford Kent DA1 5BW firstname.lastname@example.org www.britcut.co.uk Tel: 01322 221533 Fax: 01322 220790 C A Drillers Ltd Dockers Field Farm Pean Hill Whitstable Kent CT5 3BJ email@example.com www.cadrillers.com Tel: 01227 458883 Fax: 01227 458884
Carthew’s Diamond Drilling Unit C2 Alpha House Alpha Place Garth Road Morden Surrey SM4 4TS firstname.lastname@example.org www.carthewsdrilling.co.uk Tel: 0208 3936700 Fax: 0208 3936767 Castle & Pryor Elles House 4B Invincible Road Ind Estate Farnborough Hampshire GU14 7QU email@example.com www.castle-pryor.co.uk Tel: 01252 524080 Fax: 01252 524090 Clifbreakers Ltd Unit 16 Blackheath Business Estate 78B Blackheath Hill Blackheath London SE10 8BA firstname.lastname@example.org Tel: 020 8318 5155 Fax: 05600 751875
Silk Mill Industrial Estate Brook Street Tring Hertfordshire HP23 5EF email@example.com www.diamond-cutters.co.uk Tel: 01442 891313 Fax: 01442 890751
Kent TN15 8PY firstname.lastname@example.org www.invictacut.co.uk Tel: 01732 884977 Fax: 01732 887400 J Hare Diamond Drilling (Hitchin) Ltd 5-7 Wallace Way Hitchin Hertfordshire SG4 0SE email@example.com www.jhare.com Tel: 01462 433199 Fax: 01462 420196
Diamond Edge Drilling Ltd Hall Place Penshurst Road Leigh Kent TN11 8HH firstname.lastname@example.org www.diamondedgedrilling.co.uk 01732 832223 01732 834442
John F Hunt Demolition Ltd Europa Park Grays Essex RM20 4DB email@example.com www.johnfhunt.co.uk Tel: 01375 366748 Fax: 01375 366769
Drilltec Ltd Diamond House Dencora Way Sundon Park Road Luton Bedfordshire LU3 3HP firstname.lastname@example.org www.drilltec.co.uk Tel: 01582 564455 Fax: x: 01 01582 015 847016
Kilnbridge Construction Services Ltd McDermott House Cody Road Business Centre South Crescent London E16 4TL email@example.com www.kilnbridgegroup.com Tel: 0207 511 1888 Fax: 0207 511 1114
p15 DSA Membs 2 (further edits TBA) Concrete Construction United ted Ltd L Borstal Bors stal Court Farm Burham Burh ham Road Rochester hester Kent ME1 3DH M firstname.lastname@example.org Tel: 01634 826960 Fax: 01634 827025 Corehard Ltd 4 Viewpoint Babbage Road Stevenage Hertfordshire SG1 2EQ email@example.com www.corehard.com Tel:l 01438 225102 T Fax: 01438 213721 Diacore Concrete Cutting Ltd 2 Witheygate Avenue Staines Middlesex TW18 2RA firstname.lastname@example.org www.diacore.co.uk Tel: 01784 456 013 Fax: 01784 456 026 Diacutt Concrete Drilling Services 8 The High Street Colliers Wood London SW19 2AE email@example.com www.diacutt.com Tel: 020 8540 0300 Fax: 020 8542 9901 Diamond Cutters (Herts) Ltd Unit 10
Elmcrest Elmcre mcrest Diamond Drilling Ltd Duncrievie 4 Dunc crievie Road Lewisham Lewisha London SE13 6TE elmcrest.shane@elmcrest-diamond elmcrest.shane@elmcrest-diamond. co.uk co uk www.elmcrest-diamond.co.uk Tel:l: 020 8318 9923 Fax: 020 8318 1034
First Cut UK Lt Ltd 122 Weston Road Strood Rochester Kent ME2 3HD firstname.lastname@example.org www.firstcutdiamonddrilling.co.uk Tel: 07518 206 785 Fax: 01634 712 011 Hampshire Chasing Ltd 12 Station Road North Totton Southampton SO40 3AB email@example.com www.hampshirechasing.co.uk Tel: 02380 871124 Fax: 02380 663909 Hydro Pumps Ltd 19 Highmead Fareham Hampshire PO15 6BL firstname.lastname@example.org www.hydro-pumps.co.uk Tel: 01329 823420 Fax: 01329 823425 Invictacut Ltd. Landway Farm Basted Lane Crouch Sevenoaks
KSS Diamond Drilling & Sawing Ltd S Russell Russell Gardens Rus Wickford Wickford Essex Essex SS11 SS 8BH SS1 email@example.com www.kssgroup.co.uk Tel: 01268 578402 Fax: 01268 561034 M25 Contracting Ltd Unit A East Duck Lees Lane Enfi eld Enfield Middlesex EN3 7SR firstname.lastname@example.org www.m25contracting.com Tel: 0208 804 5961 Fax: 0208 804 0014 MB Diamond Drilling Ltd Unit 5A Algrey Trading Estate Cooks Way Hitchin Herts SG4 0JA email@example.com Tel: 01462 471 130 Fax: 01462 457 104 Mohan Building Services Ltd 3A Manor Road Gravesend Kent DA12 1AA firstname.lastname@example.org www.mohanbuildingservices.com Tel: 01474 323943
CONCRETE CUTTER 2·2011 | 15
MEMBERS DIRECTORY NML Diamond Drilling Ltd 16 Phoenix Road Washington NE38 0AD email@example.com www.nmldiamonddrilling.co.uk Tel: 0191 416 0077 Fax: 0191 416 0131
Unit 16 Mitcham Industrial Estate Streatham Road Mitcham Surrey CR4 2AP firstname.lastname@example.org www.robore.com Tel: 020 8646 4466 Fax: 020 8646 4046
Greenlands House Southbrook Road West Ashling Chichester West Sussex PO18 8DN email@example.com www.technicalconcretecutting.co.uk Tel: 01243 572784 Fax: 01243 576060
