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Precision rock removal with Alpine Rockwheel

Posted by Chip Kogelmann

May 31, 2016 4:57:16 PM

An interesting project is underway in the State of Indiana in the USA.  The contractor is using an Alpine D30 Rockwheel installed on a CAT336 excavator to precisely remove 4-ft of hard limestone shelf rock in order to place 96-ft long concrete box culverts in a river tributary.  The job required rapid and precise rock removal as well as a smooth, flat finished surface.  The D30 rock grinder was the ideal tool for this job.  Hydraulic hammers were not an option because of the rough irregular surface they create and inability to cut accurately within inches to get the final grade right.  A further benefit was the generation of ground rock which can be reused onsite rather than hauled away.  Alpine Rockwheels are the go-to tool for rapid and precise rock cutting.  See video:  https://youtu.be/a1PdLC_feac 

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Topics: Excavation, Rockwheel

Alpine D20 RockWheel for Rock Trenching: When is a RockWheel the best call?

Posted by Chip Kogelmann

Jun 12, 2015 3:08:27 PM

With regard to trenching in rock, a frequent question I get from customers and equipment dealers is "When do I use a RockWheel vs. a hammer or ripper bucket?"  The answer is somewhat simple, the RockWheel is the best option when the ground is too hard to rip with a bucket yet not so hard that a heavy hammer is required.  There is a wide range of rock strength that falls within this RockWheel Zone as the figure below illustrates.

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Of course we live in a world of nuances and gradients where the choice isnt always so easy so here are a few other pointers on when a RockWheel should be the tool of choice for a rock trenching job:

  • If the hammer is just punching holes in the rock, a RockWheel is a better option.
  • If noise and seismic disturbance (e.g. in residential area or near sensitive structures) is an issue, the quieter, smooth cutting RockWheel is a better option.
  • If you want to create reusable fill (2" and smaller rock cuttings) and not bring in a crusher, a RockWheel is a better option
  • If a flat trench bottom is required, the RockWheel is a good choice.  Even if you option to break out the rock with a hammer, the RockWheel can be used to trim the walls and trench bottom.
  • If the rock is highly fractured, the RockWheel is an excellent choice because the many teeth on the drums will act as multiple rippers and excavator very rapidly.
  • If a slot cut it desired, not the "V" trench one gets with a hammer, a RockWheel is an excellent choice.

An Alpine D20 RockWheel was rencently employed for sewer line trenching in upstate, NY.  The very hard shale was not rippable with the CAT 345 bucket with Tiger Teeth and becasue it was in a residential zone with concerns about noise, a hammer was problematic. Alpine installed a D20 RockWheel on a new LinkBelt 250X4 (Tier 4).  The LinkBelt was easily programmed to allow three speed & torque settings for the RockWheel and the customer made rapid headway in the trenching job.  When the rock was softer he went for faster drum RPMs and when  harder rock was encountered, they went for lower RPMs but more torque in seconds.  The result was a trench cut to the excact cross section without any overbreak or extra width at the top as is often the case when trenching with a hammer.  Moreover, the milled rock made for perfect pipe bedding and backfill, saving the cost of bringing in this material.

 

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Here are a few photos:IMG_7800

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Topics: Cutter Heads

How to: Do's and Don'ts of Rockwheel Operation

Posted by Ryan Leech

May 29, 2015 11:00:00 AM

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Operationally, the Rockwheel is a simple tool: push the button and the drums spin, rock is engaged and it starts cutting. To help operators get optimal work out of a Rockwheel, we made a short video on how to hit the "sweet spot" while cutting. Check it out!

 

 

 

 

 

 

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Topics: Concrete Grinding, Rockwheel, How-to

Does your Hoe Ram do this?

Posted by Ryan Leech

Apr 21, 2015 1:30:00 PM

This is debris direct from a RockWheel G5 cutting on a concrete block. 

Quick cutting + usable backfill = $$$ saving

 

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Topics: Concrete Grinding, Rockwheel

Watch the RDC 22.20 Working in 60" Headroom

Posted by Ryan Leech

Apr 16, 2015 11:00:00 AM

RDC Demo Robot with Rockwheel G5Alpine RDC Robot equipped with G5 RockWheel excavating hard ground beneath a sensitive structure.

The RDC Robot was a zero emission solution and was the only machine suitable for working in the confined space that was limited to 60-inches of headroom.

 

 

 

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Topics: Demolition Robot

How Deep into Rock Will a RockWheel Cut?

Posted by Ryan Leech

Apr 14, 2015 10:30:00 AM

deep_cutterheadWhen you are placing a bid on an excavation project there are an abundance of factors that you are taking into consideration.

There are concerns about the geographical location of the project site and the conditions you will potentially face and what equipment and manpower will be necessary to complete the task to the customer’s highest level of satisfaction.

