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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.<\/p>\n
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As expected, the construction\u00a0 \u2014 one of the largest infrastructure projects in the country \u2014 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\u2019s 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<\/a> was the only process with the precision and productivity to keep the project on track.<\/p>\n Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment<\/a>, the region\u2019s 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<\/a> Hydrodemolition robot and Jetstream HP Waterjetting Pump.<\/p>\n <\/p>\n When a bad batch of concrete threatened to derail progress on a major bridge project in the Philippines, Asia Waterjet Equipment turned to Aquajet for a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule<\/em><\/p>\n <\/p>\n <\/p>\n Passion for Problem Solving<\/strong><\/p>\n In the early 1990s, Asia Waterjet Equipment\u2019s 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<\/a> and South East Asia<\/a>.<\/p>\n Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain<\/a> and Singapore<\/a> and a strong presence and partnerships throughout these territories, the company is known for creative problem solving \u2014 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.<\/p>\n \u201cOur focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,\u201d said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. \u201cFrom the very beginning, we\u2019ve 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.\u201d<\/p>\n 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.<\/p>\n \u201cFrom North Africa to South East Asia, we cover a lot of ground,\u201d Parkhill said. \u201cBut 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.\u201d<\/p>\n <\/p>\n To protect rebar and the existing good concrete, 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.<\/em><\/p>\n <\/p>\n Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. Asia Waterjet Equipment knew Hydrodemolition was the only process with the precision and productivity to keep the project on track.<\/em><\/p>\n <\/p>\n <\/p>\n Troubled Water<\/strong><\/p>\n Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project\u2019s 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.<\/p>\n Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) \u00a0pilon 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.<\/p>\n \u201cWhen you are working with concrete, sometimes things don\u2019t go to plan,\u201d Parkhill said. \u201cIt\u2019s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn\u2019t an easy fix.\u201d<\/p>\n Crews knew there was a problem immediately. The concrete was already setting as they pumped. \u00a0Vibrating 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.<\/p>\n 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.<\/p>\n 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\u2019s integrity.<\/p>\n \u201cThere was no option;\u00a0the rebar and existing good concrete had to be protected,\u201d Parkhill said. \u201cIf CLJV went with traditional demolition methods, they\u2019d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There\u2019s no guarantee a man using a jack hammer could gauge what\u2019s good and what\u2019s bad, so they\u2019d end up removing extra. Then they\u2019d 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\u2019t afford it.\u201d<\/p>\n 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.<\/p>\n Additionally, the method meets European Standards EN 1504<\/a> and provides a superior bonding surface for new concrete. The Aqua Cutter 710V\u2019s 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.<\/p>\n <\/p>\n With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aquajet\u2019s Aqua Cutter provided the necessary solution to keep the Asia Waterjet Equipment\u2019s project on schedule.<\/em><\/p>\n <\/p>\n <\/p>\n Building Bridges<\/strong><\/p>\n 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 \u2014 with minimal labor.<\/p>\n 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.<\/p>\n \u201cThere were a lot of variables and no room for error,\u201d Parkhill said. \u201cTo minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.\u201d<\/p>\n 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.<\/p>\n <\/p>\n The uneven, muddy terrain at the jobsite presented no problems for the self-propelled Aqua Cutter. This minimized necessary site preparations and helped accelerate repairs.<\/em><\/p>\n \u00a0<\/strong><\/p>\n Crossing the Bridge to Success<\/strong><\/p>\n 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.<\/p>\n 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.<\/p>\n 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.<\/p>\n \u201cWith the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,\u201d Parkhill said. \u201cWithout Hydrodemolition, there\u2019s no way CLJV would have been able to do that.\u201d<\/p>\n <\/p>\n 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).<\/em><\/p>\n <\/p>\n <\/p>\n The Future of Hydrodemolition<\/strong><\/p>\n While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge.<\/p>\n \u201cConstruction in Southeast Asia is changing,\u201d Parkhill said. \u201cRobotic processes like Hydrodemolition are proving you can have productivity and<\/em> safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.\u201d<\/p>\n <\/p>\n <\/p>\n <\/p>\n Location:<\/strong> Bridge project:<\/strong> Hydrodemolition project:<\/strong> Material demolished:<\/strong> Equipment:<\/strong> Aqua Cutter 710V.<\/p>\n <\/p>\n <\/p>\n Aqua Cutter 710V<\/a><\/p>\n Hydrodemolition<\/a><\/p>\n Aquajet global dealer network<\/a><\/p>\n <\/p>\n <\/p>\n<\/h5>\n
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\nShort facts<\/h3>\n
\nA massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island in the Philippines.<\/p>\n
\nThe 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.<\/p>\n
\nSelective concrete removal of poor-quality concrete without damaging the rebar or putting the project behind schedule.<\/p>\n
\n10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches).<\/p>\n
\nMore information<\/h3>\n
\nPrintable pdf<\/h3>\n