Precision Cutting Ltd Unit 2 Sunset Farm Cross-in-Hand Heathfield East Sussex TN21 0TX firstname.lastname@example.org www.precisioncutting.co.uk Tel: 01435 864666 Fax: 01435 867888
Speed Drill Ltd Units 17 & 18 Chingford Ind Centre Hall Lane Chingford London E4 8DJ email@example.com www.drilling-contractor.co.uk Tel: 020 8524 0004 Fax: 020 8524 6778
Tideway Plant Services Ltd Northend Park Corner Road Betsham Kent DA13 9LJ firstname.lastname@example.org www.tidewaydrilling.com Tel: 01474 833444 Fax: 01474 834 40
Protech Construction (UK) Ltd. 14a Sidley Green Bexhill on Sea East Sussex TN39 5AH email@example.com Tel: 01424 215400 Fax: 01424 734456
Strata Coring Ltd 461 London Road High Wycombe Bucks HP11 1EL firstname.lastname@example.org www.stratacoring.co.uk Tel: 01494 447006 Fax: 01494 447006
Fax: 01474 567617
Robore Cuts Limited
The Bush Hammering Co Ltd 26 Huntsmans Drive Upminster Essex RM14 3YU email@example.com www.bushhammering.com Tel: 01708 227673 Fax: 01708 223687
Applied Diamond (Products) Ltd Holly Farm Business Park Honiley Kenilworth Warwickshire CV8 1NP firstname.lastname@example.org www.applieddiamond.com Tel: 01926 485185 Fax: 01926 485186 Pentruder UK Ltd Unit 2, Cranford Ind Units Berwick B i k East Sussex BN26 6TF email@example.com www.pentruder.co.uk Tel: 0845 241 9616 Fax: 0845 241 9617 Edge Tools & Equipment Ltd Unit 9, Victoria Centre Victoria Way Pride Park Derby Derbyshire DE24 8AN firstname.lastname@example.org www.edgediamond.com Tel: 01332 226699 Fax: 01332 210211 Golz UK Ltd Unit 5A Springhead Enterprise Park Springhead Road Northfleet Kent
SOUTH WEST Drill Cut Ltd Units 2 & 3 Bowling Hill Business Park Chipping Sodbury Bristol BS37 6JL email@example.com www.drillcut.co.uk Tel: 01454 324236 Fax: 01454 317230 European Plant Services Ltd No. 8 Bakers Park Cater Road Bishopsworth Bristol BS13 7TT firstname.lastname@example.org www.europeanplantservices.co.uk
p p16 DSA Membs 3 (further edits TBA) Truecut ruecut Diamond Drilling Ltd
Technical Concrete Cutting LLtd td
Tel: 0117 9649 777 Fax: 0117 9649 888
Unit 14 Canterbury Industrial Park Island Road Hersden Canterbury Kent CT3 4HQ email@example.com www.truecutdrilling.co.uk Tel: 01227 713280 Fax: 01227 719568
DA11 11 8HB 8H firstname.lastname@example.org pete email@example.com www.goelz.de www w.goelz.de Tel: 01474 321679 32167 Fax: 01474 321477
Hertfordshire Diamond Products Lt Ltd Unit F Gunnels G l Wood W d Park P k Gunnels Wood Road Stevenage Herts SG1 2BH colin.greenall@hertsdiamondproducts. com Tel: 01438 748758 Fax: 01438 362060 Hilti (Gt. Britain) Ltd 1 Trafford Wharf Road Trafford Park Manchester M17 1BY firstname.lastname@example.org www.hilti.co.uk Tel: 0844 815 6280 Fax: 0800 886200 Husqvarna Construction Products Unit 4 Pearce Way Gloucester Gloucestershire GL2 5YD email@example.com www.husqvarnacp.com Tel: 0844 844 4570 Fax: 0844 844 4568 ICS Blount Europe Rue Emile Francqui 5 1435 Mont-Saint-Guibert Belgium
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firstname.lastname@example.org europe marketing@icsbestway email@example.com com www.icsbestway.com Tel: + 32 10 301251 Fax: + 32 10 301259 Major ajor Diamond Supplies Ltd Unit 23 Rothersthorpe othersthorpe Crescent Crescen Rothersthorpe Ave Trading Estate Northampton NN4 8JD firstname.lastname@example.org www.majordiamondsupplies.co.uk Tel: 01604 767600 Fax: 01604 767658
Pegasus Industrial Products Ltd Unit 2 Cardigan Close Tonteg Pontypridd CF38 1LD email@example.com www.pegasusindustrial.co.uk Tel: 01443 217699 Fax: 01443 202896 Premier Diamond Products Ltd Unit 21 Chislet Close Lakesview Business Park Hersden Canterbury Kent CT3 4LB steve.webb@premierdiamondproducts. co.uk www.premierdiamondproducts.co.uk Tel: 01227 711555 Fax: 01227 710540 Robert Bosch UK Ltd Power Tools (PT/SEU) Broadwater Park
Denham Uxbridge Middlesex UB9 5HJ firstname.lastname@example.org www.bosch-pt.com ww Tel: el:: 0844 7360107 Saint-Gobain Abrasives Abr brrasives Ltd Albert Al Alb bert Drive Burgess Hill West Sussex RH15 9TN email@example.com www.nimbus-diamond.com Tel: +44 (0) 1444 259444 Toolguy Ltd 14 Lonsdale Drive Washford Park Shrewsbury SY3 9QJ firstname.lastname@example.org www.toolguyltd.co.uk Tel: 07545 559 889 Fax: 0872 1154119 Tyrolit UK Ltd Eldon Close Crick Northants NN6 7UD Mike.Hetherington@tyrolit.com www.tyrolit.com Tel: 01788 823738 Fax: 01788 823089 Heger GmbH European Diamond Tools Grissheimer Weg 5 D-79423 Heitersheim Germany email@example.com www.heger.com Tel: 049 7634 5020 Fax: 049 7634 502213
