Piling installation. Cutting pile heads - the process of work, safety and control. Best Choice - Hydraulics

An analysis of the effectiveness of the equipment shows that its performance can reduce the construction time of the structure by several times when constructing a pile field. The economic effect of the application significantly reduces costs. Mechanizing all work operations, you can save human resources, and this is also an increase in safety at the construction site.

Overview of models from leading manufacturers

The construction market today offers various models of pile cutting equipment from well-known manufacturers such as Taets, Delta, Pilemaster, Kinhan.

Pilemaster

In the photo - Pilemaster equipment for cutting piles

Equipos especiales Pilemaster S.A is known not only at home in Spain, but throughout Europe. In Russia, this brand is represented by Stroymost. Keeping pace with the times, the company, together with a Spanish partner, has launched the production of equipment of European standards for solving construction tasks of a narrow specialization. This made it possible to offer Russian builders modern equipment at competitive prices. The tooth extension and retraction time (one cycle) is 8-10 seconds, which makes it possible to cut 1 meter of pile per minute, without taking into account the time required for moving and transporting the felled head.

On the video - the principle of operation of equipment from Pilemaster for trimming piles

The potential of pile-cutting equipment is 4-5 thousand pile heads, then a revision is needed with the replacement of teeth (30 thousand rubles for 4 pieces). Synchronization of the teeth is provided by an active extension synchronization system or (in a simplified version) a ring circuit for connecting power cylinders. It takes 15-20 minutes to install a tooth, which can be changed right at the construction site. The equipment has a one year warranty. The network of warehouses with consumables covers all regions of Russia: Moscow, St. Petersburg, Yekaterinburg, Novosibirsk, Krasnoyarsk.

Taets

In the photo - Taets equipment for cutting piles

Taets from the Netherlands, founded in 1978, is one of the leaders in the production of piercing equipment. Its reputation is impeccable, but the high cost of installations does not allow small construction companies to take advantage of them. The payback of Taets equipment is several years, and this circumstance does not increase the demand and its implementation among foundation-building organizations. Taets has 9 different models of pile cutting nozzles, but only two of them are acceptable for the Russian market, the rest do not comply with GOST.

On the video - cutting your own with Taets equipment

Cutting speed ─ 1 r.m. piles ─ at the Pilemaster level. The potential of the installation is 4-5 thousand pile heads, the subsequent change of teeth is 200 thousand rubles for 4 pieces. Replacement in this case is possible only in the factory, as the technology provides for heating and cooling the tooth to fix it. Synchronization of the cylinders is ensured by an active extension synchronization system. The equipment has a one year warranty.

Kinhan

In the photo - Kinhan equipment for trimming piles

The basis of the Italian company Delta is the equipment of the Chinese brand Kinhan, today it is produced under the domestic brand Impulse SV400. And although the manufacturer denies the similarity with Chinese counterparts, it is positioned precisely as Chinese. The potential of the installations is 3-4 thousand pile heads, when replacing teeth, new ones cost 120 thousand rubles for 4 pieces. The replacement procedure is possible only in the factory, since heating and cooling are necessary to fix the tooth. Warranty period ─ 1 year. Consumers familiar with this equipment compare it to Pilemaster or Taets.

On the video - the process of cutting piles using Kinhan equipment

But experts note differences in power cylinders (Ø is much smaller than other models), which means that its power and performance are much lower. The technical specifications on the dealer website indicate a capacity of 160 piles per shift, which is 20% lower than Pilemaster or Taets. The synchronism of the operation of the power cylinders is not guaranteed by anything. When choosing a supplier, these parameters must be taken into account.

Budget options for installations for felling piles

The construction market offers many other options at a budget price, but sometimes this is their only advantage. The quality of materials has a direct relationship with the performance and service life of the equipment.

Another disadvantage in the equipment of this category will be the ill-conceived fastening of the cutting tooth: with a screw in its center. Unscrewing such a screw even after felling one pile is very difficult, since its head wears out along with the tooth itself, absorbing all the force generated by the hydraulic cylinder.

