Hydrodemolition steigert Produktivität bei Brückenprojekt auf den Philippinen

 

Ganz gleich, um welches Projekt es sich handelt – von einem einfachen Bauwerk bis hin zu einem massiven, mehrere Millionen Dollar teuren Brückensystem – eine effiziente Konstruktion erfordert eine gründliche Planung. Aber selbst bei einer einwandfreien Logistik können Projekte auf Herausforderungen stoßen, die die Fristen in Gefahr bringen.

 

Auf den Philippinen wird derzeit ein massives Brückensystem gebaut, das Cebu City mit Cordova am südlichen Ende der Insel Mactan verbindet. Der 8,5 Kilometer (5,3 Meilen) lange Cebu-Cordova Link Expressway, der 2021 fertiggestellt werden soll, wird den Mactan-Kanal mit einer Durchfahrtshöhe von 51 Metern (167 Fuß) für Schiffe überspannen. Sie verspricht, die Staus zwischen Cebu und Mactan zu verringern und die wirtschaftlichen Aktivitäten in der gesamten Region anzukurbeln, indem sie schätzungsweise 50.000 Fahrzeugen pro Tag einen zusätzlichen Zugang zur Insel und zum internationalen Flughafen Mactan-Cebu bietet.

Wie nicht anders zu erwarten, ist der Bau – eines der größten Infrastrukturprojekte des Landes – auf einen sorgfältig choreographierten Plan gleichzeitiger Arbeiten angewiesen, um strenge Fristen einzuhalten. Dank einer ausgefeilten Logistik können viele Hürden umgangen werden, aber es können auch unvorhergesehene Herausforderungen auftreten. Als eine schlechte Betonmischung die Arbeiten an einem der ersten Pfeiler der Brücke zu gefährden drohte, brauchten die Projektmanager eine kreative Lösung, um den minderwertigen Beton schnell zu entfernen, ohne die Bewehrung zu beschädigen oder den Zeitplan zu gefährden. Hydrodemolition war das einzige Verfahren mit der nötigen Präzision und Produktivität, um das Projekt auf Kurs zu halten.

Cebu Link Joint Venture (CLJV) wandte sich an Asia Waterjet Equipment mit Sitz in Singapur, den führenden Experten für Hydrodemolition in der Region. Der Zugang und die Bedingungen vor Ort stellten eine ziemliche Herausforderung dar, aber mit jahrzehntelanger Erfahrung in einigen der gefährlichsten Anwendungen war Asia Waterjet Equipment der Aufgabe mehr als gewachsen. Während die Uhr tickte und die Monsunzeit in vollem Gange war, kam das Team mit einem Aquajet Aqua Cutter 710V Hydrodemolition-Roboter und einer Jetstream HP Wasserstrahlpumpe vor Ort an.

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

Als eine schlechte Betonmischung den Fortschritt eines großen Brückenprojekts auf den Philippinen zu gefährden drohte, wandte sich Asia Waterjet Equipment an Aquajet, um eine kreative Lösung zu finden, mit der der minderwertige Beton schnell entfernt werden konnte, ohne die Bewehrung zu beschädigen oder das Projekt in Verzug zu bringen

 

 

Leidenschaft für das Lösen von Problemen

In den frühen 1990er Jahren gehörten die Gründer von Asia Waterjet Equipment zu den tapferen Mannschaften, die die Aufgabe hatten, die während des Golfkriegs zerstörten Ölquellen in Kuwait einzudämmen. Ihre Erfahrung half, eine große Umweltkrise abzuwenden. Sie blieben im Nahen Osten und gründeten schließlich 2006 Asia Waterjet Equipment, das Hochdruckwasserstrahlen und robotergestützte Hydrodemolition in den Nahen Osten und nach Südostasien brachte.

Mit Niederlassungen in Dubai, Abu Dhabi, Saudi-Arabien, Bahrain und Singapur und einer starken Präsenz und Partnerschaften in diesen Gebieten ist das Unternehmen für kreative Problemlösungen bekannt. Es liefert innovative Schneid- und Reinigungslösungen für gefährliche Bereiche oder schwer zu pumpende Produkte in der Petrochemie, im Abwasserbereich, im Bergbau, im Bauwesen und in anderen Branchen. Das Unternehmen bietet auch eine Reihe von Roboterlösungen an, die den Kunden helfen, ihre Mitarbeiter zu schützen und die Erwartungen zu übertreffen.