MEMBER’S CASE HISTORIES PROFILE Celtest Ltd Formed in 1980, Celtest offers quality materials testing, diamond core drilling and sawing, and controlled demolition services to the construction, quarrying, civil engineering and nuclear Industry. Our experience in quality management, together with our skilled staff,
has helped Celtest grow rapidly to become one of the foremost materials testing laboratories in the UK. Celtest’s North Wales laboratories are exceptionally well equipped for construction materials testing and are accredited by UKAS to ISO/IEC 17025:2005 (General Requirements for the Competence of Testing Laboratories) for the majority of tests performed both at our laboratories and on clients’ sites. We are an approved NVQ centre for drilling and sawing activities; we also help organisations develop management systems to meet international standards. Our diamond drilling, sawing, controlled demolition and anchor installation services complement our testing services, giving customers an effective solution from one supplier or one point of contact. Resources include a range of modern, specialist equipment, vehicles, and highly skilled operatives. We work sustainably and adhere to all health and safety regulations. With UK coverage and years of experience, Celtest’s high-standard service will help ensure your projects remain on time and within budget. With unrivalled inhouse resources, fast turnaround, and a drive towards sustainable working, Celtest has become the partner of choice for many organisations, both large and small. For further information call 01248 355269, visit www.celtest.com or email firstname.lastname@example.org
CONCRETE CUTTER 2·2011 | 17
Diamond provides the right angle When a slipway needed to be formed at an angle across a new sea defence wall, diamond track sawing was used to cut the precise lines needed.
Sawing of the first cut proceeds as the surveyor sets out the line for the second one Short track lengths were required to cope with the stepped wall
Close up of 800 mm diameter blade making an initial cut
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The Environment Agency has invested £30 million on a flood defence scheme at Dymchurch, in Kent. When complete, the scheme will have improved flood protection for more than 2,300 properties in Dymchurch Village. This project is one of six within the Folkestone to Cliff End coastline, which collectively will provide protection against rising sea levels for 14,000 homes across the Romney Marsh area. A crucial part of the project was the placing of 1,662 pre-cast concrete revetment units along the coast of Dymchurch from High Knocke to Martello Tower 23, covering a 2.2 km section of seafront. These works form a major part of the new Dymchurch Sea Defence which brings the defence out of the tidal zone. Main contractor, Birse Civils used a 120 tonne crane and specialist vacuum lifting equipment to place the revetment units, which weighed 20 tonnes each. Part of the work involved the provision of a ramped slipway that runs at an angle across the sea wall. The easiest and most economical way to do this – rather than producing special precast units – was to cut the line of the slipway using diamond saws. Kent based drilling and sawing contractor Invictacut was called in to do the work. Although the two cuts needed were each 30 m long, they had to be made in relatively short lengths and be ‘stepped’ up or down across the steep face of the individual concrete units. Invictacut therefore chose to use a wall saw with a short length of track, which could be moved up or down as the job progressed. The wall saw in question was a Pentruder CBK-HF 22 kW model, which was powered by a 427-HF powerpack (380 – 480 V). Maximum depth of cut was 625 mm so a series of 800, 1,200 and 1,500 mm diameter sawblades were used progressively. Working with such short lengths of cut obviously took longer than conventional continuous cutting, and working time was restricted by the tide, which at the time of year that the job was done, meant working in either the early hours or late at night. Even so the job was completed within a 4 week period to the satisfaction of all involved.
