{"data":{"news":{"items":[{"title":"Aquajet introduces Aqua Cutter 750V hydrodemolition robot","date":"2022-02-03 11:09:10","id":3504,"author":"","blurb":"","blurb_image_uid":"https://dxfpracgmlczp.cloudfront.net/2022/01/1643375036129_Aquajet_Aquacutter750V_1-1536x1046.jpg","blurb_expanded_image_uid":null,"article":"\n\t\n\n\n

Aquajet has introduced its latest hydrodemolition robot, the Aqua Cutter 750V. This new model features Aquajet’s patented Infinity oscillation that moves the water jet in an infinity – or figure 8 – pattern, removing more concrete in a single pass while reducing shadowing, eliminating the risk of pipe holes and providing an ideal bonding surface.

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Unveiled at the World of Concrete exhibition in Las Vegas, which took place from 18 to 20 January 2022, the new Aqua Cutter 750V is equipped with the next generation Evolution 3.0 control system that incorporates new functions, including the ability to automatically calculate optimal settings for lance motion for greater precision and efficiency.

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Like all Aqua Cutter robots, the 750V cleans and descales rebar without causing microfracturing. It also maintains exceptional horizontal, vertical and overhead reach, making it suitable for a wide variety of concrete removal tasks, such as renovation and bridge and road repair.

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“Infinity oscillation is the next technological evolution, and it is changing how hydrodemolition contractors think about productivity,” explained Roger Simonsson, managing director of Aquajet. “In the coming years, we will see it replacing rotating lances and similar tools to become the new industry standard. With the productivity gains realised during customer testing, the Aqua Cutter 750V is a significant advancement for hydrodemolition.”

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The new machine offers constant lance motion in an infinity – or figure 8 – pattern, rather than the standard wave pattern that has natural fluctuations in speed. The continuous movement of the infinity pattern allows the 750V to remove more material in a single pass, significantly reducing shadowing and making it unnecessary to follow-up with hand lancing.

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The consistent motion also increases the digging effect and virtually eliminates pipe holes, resulting in a superior bonding surface and increased productivity. Another benefit is the constant, low noise that is less disruptive in urban areas and other noise-sensitive environments.

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“Do you know what this level of performance means?” asked Alessandro Campa, managing director of Atümat, Aquajet’s distributor in Switzerland, when he saw the 750V operate for the first time. “It’s the biggest revolution in the history of hydrodemolition.”

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The Aqua Cutter 750V shares several similarities with Aquajet’s Ergo System. The infinity power head has Ergo-style spring-tensioned rollers and quick connection to the roller beam. It also uses absolute sensors, which means it automatically adjusts at the touch of a button. With a larger roller width and a new triangulated base frame for improved stability, the infinity power head contributes to precision while improving the hydrodemolition result.

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As part of the revolutionary design, the Aqua Cutter 750V also includes an upgraded version of the Evolution control system. First released in 2004, this innovative control system still features Aquajet’s patented Equal Distance System (EDS) as well as the ability to cut shapes and remove concrete at different depths in the same pass. The new version ratchets up its performance even more with an oscillation menu that automatically calculates optimal settings for the operator. This not only maximises production from the machine, but also prevents miscalculations from manual adjustments.

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Another key feature is remote start and stop of the diesel engine through radio remote control, making it possible for the operator to stop or start the robot from a safe distance and eliminating the need for the machine to run all day. In addition, the machine will automatically shut down if there’s no activity for a certain amount of time, saving battery power.

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The engine control on the 750V offers increased power, thanks to the automatic speed-controlled throttle that automatically adapts RPMs to the load. This improves sustainability with lower fuel consumption and emissions.

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The Evolution 3.0 control system uses a visual status light to show the state of the machine with different colours. This allows operators to easily see when the machine is working correctly, when it needs attention and when automatic functions or the engine have stopped.

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The 750V also offers a new level of performance with Aquajet’s precision drive. This technology provides highly accurate hydraulic movements, eliminating the inconsistencies that compromise the result. In automatic mode, the robot’s lance is highly controlled and always keeps the water jet in the ideal position, which is key to achieving an excellent hydrodemolition result.

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With an all-new tracked system, the 750V is smooth-driving, similar to a car. The smooth motion increases service life by eliminating bounces that can compromise components and improves the accuracy of nozzle distance to surface, further improving precision.