“Wir haben uns schon immer darauf konzentriert, hochmoderne Werkzeuge anzubieten, um anspruchsvolle Anwendungen sicherer und effizienter zu machen”, sagt Chris Parkhill, Asia Waterjet Equipment Sales Director für Südostasien. “Von Anfang an waren wir an einigen der gefährlichsten Arbeiten beteiligt. Wir kennen die Anforderungen und Gefahren. Deshalb arbeiten wir mit branchenführenden Anlagenherstellern zusammen, um robuste Lösungen zu entwickeln, die die Sicherheit und Produktivität maximieren.”

Durch die Kombination der richtigen Werkzeuge mit erfahrenen Teammitgliedern, die eine Fülle von Branchenkenntnissen und ein tiefes Verständnis der lokalen Märkte in jedes Projekt einbringen, hat sich Asia Waterjet Equipment einen Ruf für hochwertige Ergebnisse erworben. In aufstrebenden Märkten wie den Philippinen, wo die Anforderungen millionenschwerer Projekte zu einem Testfeld für neuere, effizientere Technologien geworden sind, verschafft dieses Know-how dem Unternehmen eine Vorreiterrolle.

“Von Nordafrika bis Südostasien decken wir ein weites Gebiet ab”, sagte Parkhill. “Aber der Schlüssel zu einer erfolgreichen Lösung ist die Fähigkeit, den Auftragnehmer dort zu treffen, wo er sich befindet. Bei der Zusammenarbeit mit CLJV mussten wir eine Reihe von Herausforderungen meistern, um das Projekt auf Kurs zu halten. Hydrodemolition war die beste Lösung und Aquajet war das beste Werkzeug für diese Aufgabe.

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

Um die Bewehrung und den vorhandenen guten Beton zu schützen, wusste Asia Waterjet Equipment, dass Hydrodemolition die einzige Lösung war. Bei dieser nicht-intrusiven Methode werden Hochdruck-Wasserstrahlen mit einer Stärke von bis zu 40.000 psi eingesetzt, die von einem automatisierten Roboter bedient werden, um Schichten von verfallenem und beschädigtem Beton zu entfernen.

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

Crews mit Handhämmern oder Baggern konnten den minderwertigen Beton zwar entfernen, aber nur, indem sie den Betonstahl zerstörten. Asia Waterjet Equipment wusste, dass Hydrodemolition das einzige Verfahren mit der nötigen Präzision und Produktivität war, um das Projekt am Laufen zu halten.

 

 

Trübes Wasser

Der Zugang war das Hauptproblem. CLJV führte die Bauarbeiten an mehreren Brückenpfeilern gleichzeitig durch. Um die Beeinträchtigungen für die örtliche Bevölkerung so gering wie möglich zu halten, waren der primäre Bereitstellungsbereich des Projekts sowie der erste Pfeiler nur von der Küste aus zugänglich. Das bedeutete, dass der Beton 2,5 Kilometer (1,6 Meilen) küstenabwärts gemischt und dann per Lastkahn zur Baustelle transportiert werden musste. Von dort aus wurde der Lastkahn auf Grund gesetzt, und die Lastwagen konnten direkt am Strand entladen werden. Der Pfeiler lag 30 Meter (98 Fuß) landeinwärts.

Insgesamt hatte die Transportverzögerung keine negativen Auswirkungen auf den Beton, und der 16 mal 14 Meter große Pilon wuchs schnell auf eine Höhe von 4 Metern (13 Fuß) an. Eine Komplikation bei einer einzigen Lieferung drohte jedoch das gesamte Projekt in Verzug zu bringen und das Budget zu sprengen.

“Wenn man mit Beton arbeitet, laufen die Dinge manchmal nicht nach Plan”, sagte Parkhill. “Es ist schließlich eine heikle Gleichung, und schon ein kleiner Rechenfehler kann die Mischung ruinieren. Wenn das passiert, gibt es leider keine einfache Lösung.”

Die Crews wussten sofort, dass es ein Problem gab. Der Beton war bereits am Erstarren, als sie pumpten. Rütteln und andere Korrekturmethoden schlugen fehl, und der Guss war letztlich erfolglos. Noch schlimmer war, dass der Beton 350 Millimeter (13,8 Zoll) zu kurz war und ein Netz aus freiliegenden Bewehrungsstäben hinterließ.