Contacts: Invictacut Ltd, Landway Farm, Basted Lane, Crouch, Sevenoaks, Kent, TN15 8PY. Tel: 01732 884977 www.invictacut.co.uk Pentruder UK Ltd, Unit 5 Cranford Industrial Units, Berwick, East Sussex, BN26 6T. Tel: 0845 241 9616 www.pentruder.co.uk
CASE HISTORIES Part of remedial works being carried out at a cardboard processing factory in Monmouth, Wales involved the removal of 13 concrete bases from the factory floor in order to relay concrete that was structurally capable of coping with the heavy loads imposed by the rolls of cardboard. A total of 13 bays, each 15 x 3 m in area and 600 mm deep had to be removed sequentially. Initially, main contractor, Thackway and Cadwallader employed standard jack hammering techniques, but the company soon realised – after spending two weeks working on one bay – that there must be a better way. And there was. D-Drill (Master Drillers) Ltd, which has offices throughout the UK, was called in to offer expert advice on using diamond cutting methods and came up with a proposal that cut the demolition time on a single bay to just three days. This involved cutting out the area of the base with a 1.6 m diameter diamond sawblade mounted on a diesel floor saw, followed by the removal of the concrete within the area using a Brock 180 remote-controlled demolition robot. The 180 was chosen because it was small enough to fit within the 2.5 m restricted height available within the factory, yet powerful enough to do the job. Each bay could now be completed within three days, at which point D-Drill moved off the site for two days to allow Thackway and Cadwallader to complete the new concrete works, before returning again to start on the next bay. Needless to say, the cutting of very deep channels such as this requires highly trained diamond sawing operatives with a great deal of experience in order to make it a success. The 1.6 m diameter blade was purchased specially for this job and completed around 450 linear m of cut, 600 mm deep and still had a lot of life in it. In fact, the main contractor was so impressed with the work carried out by D-Drill that they have been asked to help on similar jobs coming up in the future.
Diamond cutting deep
D-Drill cut out 600 mm deep channels with this 1.6 m diameter diamond sawblade
Breaking out a reinforced concrete floor to a depth of 600 mm using conventional jack hammering was taking too long until the contractor appointed a diamond sawing and drilling company to do the job. Contact: D-Drill (Master Drillers) Ltd, Shilton Industrial Estate, Bulkington Road, Shilton, Coventry, CV7 9QL. Tel: 0800 612 8174 www.d-drill.co.uk
Pentruder - Stronger than ever! Pentruder MDU3065 Drill motor - Soon to be introduced!
Discover Pentruder Modular Concrete Cutting System.
- A modular system which builds on our well proven saw track and offers many solution to facilitate the everyday work of the concrete cutter.
Wide speed range, 100 - 1440 rpm. Very high power on spindle, 10 kW in top gear. The drill motor can be run on 1-phase or 3-phase power. 5 electronic spindle gears.
- Use the same drive motor, power pack, cables and remote control for wall sawing, wire sawing and drilling.
Pentruder MCCS Universal Drill Rig A rigid, yet light weight drill rig for big and small jobs. Pentruder MCCS Corner and Stitchdrilling chassis A really useful accessory.
Please visit www.pentruder.co.uk for more information on our products. Pentruder UK Limited
Unit 5 Cranford Industrial Units
T: + 44 (0) 845 241 9616 E: email@example.com CONCRETE CUTTER 2·2011 | 19
Cutting up a storm On the surface, cutting out a 1 m thick concrete wall in a water treatment plant seemed a relatively simple job for an experienced contractor. However, throw in the facts that it is located underground with no easy access and subject to flooding at any time, and it starts to get a bit more complicated. Diamond cutting of concrete can involve working in many weird and wonderful environments. However some jobs can be a bit more complicated than others, for example, when Black & Veatch recently appointed GT Diamond Drilling Services, based in Dundee, Scotland, to remove a concrete wall from a water treatment plant near the beautiful Campbeltown Loch, At first, it did not seem to be a particularly complicated job. However when the wall is in an underground storm tank and the tank itself is under a building with no obvious exit for debris, you start to think it might be a bit of a challenge. Add to this that the storm tank could potentially be flooded requiring a speedy evacuation at any time during the job and that any demolition works must be vibration and fume free, you start to realise that this will take a bit of thought. This was precisely the situation that was facing GT Diamond, a company that has always relished a challenge since it started up in 1996. The first part of this project required the controlled demolition of a flying chamber area in the upper part of the storm tank. In order for this to be removed, a Top Tec robotic demolition unit was lowered down on to the floor of the balcony and, through a process of pecking and crushing, the Top Tec removed the vast majority of the structure leaving what remained to be cleanly cut away. The main body of the project was the removal of a 1 m thick concrete wall. Because of the location and the limited access the wall would have to be cut into manageable sections which then could be transported away from site. It soon became apparent that the most efficient way of doing this was to crane the sections out of the storm tank and up through the roof of the building above. In order to fi t between the roof trusses of the building, the sections would need to be no more than 600 mm wide and 3.5 m high. Even though the storm tank was designed to hold significant volumes of water the job required work to be carried out in a confined space with limited access and due to the threat of flooding all equipment had to be removed at the end of the shift and reinstalled the next day. The 8 m wide wall was cut using a Hilti TS20 wall saw with Hilti drill rigs, using 3 phase motors. Great care had to be taken that no resulting slurry could enter into the water system, which could result in contamination. The project clearly illustrates the advantages of using diamond cutting technology over traditional methods: accuracy of cutting, low levels of vibration and minimal debris. It also demonstrates how often in this industry you need to put your thinking cap on when a customer comes to you with a problem for you to solve.