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What’s more, the 750V is compatible with Aquajet’s line of accessories, including the rotolance, circular power head and Aqua spine. It is also compatible with Aquajet’s Ecosilence high-pressure pump that supplies the water to run the machine and provides a cost-effective option for transport and storage. Finally, Aquajet’s EcoClear is a fully automated system that allows contractors to treat water on-site and release it or recirculate it in the robot.

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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-km Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-m navigational clearance for shipping vessels. It is aimed 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.

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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 considered the only process with the precision and productivity to keep the project on track.

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Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier hydrodemolition experts. 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.

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Asia Waterjet Equipment delivers innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. The company also offers a range of robotic solutions. Headquartered in Dubai, UAE, Asia Waterjet Equipment also has offices in Abu Dhabi (UAE), Saudi Arabia, Bahrain, and Singapore.

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“Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, sales director for Southeast Asia at Asia Waterjet Equipment. “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 maximise safety and productivity.”

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“From North Africa to Southeast Asia, we cover a lot of ground,” added Mr Parkhill. “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.”

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Troubled water

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Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimise 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 km 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 m inland.

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Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-m pilon quickly grew to 4 m tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget.

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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 mm short, leaving a mesh of exposed rebar.

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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.

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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.

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“There was no option; the rebar and existing good concrete had to be protected,” said Mr Parkhill. “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.”

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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.

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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.

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Self-propelled hydrodemolition robot

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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 labour.

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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.

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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 minimised necessary site preparations and helped accelerate repairs.

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This mobility was also necessary for tackling the demolition itself. Once lifted 4 m onto the pile cap by a crane, the Aqua Cutter was able to easily manoeuvre over the rebar. The high-pressure pump was set up 7 m away and connected to the hydrodemolition robot by a high-pressure hose.

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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-cu-m 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.

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Using the hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cu m of poor-quality concrete at a depth of 150-250 mm in days.

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“With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” said Mr Parkhill. “Without hydrodemolition, there’s no way CLJV would have been able to do that.”

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Aquajet Systems offers three power packs for powering Aqua Cutters, the company’s range of hydrodemolition robots: the standard Aqua Power Pack, the Ecosilence and the Aqua Skid. The power pack is a combination diesel engine and high-pressure pump, necessary for hydrodemolition.

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“We understand that not all projects are the same, which is why we have developed a series of power packs to best meet your operation’s requirements,” said Roger Simonsson, managing director of Aquajet Systems. “The Aqua Packs are designed to accommodate a wide range of projects, whether they require a standard pack, a compact footprint or a quieter alternative.”

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The power packs are cost effective and easy to transport and set up. The standard Aqua Power Pack contains more than just motors and pumps to power the Aqua Cutter; the container also serves as storage for machine accessories and tools. A built-in workbench with a vise provides contractors a space for jobsite maintenance and a place to store spare parts. Operating at as high as 43,500 psi, the standard Aqua Power Packs are available in multiple versions: Aqua Power Pack 270, 400 and 700.

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Similar to the Aqua Power Pack, the Ecosilence provides everything contractors need in a quieter package. Both the standard and Ecosilence measure 7 m by 2.4 m by 2.6 m. The container’s sound-absorbing design features insulated walls and double doors, as well as seals on all doors and hatches. The Ecosilence offers noise levels less than half that of competitive high-pressure units on the market. With an average of 57.5 dB, the unit is ideal for use in urban areas that have high noise restrictions. Users will also see an improved fuel consumption of as much as 10% compared to alternative high-pressure units, said Aquajet.

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The Ecosilence can be equipped with a roll-off frame for simplified on/off truck loading and transport. Maintaining the same dimensions of the standard power pack, the Ecosilence is available in two sizes: the Power Pack 400 and 700 and operates at as high as 18,700 psi.

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Aquajet’s compact Aqua Skid power pack measures 2.6 m by 1.8 m by 1.7 m and provides the same performance and basic functions as the containerised packs, just in a smaller footprint. The compact high-pressure unit is designed for installation on a truck, trailer or local container, which is ideal for contractors or operations with space restrictions, such as plants or factories. Operating at 43,500 psi, this power pack offers contractors a fast and easy way to upgrade an outdated high-pressure unit, plus, the Aqua Skid can be used in areas where metal enclosing - such as the exterior of the standard power pack or Ecosilence - is not necessary or possible.

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Aquajet’s power pack series requires fuel and water to operate. Each is equipped with the Revo Control System, which displays the necessary information to control and monitor the power pack. An optional extension of that system is the Revo Remote Control System, which allows for operation away from the power pack. Each Aqua Pack comes standard with a Volvo engine. Customers can opt for an engine from a different manufacturer, if necessary.