Für CLJV und Asia Waterjet Equipment summierten sich die Herausforderungen und machten die Reparatur zu einer sehr schwierigen Angelegenheit. Der Pfeiler war fast vollständig zerstört. CLJV hatte zwar Zeit und Geld für kleinere Komplikationen eingeplant, konnte es sich aber nicht leisten, den gesamten Pfeiler abzureißen und neu zu beginnen.

Crews mit Handhämmern oder Baggern könnten den minderwertigen Beton entfernen, aber nur, indem sie den Bewehrungsstahl zerstören. Sie müssten den freiliegenden Bewehrungsstahl am oberen Ende des Pfeilers durchschneiden, um an den Beton einen Fuß darunter zu gelangen. Beim Entfernen des minderwertigen Betons würden weitere Bewehrungsstäbe beschädigt werden, und die durch die Vibrationen der Presslufthämmer oder Bagger verursachten Mikrobrüche würden den verbleibenden Beton schwächen und die Integrität des Pfeilers gefährden.

“Es gab keine andere Möglichkeit. Der Bewehrungsstahl und der vorhandene gute Beton mussten geschützt werden”, sagte Parkhill. “Wenn CLJV herkömmliche Abrissmethoden anwenden würde, müssten sie das Gebäude öffnen, die Bewehrung aufbrechen oder durchschneiden und den schlechten Beton mit einem Presslufthammer herausschlagen. Es gibt keine Garantie dafür, dass ein Mann mit einem Presslufthammer beurteilen kann, was gut und was schlecht ist, so dass sie am Ende noch mehr entfernen müssten. Dann müssten sie den Betonstahl wieder an seinen Platz biegen, ohne ihn zu brechen, oder neue Gewinde schweißen oder schneiden und mit Gewindekupplungen verbinden. Das würde das Projekt um Wochen verlängern und das Budget erheblich belasten. Das konnten sie sich einfach nicht leisten.”

Asia Waterjet Equipment wusste, dass Hydrodemolition die einzige Lösung war. Bei dieser nicht-intrusiven Methode werden Hochdruck-Wasserstrahlen mit einer Stärke von bis zu 40.000 psi eingesetzt, die von einem automatisierten Roboter bedient werden, um Schichten von verfallenem und beschädigtem Beton zu entfernen. Das Hochdruckwasser übersteigt die Festigkeit des Betons, um vorhandene Poren und Mikrorisse zu erweitern und den Beton auf kontrollierte Weise aufzubrechen. Im Gegensatz zu anderen mechanischen Methoden ist Hydrodemolition stoßfrei und eliminiert die Vibrationen, die Mikrorisse verursachen.

Außerdem erfüllt die Methode die europäische Norm EN 1504 und bietet eine hervorragende Haftfläche für neuen Beton. Der Hochdruck-Wasserstrahl des Aqua Cutter 710V hinterlässt nach dem Entfernen der ersten Betonschicht ein raues, unregelmäßiges Profil, das zu einer besseren Bindekraft führt. Der Roboter reinigt und entkalkt auch die freiliegenden Bewehrungsstäbe und entfernt nicht sichtbare Verunreinigungen wie Schmutz, Schlamm, Fundamentschlamm, Salze, Chloride und Sulfate.

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

Mit der Fähigkeit, Beton bis zu 25 Mal schneller zu entfernen als eine Handlanze, war der Aqua Cutter von Aquajet die notwendige Lösung, um das Projekt von Asia Waterjet Equipment im Zeitplan zu halten.

 

 

Brücken bauen

Auch die Produktivität war ein Problem. Da gleichzeitig an mehreren anderen Pfeilern in der Gegend gebaut wurde, mussten die Teams den minderwertigen Beton entfernen und die Reparaturen schnell und mit minimalem Arbeitsaufwand durchführen.

Mit der Fähigkeit, Beton bis zu 25 Mal schneller zu entfernen als eine Handlanze, war der Aqua Cutter die notwendige Lösung, um das Projekt im Zeitplan zu halten. Asia Waterjet Equipment holte Aquajet Special Application Manager Kjell Isaksson zur Unterstützung des Projekts hinzu.

“Es gab viele Variablen und keinen Spielraum für Fehler”, sagte Parkhill. “Um das Risiko von Verzögerungen zu minimieren, beschlossen wir, dass es am besten wäre, einen Aquajet-Spezialisten vor Ort zu haben.

