Dry Coring and Dry Wire Sawing in Reinforced Concrete
Dry Coring and Dry Wire Sawing in Reinforced Concrete
Dry Coring and Dry Wire Sawing in Reinforced Concrete
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<strong>Dry</strong> <strong>Cor<strong>in</strong>g</strong> <strong>and</strong> Cutt<strong>in</strong>g – Typical Applications<br />
<strong>Dry</strong> <strong>Cor<strong>in</strong>g</strong> <strong>and</strong> <strong>Dry</strong> <strong>Wire</strong> <strong>Saw<strong>in</strong>g</strong><br />
<strong>in</strong> Re<strong>in</strong>forced <strong>Concrete</strong><br />
BAUMA - IACDS 2010<br />
Applications<br />
• Probes to assess level of contam<strong>in</strong>ation <strong>in</strong> chemical <strong>and</strong> nuclear plants<br />
• Removal of anchors to prepare surface removal <strong>in</strong> power plants<br />
• Drill<strong>in</strong>g of through holes for <strong>in</strong>stallations <strong>in</strong> sensitive environment<br />
• <strong>Saw<strong>in</strong>g</strong> of open<strong>in</strong>gs <strong>in</strong> re<strong>in</strong>forced concrete<br />
• <strong>Saw<strong>in</strong>g</strong> of wood/concrete structures e.g. parquet on concrete<br />
• Rehabilitation of historical build<strong>in</strong>gs<br />
Mart<strong>in</strong> Gödickemeier,<br />
Ernst Siegenthaler<br />
Hilti Corporation, Schaan, Pr<strong>in</strong>cipality of Liechtenste<strong>in</strong><br />
Challenges<br />
• Drill<strong>in</strong>g <strong>and</strong> saw<strong>in</strong>g methods <strong>in</strong>volved usually need water cool<strong>in</strong>g<br />
• Cool<strong>in</strong>g water leads to secondary damage <strong>in</strong> sensitive environment<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 1<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 2<br />
Proposed Solutions for <strong>Dry</strong> Cutt<strong>in</strong>g <strong>and</strong> <strong>Cor<strong>in</strong>g</strong><br />
Conventional Technology needs water cool<strong>in</strong>g<br />
Applications<br />
Hilti solutions<br />
<strong>Dry</strong> drill<strong>in</strong>g <strong>in</strong><br />
re<strong>in</strong>forced concrete<br />
• Polycrystall<strong>in</strong>e diamond<br />
cutters PCD<br />
• Efficiency of drill<strong>in</strong>g<br />
process allows dry<br />
operation<br />
• Through holes for<br />
diamond wire<br />
<strong>Dry</strong> wire saw<strong>in</strong>g <strong>in</strong><br />
re<strong>in</strong>forced concrete <strong>and</strong> steel<br />
• Electroplated Diamond wire<br />
• Cool<strong>in</strong>g length allows for dry<br />
operation<br />
• Cutt<strong>in</strong>g of re<strong>in</strong>forced concrete<br />
• Cutt<strong>in</strong>g of steel structures<br />
Segment matrix<br />
Re<strong>in</strong>forced concrete<br />
10 mm<br />
Plough<strong>in</strong>g<br />
Crack<strong>in</strong>g<br />
Diamond<br />
1 mm<br />
Cutt<strong>in</strong>g direction<br />
500 microns<br />
• Process with low efficiency<br />
• Primarily a gr<strong>in</strong>d<strong>in</strong>g process<br />
f<strong>in</strong>e debris produced<br />
• Water cool<strong>in</strong>g needed except<br />
for wire saw<strong>in</strong>g<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 3<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 4<br />
1
Polycrystall<strong>in</strong>e Diamond PCD for <strong>Dry</strong> Drill<strong>in</strong>g<br />
PCD carrier<br />
Cutt<strong>in</strong>g<br />
Re<strong>in</strong>forced concrete<br />
¼<strong>in</strong>ch<br />
Cutt<strong>in</strong>g direction<br />
¼<strong>in</strong>ch<br />