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In addition, the hydrodemolition machine’s remote control can be seamlessly paired to the pump unit. This feature allows the operator to turn the flow on and off and control the flow of the high-pressure water as well as operate the robot from one remote. In the case of an emergency, the operator can completely shut down and depressurise both units from the emergency stop button on the remote, the robot or the power pack.

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To enhance safety, an engine shutoff option on the remote allows for quick shutdown in the field, depressurising the pump and pressure hose and reducing engine rpm to a low idle.

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www.aquajet.se

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Aquajet Systems has launched the Ergo System. This hydrodemolition robot is said to offer four times the power of a hand lance in a compact footprint that contractors can easily move around the jobsite. It is ideal for work on floors, walls and ceilings.

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The Ergo System incorporates several features: the controller unit, which powers and controls the hydraulics; the Ergo Power Head, which manipulates the high pressure lance; and either the spine or the climber, innovative systems used to support and manoeuvre the power head, based on project needs. The climber attaches to any standard scaffolding pipes and robotically moves along it to deliver powerful hydrodemolition forces for vertical concrete removal and repair, such as high-rise construction.

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The Ergo System exerts an impressive 1,000 N of reaction force, which is about half of the force employed by Aquajet’s largest hydrodemolition robot, the Aqua Cutter 710V. According to the company, the Ergo System can handle higher volumes of water, as much as four times greater reaction force than a human operator with a hand lance, allowing the machine to remove concrete faster and easier.

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Hydrodemolition robots, such as the Ergo System, are used to remove concrete to a preset depth consistently. Alternatively, a hand lance will likely leave inconsistent depths due to being held by an operator, said Aquajet, meaning that contractors may have to do another pass with handheld breakers to even out the surface.

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Contractors can easily move the 123-kg Ergo Controller unit around the jobsite and over soft or rough surfaces, thanks to the wide wheels and low ground pressure. The system is also service-friendly with hydraulic hose multiconnectors that are 100% sealed from moisture to virtually eliminate the risk of leaks during transportation.

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The Ergo System requires a high-pressure pump to operate. Aquajet offers a compact Power Pack ideal for the purpose, featuring a high-pressure Hammelmann pump, diesel engine and an integrated control system.

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Aquajet has also launched the Ergo Spine attachment, which wields four times the water reaction force of hand lances, giving contractors a more powerful and safer alternative.

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The Spine includes an Aquajet Power Head attached with a single bolt to a roller beam, which is connected to a spine roller mounted on a spine rail. Depending on the configuration, the setup may be supported by standard support legs, or the spine rail may be attached directly to a surface.

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Aquajet manufactures the roller beam with a lightweight aluminium core coupled with a steel gear rack and guide rails. Beam sections are mounted together with a single bolt. The Ergo Spine roller features a low weight, high strength skeleton base with a wheel setup that divides forces for the ability to handle high reaction forces.

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The spine rail is fabricated with high-strength aluminium, reducing its weight by half compared to steel. A 2-m rail weighs just 20 kg. Despite its lightweight properties, the rail handles the same reaction force as an entirely steel rail. The rail allows for quick connections with a single bolt for different brackets and tools.

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The Ergo Controller’s intelligent sensing controls automatically adjust and move the Power Head along the roller beam. Aquajet’s high-pressure Power Pack, sold separately, provides water pressure and flow to the Power Head´s lance and nozzle, creating a reaction force up to 1,000 N. The Ergo Power Head can tilt at up to a 45-degree angle to attack the material efficiently and oscillates to get the best results for each job.

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As the Power Head moves along the Ergo Spine, it removes concrete in sections as small as 0.25 m up to 2 m, leaving the rebar clean and undamaged. An Ergo Spine with a Power Pack producing 2,800 bar of pressure and 40 l of water per minute can remove an estimated 0.25 cu m of concrete per hour.

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The Spine simplifies use as well as maintenance, and is highly portable. One person can carry and set up the unit and secure it with a single bolt, said Aquajet. All connection points are marked in red, and all bolt sizes on the unit are the same, ensuring easy replacements. Further, the wheeled controller measures just 1 m tall and 0.42 m wide, making it easy to get to the jobsite on a pallet and then move effortlessly around the site.

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The Spine’s standard setup easily tackles concrete walls, floors and ceilings while the side setup delivers hydrodemolition power to narrow spaces.

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www.aquajet.se

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