Contacts: GT Diamond Drilling Services, 26 Fairfield Road, Dundee, DD3 8HR. Tel: 01382 813399 www.gtdiamonddrilling.com Hilti (Great Britain) Limited, 1 Trafford Wharf Road, Trafford Park, Manchester, M17 1BY. Tel: 0800 886 100 www.hilti.co.uk
20 | CONCRETE CUTTER 2路2011
The Hilti TS20 wall saw cutting into the 8 m wide by 1 m thick concrete wall View showing the roof which was removed using a Top Tec robotic demolition unit
A 3.5 m high by 600 mm wide section of the wall being lifted away
INDUSTRY NEWS Looking below the surface World of Concrete 2011 saw the launch of Hilti’s PS 30 and PS 35 ferrodetectors. These ferrodetectors look beneath the surface to help locate hazards within concrete and masonry, such as reinforcement bars or metal pipework. These hazards not only present a safety risk, but are also a potential source of costly delays to the progress of building work when coring and drilling The PS 30 and PS 35 ferrodetectors are capable of locating reinforcing bars in concrete up to a depth of 120 mm as well as copper or aluminium pipes in concrete or masonry to a depth of up to 75 mm – with an accuracy of ± 10 mm. The PS 30 can determine whether a reinforcing bar, copper or aluminium pipe is located beneath the concrete surface before drilling in order to avoid destroying expensive bits or tools or cutting through structurally-relevant reinforcement. The PS 35 takes it one step further by indicating the depth of the detected object before expensive damage is done to concealed pipes or cables. And, the PS 35’s maximum detection range can be set so that the tool only detects these objects within a certain distance, helpful for setting anchors at a specific depth. The PS 35 is designed to locate rebar, copper, EMT in concrete, CMU, or brick. Both the PS 30 & 35 ferrodetectors are easy to use with single button operation and easy-to-read red and green LED indicator lights, and come with durable rubber casing designed to withstand tough jobsite conditions. Backing the Hilti PS 30 & 35 ferrodetectors is Hilti’s Calibration Service to help ensure reliability and accuracy. Even with Hilti’s built-in protection features, precision instruments can be affected by everyday use. Through the Calibration Service, the ferrodetectors will be calibrated and adjusted as needed, with the calibration confirmed in writing. The PS 30 & 35 ferrodetectors are also covered by Hilti’s Lifetime Service, which includes two years of no-cost coverage. www.hilti.com
Slurry solution from Golz Golz (UK) Limited is marketing a portable filtering system called the Golz Air Slurryfox SFP8L which offers an on-site green solution for the management of concrete slurry. The system won the top award in innovation & design at the 2009 Sweden Construction expo. Golz claims that its Air Slurryfox represents a revolution in recycling, being one of the most efficient methods of dewatering liquids from solids. It provides a portable, easy to use, air powered filter press, which effectively separates water and solids within EPA regulations, for reuse or proper disposal. Therefore no more leaking slurry pits, storage drums and no more dumping fees or expensive hauling costs. Slurry recycling is a hot topic within the diamond cutting industry today. So much so, that the USA’s Concrete Sawing & Drilling Association sponsored a roundtable at the 2009 World of Concrete exhibition to discuss developments in the recycling of concrete slurry. In some countries, slurry recycling has been mandatory for several years, and regulations in the UK are likely to be tightened up in the near future. Clearly, the traditional approach of just dumping slurry onto the ground is becoming less acceptable and dumping the slurry down the sewer can result in hefty fines. Homemade systems can be as simple as lined pits where the slurry is dumped and allowed to settle then the clear water is removed and neutralized before reuse. These pits though can be costly to construct. Other cutting contractors allow the slurry to settle and then run it through a filtering system. Portable manufactured systems may end up being cheaper than hauling the slurry. The Slurryfox has received positive reviews so far. ISG Pearce purchased one for a new build Asda site in Gorseinon, Swansea. The company confirmed that it proved very successful, removing 25 tonnes of slurry from the site with the end product, the slurry cakes, being sent to a cement kiln. This meant the whole of the waste was 100% recycled. Craig Welmers of ISG Pierce stated that the Slurryfox was an excellent machine and would be happy to recommend it to anyone in the construction industry for the removal of on-site slurry. Golz (UK) Ltd, Unit A5, Springhead Enterprise Park, Northfleet, Kent, DA11 8HB. Tel: 01474 321679 www.golz.co.uk
CONCRETE CUTTER 2·2011 | 21