• Process with high efficiency<br />
• Primarily cutt<strong>in</strong>g<br />
coarse debris produced<br />
• Air cool<strong>in</strong>g feasible<br />
1 mm<br />
PCD cutt<strong>in</strong>g – Effect on Gra<strong>in</strong> Size of Debris<br />
Share <strong>in</strong> volume [%]<br />
12<br />
10<br />
8<br />
6<br />
4<br />
PCD<br />
Diamond Segment<br />
2<br />
0<br />
1 10 100 1000<br />
Gra<strong>in</strong> size [µm]<br />
• Coarse debris can be removed easily<br />
• Energetically favorable process<br />
• Coarse debris facilitates dust collection<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 5<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 6<br />
Energetic Considerations<br />
Geometrically Def<strong>in</strong>ed Cutters<br />
Diamond impregnated<br />
segments – wet<br />
PCD cutter – dry<br />
W 0 = 1900 J/mm 3 W 0 = 380 J/mm 3<br />
W heat = 1600 J/mm 3<br />
W heat = 330 J/mm 3<br />
Fracture energy<br />
Plastic<br />
deformation<br />
Plastic<br />
deformation<br />
Fracture energy<br />
5x higher efficiency with PCD<br />
Basic experiments – lathe test on re<strong>in</strong>forced concrete<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 7<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 8<br />
2
<strong>Dry</strong> drill<strong>in</strong>g with Poly Cristall<strong>in</strong>e Diamonds<br />
<strong>Dry</strong> drill<strong>in</strong>g with Poly Cristall<strong>in</strong>e Diamonds<br />
PCD Drill bit ∅ 1 5/8´´, 7 ft deep hole cor<strong>in</strong>g<br />
6.6 ft<br />
Complete core<br />
Sta<strong>in</strong>less steel with anchor<br />
Steel core<br />
Alu<br />
0.06“<br />
Graphite<br />
10“<br />
Fe St.37<br />
1“<br />
Lead<br />
4 cm<br />
C-Steel<br />
½“<br />
<strong>Concrete</strong><br />
60“<br />
C-Steel<br />
1“<br />
Lead core Graphite Alum<strong>in</strong>ium<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 9<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 10<br />
The Hilti <strong>Dry</strong> <strong>Cor<strong>in</strong>g</strong> System – DD 200 air cooled<br />
The Hilti <strong>Dry</strong> <strong>Wire</strong> <strong>Saw<strong>in</strong>g</strong> System<br />
Diamond equipment<br />
Start<strong>in</strong>g aid<br />
DS WS15-E electrical 400V wire saw cpl. system<br />
Core Bit<br />
DD-B PCD<br />
DD 200<br />
air cooled motor<br />
DD-HD 30 drillst<strong>and</strong><br />
Key features enabl<strong>in</strong>g dry saw<strong>in</strong>g<br />
• Adjustable wire speed<br />
• >10 m <strong>in</strong>ternal wire storage cool<strong>in</strong>g by convection<br />
• <strong>Wire</strong> guards to protect operator<br />
• Dust collection channels<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 11<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 12<br />
3
Hilti VC 40-U Vacuum Cleaner with APFC<br />
Cost of Diamond Tools <strong>and</strong> <strong>Cor<strong>in</strong>g</strong> Equipment<br />
Outlast<br />
Robust design <strong>in</strong>- <strong>and</strong><br />
outside,<br />
Jobsite suitability<br />
Outperform<br />
Compact filter <strong>and</strong> <strong>in</strong>telligent<br />
plac<strong>in</strong>g of hose connection <strong>in</strong><br />
suction head<br />
Best <strong>in</strong> class<br />
volume/capacity ratio<br />
Diamond tools<br />
Core bits 4“ 1200 USD 0.5 – 2 m life expectancy<br />
2“ 900 USD<br />
<strong>Wire</strong> (electroplated) 150 USD/m 1 m 2<br />
Easy filter access<br />
Comfortable h<strong>and</strong>l<strong>in</strong>g,<br />
easy clean<strong>in</strong>g, time sav<strong>in</strong>g<br />
Advanced Power Filter Clean<strong>in</strong>g<br />