Wie die Zementlaster mussten auch der Aqua Cutter und die gesamte Ausrüstung, einschließlich eines Hochdruck-Wasserstrahlaggregats mit einer Jetstream-Pumpe der Serie 4200, die Baustelle vom Mactan Chanel aus erreichen. Die Nähe zum Wasser und die häufigen, starken Regenfälle während der Monsunzeit erschwerten die Bodenverhältnisse. Da der Aqua Cutter jedoch selbstfahrend ist und über Ketten verfügt, stellte das unebene, schlammige Gelände für Asia Waterjet Equipment kein Problem dar. Dies minimierte die notwendigen Vorbereitungen vor Ort und half, die Reparaturen zu beschleunigen.

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

Das unebene, schlammige Gelände auf der Baustelle stellte für den selbstfahrenden Aqua Cutter kein Problem dar. Dies minimierte die notwendigen Vorbereitungen vor Ort und half, die Reparaturen zu beschleunigen.

Überqueren Sie die Brücke zum Erfolg

Diese Mobilität war auch notwendig, um den Abriss selbst in Angriff zu nehmen. Nachdem der Aqua Cutter von einem Kran die 4 Meter (13 Fuß) auf die Pfahlkappe gehoben worden war, konnte er problemlos über den Betonstahl manövrieren. Die Hochdruckpumpe wurde 7 Meter (23 Fuß) entfernt aufgestellt und über einen Hochdruckschlauch mit dem Hydrodemolition-Roboter verbunden.

Um die Kosten zu senken und die Produktion zu steigern, entschied sich Asia Waterjet Equipment dafür, für den Großteil der Abbrucharbeiten Meerwasser zu verwenden, anstatt Frischwasser heranzuschaffen. Das Unternehmen füllte kontinuierlich zwei 20-Kubikmeter-Nachttanks (5.283 Gallonen) direkt aus dem Mactan Chanel. Süßwasser wurde nur in den letzten beiden Tagen des Projekts verwendet, um Salz und andere Verunreinigungen zu entfernen, die die Haftung beeinträchtigen könnten.

Mit dem Hydrodemolition-Roboter, der mit 1.000 bar (15.000 psi) arbeitet, und zwei Mitarbeitern entfernte Asia Waterjet Equipment innerhalb von Tagen 10 Kubikmeter (13 cubic yards) schlechten Beton in einer Tiefe von 150-250 Millimetern (6-10 inches).

“Mit dem Aquajet Aqua Cutter konnten wir die Produktivität so weit steigern, dass die Bauarbeiten wieder im Zeitplan lagen”, sagte Parkhill. “Ohne Hydrodemolition hätte CLJV das nicht geschafft.”

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

Mit dem Hydrodemolition-Roboter, der mit 1.000 bar (15.000 psi) arbeitet, und zwei Mitarbeitern entfernte Asia Waterjet Equipment 10 Kubikmeter (13 cubic yards) minderwertigen Beton in einer Tiefe von 150-250 Millimetern (6-10 inches).

 

 

Die Zukunft der Hydrodemolition

Während der Bau des Brückensystems weitergeht, ist Asia Waterjet Equipment bereits mit der nächsten Herausforderung beschäftigt.

“Das Bauwesen in Südostasien verändert sich”, sagte Parkhill. “Roboterverfahren wie Hydrodemolition beweisen, dass man Produktivität und Sicherheit haben kann. Mit innovativen Partnern wie Aquajet spielt Asia Waterjet Equipment eine führende Rolle bei der Erleichterung dieses Wandels.”

 

 

 

Kurze Fakten

Lage:
Ein massives Brückensystem, das Cebu City mit Cordova am südlichen Ende der Insel Mactan auf den Philippinen verbindet.

Brückenprojekt:
Der 8,5 Kilometer (5,3 Meilen) lange Cebu-Cordova Link Expressway, dessen Fertigstellung für 2021 geplant ist, wird den Mactan-Kanal mit einer Durchfahrtshöhe von 51 Metern (167 Fuß) für Schiffe überspannen.

Hydrodemolition-Projekt:
Selektive Betonentfernung von minderwertigem Beton ohne Beschädigung der Bewehrung oder Verzögerung des Projekts.

Abgerissenes Material:
10 Kubikmeter (13 cubic yards) minderwertiger Beton in einer Tiefe von 150-250 Millimetern (6-10 inches).

Ausrüstung: Aqua Cutter 710V.

 

 

Mehr Informationen

Aqua Cutter 710V

Hydrodemolition

Aquajet weltweites Händlernetz

 

 

Druckfähiges pdf

Aquajet vor Ort – Die innovative Roboterlösung von Aquajet sorgt für Produktivität bei einem philippinischen Brückenprojekt