High-power electric wall saw The latest in Husqvarna’s series of electric wall saws, the WS 482 HF, is based on the same technology as the WS 440 HF launched last year but can hold up to 1600 mm diameter blades and is operated by radio remote control. It has a newly developed two-speed gearbox combined with variable speed transmission, which allows the optimal speed to be set according to blade diameter, blade type and cutting material. Husqvarna has succeeded in optimizing the power-to-weight ratio and has developed a saw that is lightweight and flexible while at the same time being extremely powerful. The WS 482 provides a total of 19 kW to the blade shaft with a 32 amp fuse, despite the saw weighing only 28 kg. A great advantage is that if only 16 amps are available at the workplace, the WS 482 still delivers a high power of 9 kW. Husqvarna claims that no other electric wall saw on the market today can do this. Just like all Husqvarna products, the WS 482 HF was developed to make the operator’s work easier and more efficient. The saw is of modular construction, making it easy to hang on the wall and transport. It is possible to cut on both sides of the track. Its direction of rotation can be selected so that the water always sprays in the desired direction – irrespective of which side of the track you saw on. These combined properties, says Husqvarna, make its electric wall saws unique. The PP 480 HF is the power pack for the WS 482. It weighs only 23 kg, is compact and ergonomically designed and thus very easy to transport. The WS 482 HF powered by the PP 480 will be launched at the end of the year. Contact Richard Scott of Husqvarna Construction Products. Tel: 0844 844 4570 firstname.lastname@example.org
22 | CONCRETE CUTTER 2·2011
INDUSTRY NEWS New sawblade range from Bosch Bosch has introduced a new range of diamond cutting discs and core cutters, which are optimized for high cutting speed and meet the current user requirements for fast work progress. The “Speed Slotted” cutting segments are said to reduce side friction and ensure fast removal of material dust. These advantages, together with the selected optimum size of the diamonds used and the self-sharpening effect of the diamond segments, ensure top scores in cutting speed. Bosch has increased the segment height on the diamond cutting discs to up to 15 mm and on the diamond core cutters to up to 11.5 mm. This gives these accessories their very long lifetime. The diamond cutting discs are available in diameters of up to 500 mm for application ranges such as stone, abrasive and asphalt in the “Best”, “Expert” and “Professional” performance categories for all relevant machines. The range of diamond core cutters comprises all accessories for wet and dry drilling. The range structure is strictly geared towards the applications, and is based on a clear differentiation between three performance categories. One, two or three diamonds are shown on the packaging, so that the user can identify these categories. The new colour coding of the range indicates which materials the discs are suitable for. Together with the self-explanatory, clearly arranged
From pole to pole
pictograms on the packaging, this enables easy and quick selection of the optimum diamond accessory for the application. This saves the user time. It also reduces the amount of assistance retailers need to provide to their customers and increases their sales success. There is a clear relation between the product design and packaging design, and these provide a high-quality, attractive overall impression at the POS. Bosch manufactures all of its diamond tools to the highest quality standard in accordance with the European standard EN13236, in order to ensure that the user receives the highest possible level of safety. email@example.com
A Coventry explorer wants to achieve a world first – and two city businesswomen – one of them a DSA member – are backing him to do it. Mark Wood, 44, is a full-time explorer and is planning to be the first person to walk solo to the South Pole and the North Pole back-toback. He is currently in the process of raising sponsorship money for the adventure, which he will begin later this year and is set to take six months.
Julie White, managing director of D-Drill (Master Drillers) Ltd and a board member of the DSA, and Lee Thomas managing director, of Aesthetics Events Ltd, have both sponsored Mark in his efforts and they will also join him later this year as he walks to the Base Camp on Everest. A military service followed by employment in fire and rescue gave Mark his thirst for adventure and it went on from there. This walk will see Mark facing some of the earth’s toughest climates, with temperatures dropping down to -60 °C. He said, “This is going to be my toughest ever challenge – nobody has ever done it before. You need to do something that has never been achieved in order to get your message across. I can then use that as a platform to help talk on issues such as climate change. While I am undertaking a challenge, I very often feedback what I am doing to schools around the world.” Julie (pictured on the left) is also preparing for her own challenge as well as supporting Mark in his. Julie said, “We are delighted to be supporting Mark. It’s great to see a local guy taking on such an amazing international task and also educating young people in the process. Our part is nothing compared to his but it is still going to be unbelievably tough. It should be a fantastic experience and is one we are both very much looking forward to.”