One piece of equipment that is extremely useful in a variety of excavation applications is a cutterhead.

Like most tools, cutterheads come in a variety of options, including specialized custom cutterheads available for particularly challenging or unique situations.

Cutterheads offer numerous advantages over simpler excavating products such as hydraulic hammers.

The enhanced functionality of a cutterhead will give you more precise control over the quality and structure of your Rockwheel_foundationexcavationexcavation projects.

In addition to better overall performance, cutterheads also have the ability to lower costs and improve the efficiency of your project as well.

How deep will a cutterhead cut?

Today we’re going to look specifically at one aspect of cutterhead performance that is important to excavation projects, namely, how deep will a cutterhead cut?

The short answer is that cutterheads theoretically have the ability to operate at any depth, but they are dependent on the excavator or carrier machine they are attached to for reach and depth.

The power and rate at which a cutterhead operates should be constant, so the biggest restriction to a cutterhead’s ability to cut is how far the carrier machine can physically put the cutterhead into the ground.

This means the machine type will obviously have an impact on how the cutterhead performs. Knowing what excavator or carrier machine you have will affect the scope of your project.

Know beforehand what type of excavator or carrier machine you will be attaching your cutterhead to and you’ll be able to determine how deep your cutterhead will be equipped to cut.

Different machines have different capabilities, and even factors such as the machine’s weight and dimensions will change the way a cutterhead performs.

If you have any specific questions about an attachment or need help installing a cutterhead, feel free to contact one of our team members here at Alpine.

There are a few other factors that will directly impact the depth at which a cutterhead will perform.

These include the specific type of cutterhead you select as well as the surrounding conditions of the project site.

The soil type and the surrounding landscape such as the presence of fault lines, utility lines, and any other obstacles will have a direct correlation to how deep the cutterhead can safely excavate.

Cutterheads have the capability to operate at any depth you need to get the job done, and most scenarios will need to be evaluated on a case by case basis.

Find out everything you need to know about rock grinding with a cutterhead

 

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Topics: Cutter Heads, Trenching, Excavation

Soil mixing equipment to address in situ soil remediation challenges

Posted by Chip Kogelmann

Apr 7, 2015 11:28:44 AM

Every individual worksite comes with its own set of complications.IMG_1965

One challenge that can increase the complexity of your project is the presence of pollution or contaminants. When a site is known to be contaminated, it may be required to go through a process of remediation by law.

Remediation is the act of restoring soil to a safe, stable, and consistent state that is ecologically friendly. This can often be an expensive and time consuming process that adds difficulty to your project depending on the type of contaminant in the soil and the proliferation of contamination.

These factors influence the severity of contamination and can help you determine the best course of action to remediate the soil so that development can proceed.

Alpine provides a wide variety of soil remediation equipment that is designed to simplify the neutralization of contaminants. Our soil remediation equipment comes with options and customizations that provide you with the ability to select exactly the tools you need to complete the job.

If your project is a small one and you do not anticipate the need for your own soil remediation equipment, we also offer rentals. Whether you are looking to rent or buy, Alpine has the solution to your soil remediation needs.

One standard set of soil remediation equipment Alpine provides are powerful rock and concrete cutting tools that have been repurposed for soil mixing, remediation, and stabilization. These powerful tools are extremely useful for soil mixing which can help neutralize even some of the most volatile organic compounds.

These soil remediation mixing tools eliminate wasted time and make the process of soil mixing more efficient.

One of the best features of our soil remediation equipment is its level of customizability. Whatever your situation calls for, Alpine provides a variety of options and customizations to meet your needs. From transverse mixers and axial mixers, to drum lacing and mixing paddle layout, Alpine has it all.

Our company also has equipment for specific problems, such as container mixing or work in lined ponds or work areas where puncturing could be an issue. If puncturing needs to be avoided, soil remediation equipment can be paired with depth limiters and bumpers to ensure that puncturing does not occur.

Another special circumstance could call for the use of wet amendments. We provide soil remediation equipment with additive injection piping that is suitable for both wet and dry amendments.

The use of Alpine soil remediation equipment can greatly reduce your project cost by keeping soil remediation on-site. By removing the need for transportation, your project can proceed efficiently and cost effectively.

The majority of Alpine equipment can simply be attached to standard excavators, backhoes, and skid steer loaders which prevents the need to purchase any other special equipment. If your worksite is contaminated, contact Alpine today to find the right soil remediation equipment to take care of your contamination in situ.

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Topics: Soil Mixing, Soil Remediation

Alpine TC-B2 on site, ready to roll

Posted by Ryan Leech

Jan 30, 2015 11:44:57 AM

Our ace tech Jeremy looks on after installing a TC-B2 on a Cat318. The site required rock removal but without the heavy vibration that either a hammer or drill/blast would create.