The installation of a restrictive valve on the body that protects hydraulic cylinders from critical pressures above 240 bar is also suspicious. All this suggests that the material of the hydraulic cylinders is of poor quality and is not able to work under high pressure conditions, as on other modern excavators.

The high pressure hoses are on the outside of the equipment and can be damaged by any falling tip. At the same time, no hose armor is able to protect them from damage and leakage of hydraulic fluid.

The front flange, which acts as a tooth guide, is part of the frame or is welded tightly. This part is subject to wear and cannot be replaced by their design. The teeth are not heat treated and are also subject to wear, which contributes to the failure of the entire installation. Handicraft production of a sling does not have a brand. According to GOST, each lifting mechanism and its components must have a manufacturer's passport and a test mark.

Any of these risks sooner or later turns into a breakdown and downtime of equipment at the construction site. According to the feedback from consumers who used this technique (the St. Petersburg company Sodruzhestvo, the Novosibirsk company Stroymekhanizatsiya), they had to return to the compressor with jackhammers more than once. As you know, there is always a choice. And this choice is yours.

At the end of pile driving, the working area is a palisade of heads of various sizes protruding from the ground. The pile heads are cut off in order to equalize the height of the foundation in a single plane. The reinforcement remaining in place of the cut is used when constructing a reinforced concrete grillage to fasten the piles and the slab into a single structure.

Cutting methods

Felling of reinforced concrete piles is carried out using technologies.

Jackhammer

The method can be applied

for small volumes of work, if ordering special equipment is impractical (for example, during the construction of a cottage).
using an excavator with a jackhammer attachment

Flaws:

Large labor costs.
Low speed.
Shock vibration and rumble.
Valve damage is possible.
There is a risk of damage to the pile body (cracking).

Hydraulic cutting of pile heads

The most modern and popular cutting method.

The equipment is connected to the working boom of a crane or excavator.
Connect to the hydraulic system.
The piston compresses the head, puts pressure on the cutting teeth, crushes the concrete, removes it from the reinforcing frame

The force that falls on the pile in the process of crushing is about 1000 tons.

After cutting

Advantages of the method:

High efficiency (from 250 piles per work shift by two workers using one excavator).
Ease of workflow.
No rumble.
Accurate cut, cracks do not form along the pile body.
Armature does not suffer.
The equipment is reliable, damaged parts are easily replaced.

Flaw:

for small volumes (for example, suburban construction), the use of special equipment is unprofitable.

Pile cutting equipment

1. For manual cutting, a jackhammer is used.

2. Equipment for hydraulics is a system of cylindrical nozzles connected to each other around the circumference. The square pile head is a one piece cast construction with cylinders built into it.

3. Cutting the heads of wooden piles is done with a conventional saw.

Re-ko-men-doo-em to-look:

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We are ready to provide services for felling pile heads anywhere in the Russian Federation. By using TAETS pile head cutting heads, we achieve productivity: prismatic piles - up to 250 heads per shift, BNS - up to 70 heads per shift.

We make felling of pile heads:

Contract method - from 350 r / pile

Rent a nozzle for cutting piles - 22 500 rub/shift

It has long been evident that shockless technology felling of pile heads, which is so rapidly gaining popularity among builders, will very soon completely replace the now widespread "traditional" and obsolete method of dismantling piles with jackhammers. The only argument of builders in defense of the method of felling piles with jackhammers is that it is supposedly cheap.

We are ready to responsibly declare to you that this is not reality.

None of the construction companies that at least once used hydraulic pile cutting at their facilities has ever returned to the old method, having clearly seen the indisputable advantages of the new technology.

Let's try to disassemble the technology of felling piles using the unstressed method.
It should be noted that the key word in the dismantling method is shockless, which implies the complete absence of any destructive dynamic effect on the structure being dismantled.

Head cutting is carried out using a special nozzle, which is a cast or prefabricated metal frame equipped with hydraulic cylinders. The nozzle is one of the types of attachments to the excavator, and the working cylinders are driven by hydraulics.