CONCRETE CUTTER 2·2011 | 23
INDUSTRY NEWS HSE guidance on guarding of diamond drilling trailers The HSE has issued a Sector Information Minute (SIM 02/2011/04) on the use of diamond drilling trailers. The SIM, entitled “The Prevention of Entanglement in the Rotating Parts of Drilling and Piling Rigs” covers a wide range of drill rigs (geotechnical, mini piling, tunnelling, rock bolting, etc), and specifically includes diamond drilling trailers. Historically, rotating parts on many of these machines have not been guarded despite the requirements of the Provision and Use of Work Equipment Regulations (PUWER) 1998, the Supply of Machinery (Safety) Regulations 2008. These guidance notes seek to address that. Diamond drilling trailers, also often called diamond coring trailers/rigs, can be defined as self-contained and trailer mounted diamond drilling machines. They usually comprise a hydraulically powered diamond drill and a pumped water tank mounted on a towable chassis. They are commonly used to drill large diameter holes in runways and taxiways for runway light installation, and also in highways and car parks for core testing and safety barrier or bollard installation. Diamond drilling trailers are very specialist pieces of plant and should not be confused with the more widely used stand or hand held diamond drilling machines, which are not included within this HSE guidance note. Normal operation of the drill rig must be practicable with the guards fitted. Guards should ideally be fixed however it is generally accepted that it is impractical to operate with a fixed guard so the next best option is interlocked guards. The notes state, “Interlocks need to be sufficiently robust to withstand site conditions, the vibration that comes with drilling operations and not easily defeated. Simple roller switches are unlikely to withstand vibration, which can exacerbate through the structure of the guard and are easily defeated, as are some plunger style devices. Coded magnets are more difficult to subvert. Where possible the interlock should be such that if it is not connected or operational then rotational power is not available.” Magnetically coded interlocked systems as used by Major Diamond Supplies Ltd are accepted as achieving this. These use special matched switches that only operate when the two halves are next to each other. When the guard is opened the rotating drill must stop thus protecting the operator and other passers by on site. A simple low cost solution is to stop the engine, but this is not very practicable. The better method is to stop the rotation of the drill whilst leaving the feed controls operative to allow diamond drill bits to be removed and extension rods fi tted. To find out more, go to www.hse.gov.uk and search for SIM 02/2011/04.
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24 | CONCRETE CUTTER 2·2011
INTERNATIONAL NEWS Annual General Meeting of the International Association of Concrete Drillers & Sawers The 19th Annual General Meeting of the International Association of Concrete Drillers & Sawers (IACDS) took place on May 6, 2011 in Bruges, Belgium. The IACDS is the umbrella organisation representing the individual national professional drilling and sawing associations from the concrete construction and renovation industry around the globe. Its mission is to provide an international union to support and promote the development of professional drilling and sawing contractors and their methods. Membership is composed of the national Drilling and Sawing Associations of Australia, Austria, Germany, Japan, Spain, Sweden, Switzerland, United Kingdom and USA. In addition, there are 18 individual members comprising either major suppliers to the industry or single companies from countries with no affiliation to the IACDS. At this year’s meeting, two applications for membership were received, one from the French national association (SNED-SCBD), the other from the contractor ReverR based in the Czech Republic. Three years ago, 35 companies formed SNED, a division of the French national demolition association SCBD. As there are around 350 companies operating in the French market, the association has much potential for growth. Both candidatures were approved unanimously.
Among the many topics discussed at the meeting was the first IACDS Seminar held during the Bauma exhibition in Munich, last year. Those who attended the seminar witnessed a crowded conference room full of professionals who wanted to hear one or more of the eight speeches on the latest technologies in the field of concrete drilling and sawing. Following the success of this seminar, it was agreed to organise a second one to take place during Bauma 2013. Another international promotional event that the IACDS has been involved with for some time is the Diamond Award, a competition open to all contractors worldwide to submit entries showing excellence and innovation in the field of concrete cutting. The winners were presented with their awards at a press conference this January during the World of Concrete trade show in Las Vegas, USA (see page 27). The meeting agreed that the next Diamond Award should be presented during Bauma 2013, which takes place in April of that year. Full details of the completion will be announced towards the end of this year. Each member association reported on the state of the business within its own country and as expected most stated that they were still feeling the effects of the economic downturn with turnovers sometimes decreased by more than 50%.
CONCRETE CUTTER 2·2011 | 25
INTERNATIONAL NEWS straight-edge grooving is that it reduces tyre wear, rubber build-up and edge chipping, thereby increasing the pavement life. It also gives a comparable coefficient of friction and greatly improves drainage run-off capacity. The second presentation by John Willis from Tyrolit UK discussed the advantages of diamond grinding of concrete roads compared to overlaying with asphalt using a recent example on an 8-mile stretch of the A12 in Essex. The diamond grinding technique was shown to be half the cost of overlaying concrete with asphalt, was much faster and required considerably lower investment in capital plant. Also, the new pavement demonstrated a 33% reduction in noise levels and an increase in skid resistance of 54% . The meeting concluded with the election of a new President to take over from the DSA’s Peter White following the end of his two-year tenure. Spain’s José Blanco was elected unanimously to be President for the period 2011/2013. Lasse Sandström of Sweden agreed to stand as the second Vice President. The 2012 annual conference was scheduled for March 6, 2012, to coincide with the 40th AGM of the US-based CSDA. This will take place in Maui, Hawaii.