Technology<br />
Permanent <strong>and</strong> high<br />
suction performance<br />
Diamond equipment<br />
Dust collection unit<br />
Start<strong>in</strong>g aid<br />
350 USD<br />
1000 USD<br />
Robust tank <strong>and</strong> big wheel<br />
diameter<br />
Reliability, easy<br />
transport on the jobsite<br />
Easily changeable dust bag<br />
Comfortable h<strong>and</strong>l<strong>in</strong>g,<br />
easy dust removal, time<br />
sav<strong>in</strong>g<br />
DD 200 core rig<br />
3000 USD<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 13<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 14<br />
Does it pay off? – Example Nuclear Application<br />
<strong>Dry</strong> wire saw<strong>in</strong>g <strong>in</strong> re<strong>in</strong>forced concrete<br />
30000<br />
Application Cost USD<br />
25000<br />
20000<br />
15000<br />
10000<br />
5000<br />
reducable by<br />
evaporation<br />
Waste disposal<br />
Diamond tools<br />
Manpower<br />
0<br />
Conventional<br />
<strong>Dry</strong><br />
Application: Open<strong>in</strong>g <strong>in</strong> re<strong>in</strong>forced concrete of 2 x 2 x 1.5 m<br />
Manpower 80 USD/h, <strong>in</strong>clud<strong>in</strong>g preparational work<br />
Disposal 8000 USD/m 3<br />
Total drill<strong>in</strong>g <strong>and</strong> cutt<strong>in</strong>g time comparable for conventional <strong>and</strong> dry<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 15<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 16<br />
4
<strong>Dry</strong> wire saw<strong>in</strong>g with - dust removal<br />
<strong>Dry</strong> wire saw<strong>in</strong>g – Dust Collection Channel<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 17<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 18<br />
<strong>Dry</strong> wire saw<strong>in</strong>g <strong>in</strong> nuclear power plant, UK<br />
Opportunities & Applications<br />
Renovation <strong>in</strong> critical areas<br />
• All double walled structures <strong>in</strong> sensitive environment<br />
• Wood/concrete comb<strong>in</strong>ations<br />
• Operation <strong>in</strong> sensitive environment:<br />
Food process<strong>in</strong>g/storage, IT <strong>in</strong>frastructure, concrete plants, nuclear <strong>in</strong>stallations<br />
• Historic monuments<br />
Application cost are higher than <strong>in</strong> conventional operation<br />
20x for cor<strong>in</strong>g<br />
4x forwiresaw<strong>in</strong>g<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 19<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 20<br />
5
Conclusions<br />
• Efficient <strong>and</strong> reliable dry decommision<strong>in</strong>g of re<strong>in</strong>forced concrete<br />
strucures is only possible by comb<strong>in</strong><strong>in</strong>g PCD drill<strong>in</strong>g <strong>and</strong> dry wire<br />
saw<strong>in</strong>g.<br />
• <strong>Dry</strong> drill<strong>in</strong>g of re<strong>in</strong>forced concrete is only possible with PCD<br />
technology. High energy efficiency allows air cool<strong>in</strong>g.<br />
• <strong>Dry</strong> cutt<strong>in</strong>g of re<strong>in</strong>forced concrete is possible with wire saw<strong>in</strong>g.<br />
Short engaged length of wire gives high cool<strong>in</strong>g length.<br />
Reliable dry cutt<strong>in</strong>g <strong>and</strong> cor<strong>in</strong>g of re<strong>in</strong>forced concrete <strong>and</strong> steel is available.<br />
www.hilti.com<br />
IACDS Bauma 2010 sem<strong>in</strong>ar | ZH-Goedickemeier | 2010-04 21<br />
6
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