Best solution: Alpine Cutterhead.

Alpine TC-B2,  75hp cutterhead

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Topics: Construction

Alpine Rockwheels Used in Secant Shaft Construction

Posted by Chip Kogelmann

Jan 16, 2015 11:46:40 AM

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For larger diameter shafts through unstable soils, the use of interlocking hard / soft CFA (continuous flight auger) piles is a highly cost effective method of shaft sinking.  Alpine’s RockWheel rock & concrete grinders are often an important tool in these projects. 

 

Constructing a shaft typically involves five main stages:

 1)      Piles are drilled to required depth to form a continuous wall for the shaft. Piles are formed by drilling to the required depth using a hollow stem continuous flight auger. After reaching the designed depth, a concrete is then pumped through the hollow stem. While the concrete is being pumped, the auger is withdrawn at a controlled rate, removing the soil and forming a shaft of concrete.  Overlapping concrete columns form the supporting shaft wall. 

2)      A ring of reinforced concrete is constructed around the top of the shaft to support the shaft wall.

3)      Once the outer frame is in place, the main shaft is excavated  out with the material lifted to the surface.

Secant Wall scaling with Alpine cutterhead

4)      Shaft excavation is stopped at specific depths to construct reinforced concrete or steel support rings.  For water proofing or installation of support rings, the shaft wall must be ground smooth.  Alpine’s excavator mounted rock and concrete grinders are an ideal tool for rapid and precise concrete grinding.  The Alpine grinders can be installed in  place of the bucket on the excavator being used to dig out the shaft.

 5)      Excavation is then completed to the required depth and a steel reinforced concrete slab is constructed at the base of the shaft.

 Alpine has a wide range of RockWheel sizes allowing the grinding attachment to be utilized on excavators of any size from 1.5-ton minis to 50+ ton heavy excavators.

 

 

 

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Topics: Concrete Grinding

Precision Concrete Scaling in Wet Conditions with a Rockwheel

Posted by Ryan Leech

Dec 16, 2014 11:00:00 AM


Concrete Dam Scaling Alpine TC-DOne of the more challenging excavation site conditions is the removal of concrete in wet conditions.

The presence of water can drastically reduce the efficiency of an excavation operation by severely limiting the capacity of equipment. To finish these projects in a timely manner, the tools used for the job become very important.

The requisite amount of planning and preparation inevitably increases when dealing with wet conditions. In addition to determining what equipment decisions will result in the best work, greater attention to scaling and the slope of grades is needed to ensure that the project will proceed safely at an efficient pace. In situations that call for concrete scaling in wet conditions, an ALPINE drum cutter is usually the best tool for the job.

ALPINE drum cutters are precise and powerful instruments that are specifically designed to improve control in scaling. Whether you are operating in wet or dry concrete, drum cutters will provide you with the ability to handle the excavation efficiently. Our cutter heads limit the impact angle between the cutter bits and the surface to create a smooth wall that leaves the underlying concrete undisturbed. This prevents the development of micro-cracks and ensures the material remains sound.

Depth gauges are also available to assist in the process of measured scaling. Depth gauges can be used to check top plate angles and cutter length which allows you to limit how deep the cutter head can go into the concrete. If you are looking for improved control, using a depth gauge with your ALPINE drum cutter will provide the improvement you’re looking for.

Excavator2ALPINE drum cutters are well equipped to limit excavation volume. Whether working in wet or dry conditions, our cutter heads have the ability to improve the efficiency of your project by crushing concrete to a fine enough size that it can be used as fill matter on site. No further crushing is necessary which means costly transportation expenses are eliminated as well as additional costs associated with further crushing.

Using an ALPINE cutter head will simplify your project by reducing the unnecessary steps that notoriously waste time and expenses. The bottom line results in a more efficient worksite that saves you valuable time and money.

ALPINE cutter heads are also viable options for projects that require underwater scaling. This would be valuable at a site that included a dock or marine facility. It is only a simple matter of using one small oil plug swap to make the cutter head water tight and then the cutter head will work with the same functionality it provides in dry applications.

The power and precision afforded by an ALPINE drum cutter makes it the perfect solution for scaling in wet conditions. These carefully designed cutter heads are the logical choice for sensitive removals that require a certain amount of precision. With the superior control the cutter head provides, limiting excavation excess, and the flexibility to work underwater, ALPINE cutter heads are the solution for your next concrete project.     

Ready for more information?

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Topics: Cutter Heads, Concrete Grinding

About this blog

This blog is a resource for research, how-to's, and general news regarding rock grinders, transverse cutter heads, roadheaders, and alternatives to hydraulic hammers. 

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