Interestingly though, a few countries – notably Austria, Germany, Sweden and Switzerland – reported a healthy position, with the overall construction industry in each country flourishing helped by the fact that relationships with banks regarding credit facilities being positive. Germany had even brought back the BeBoSa Trade Show in March this year with such success that it will be repeated in 2014, one year after Bauma. Other topics discussed at the meeting included the update of the worldwide market survey on the drilling and sawing industry (see Table), a draft of the proposed amendments to the IACDS tolerances, proposals for training and PR activities and the preparation of an international dictionary. Two presentations were given, both on grinding/grooving of concrete highways. The first by Philip Zuzelo from Cardinal Grooving in the USA gave details of an innovative method of grooving which produces trapezoidal shaped grooves on airport runways. Airport runway grooving is employed to increases the coefficient of friction of the runway surface, reduce hydroplaning in heavy rainfall and therefore reduce the stopping distance of the plane in wet or dry conditions. The advantages of trapezoidal grooving over traditional
Global market estimates for the concrete sawing and drilling industry Country
Number of Association members
Total number of companies
Percentage Association membership
Average turnover per company ($)
Estimated total market ($)
Date info supplied
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
26 | CONCRETE CUTTER 2·2011
Diamond Award winners announced The International Association of Concrete Drillers and Sawers (IACDS) has announced the winners of the Diamond Award, an international competition for excellence and innovation in the field of concrete cutting. The winners were presented with their awards at a press conference in January this year during the World of Concrete trade show and exhibition in Las Vegas, USA. The gold medal in this competition was awarded to Tondin srl of Italy for the company’s outstanding work in the tunnels of a rail system that connects Bologna to Florence. The project involved large quantities of concrete cutting over a two-year period to increase safety in the tunnel system. This included the modification of around 2,300 existing lateral safety recesses by cutting out the base of the reinforced concrete slab, the cutting out of over 300 new safety recesses in the tunnel wall and making over 13,000 lin. m of cuts elsewhere within the tunnel.
From left to right: Julie White (D-Drill), IACDS President Peter White, Rodolfo Spessato (Tondin srl) and Victorria Garcia de la torre Acosta (Thayr sl)
The silver for second place went to Thayr of Spain, for its work on a wharf expansion project at the port of Huelva in the southeast region of the country. The cutting work was performed underwater using diamond wire sawing techniques to cut and remove 26 reinforced concrete piles that were 1,200 mm in diameter and made from reinforced concrete with a 6 mm steel casing. Each 20 m deep pile was cut into two sections for removal by crane using a combination of diamond drilling and diamond wire sawing. One of the reasons Thayr was chosen for this project was the company’s previous experience in underwater cutting work. For this project it called in its regular underwater services company who supplied a fi ve man diving team to supplement Thayr’s two operatives and one assistant assigned to the job. Equipment used for the cutting work comprised two hydraulic power units, two 4 W drill rigs, hydraulic drilling equipment and a multi-pulley diamond wire system.
Tondin of Italy took the gold award for major concrete cutting work on the rail tunnels that connect Bologna to Florence
The cutting contractor used a great deal of innovation to perform some of the work, using twin mechanical arms mounted to the front of ‘Jumbo’ excavation vehicles, one fi tted with a chain saw, the other with two discs. Over 80% of the recesses were successfully completed using these remote controlled Jumbos – this in itself was the key factor in completing the job in time. In total, the job involved the sawing of around 20,000 m2 of reinforced concrete and the drilling of 6,000 lin. m of concrete to accommodate wire sawing and for miscellaneous works.
Thayr took the silver award for using underwater drilling and wire sawing techniques to cut and remove 26 reinforced concrete piles on a wharf expansion project in southeast Spain
CONCRETE CUTTER 2·2011 | 27
INTERNATIONAL NEWS D-Drill Master Drillers Ltd of the United Kingdom won the bronze award, for its care and precision in using a wire saw to remove a 100-year-old tile mural during a hospital renovation. Several collections of Royal Doulton panels displaying a number
D-Drill from the UK won the bronze award for its care and precision in using wire sawing to remove a 100-year-old tile mural
of scenes from famous nursery rhymes had been on display for over 100 years. The tiles, which are worth thousands of pounds, were mounted across the hospital’s children’s ward during the reign of Kind Edward VII (1901-1910). A custom-made 110 volt wire saw was engineered to complete the job that had strict noise and vibration tolerances. Demolition work had already started when D-Drill was called in to remove the tiles without damage so they could be remounted at the new state-of-the art RVI hospital being built in Queen Victoria Road in the city. The Diamond Award competition allows concrete sawing and drilling industry professionals to present their most complex and innovative projects. Entries were judged on the degree of difficulty, planning, complexity, innovation and the quality of the work produced to ensure project success. Following a detailed review of each entry, the judging panel representing members of various countrywide sawing and drilling association chose the winning projects. The 2011 awards included entries from countries like Japan, Italy, Mexico and the UK among others. The competition began in 2000 in Germany and award ceremonies are rotated around the globe in conjunction with major exhibitions. IACDS is an international trade association of sawing and drilling associations from the concrete construction and renovation industry. The organisation was formed in 1995 and is composed of associations from Australia, Austria, France, Germany, Japan, Spain, Sweden, Switzerland, the UK and the US. www.iacds.org
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28 | CONCRETE CUTTER 2·2011
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