When the nozzle is put on the pile, the hydraulic cylinders synchronously squeeze the concrete at the design level and the pile head breaks evenly. Further, without expanding the cylinders, the excavator lifts the nozzle up and the chipped concrete is removed from the reinforcement bars. It is very important here that the reinforcement remains completely undamaged. On average, the estimated time of dismantling one square pile takes no more than 3 minutes! That is, in 3 minutes you get a pile with rebar outlets completely ready for work.

If we talk about the speed of dismantling bored piles, there are of course no definite statistics here, since these works are more labor-intensive and time-consuming. The main influence on the speed is exerted by the evenness of the poured piles, as well as the height of the cut heads. If the pile has many irregularities, which usually happens, then in order to pass each of them, it is necessary to add one or more working sections to the nozzle, increasing the diameter of the nozzle, and then unhook it again.

Nevertheless, on average, it will take from 6 to 10 minutes to dismantle the head of a bored pile with a height of no more than a meter.

You should also pay attention to the fact that when felling the reinforced head of a bored pile, a problematic moment arises, namely, the dismantling of concrete in the center of the reinforcing cage. The shape of the reinforcing cage of a bored pile, unlike square piles, does not allow the nozzle to remove the concrete inside. The workflow in this case is as follows: using a hydraulic nozzle, the top layer of concrete of the bored pile is dismantled, then, using a hand-held diamond tool, the pile rod with reinforcement is cut off at the required mark, and the remaining small part of the concrete is removed with a light chipper from the center of the remaining reinforcement issues.

What does the price of felling pile heads depend on?

First of all, this is the type of pile (square or bored).

Secondly, this is the height of the dismantled head (the higher the head, the more times it is necessary to break it). A small digression should be made here, namely: the main working element of the nozzle is hydraulic cylinders with "fingers". The heavier the piece of concrete removed from the pile, the higher the load on the working elements, which in turn can lead to a quick failure of expensive equipment. In practice, if the work is done correctly, when dismantling the head, one break is made for every 20-25 cm, that is, the higher the head, the more working breaks are performed, which in turn leads to an increase in the cost of work.

Thirdly, this is the number of piles. It is no secret that an excavator, a trawl delivering the excavator to the site, two drivers and the nozzle itself are involved in the work. This event is quite costly, but only when we are talking about the need to cut down an extremely small number of piles. Also, the need to cut down a small number of piles in several stages (with a break) may also increase the cost of work, which forces the contractor to carry out additional import and export of equipment, or its downtime.
But in the case when you have several hundreds (thousands) of piles ready for felling, this technology has no competitors in terms of speed and cheapness of work in nature.

Summarizing, we can note the following advantages of pile cutting technology using a nozzle:
- High speed of work execution;
- Silence of the performed works;
- Absence of the shock impact destroying concrete;
- Obtaining undamaged and ready-to-work reinforcing outlets;

All of the above undoubtedly gives a powerful positive economic effect to the Customer.

For example, felling 500 piles up to 400*400mm in size and head height not more than 60 cm will cost the Customer 500 rubles per piece.

The required time for dismantling the specified number of piles is 2-3 shifts! At the same time, you have an excavator on your site, a specialist in the field and a noise level that does not exceed the sound of a running excavator engine, instead of a company of unskilled labor with chippers in their hands.

Termit LLC, today, is rightfully one of the undisputed leaders in the provision of pile cutting services with a nozzle.
In our assets we have several dozens of completed objects of varying complexity and are always ready to provide you with high-quality professional assistance!

Many large construction organizations engaged in pile driving are actively introducing modern technologies in their production. At the end of driving piles, the question regularly arises of leveling and felling the pile heads, as well as preparing reinforcement protrusions for the next stage of concreting. According to the specifications for the installation of pile foundations, work on the destruction of pile heads has its limitations on the use of traditional tools. So for example the use of a hydraulic hammer to destroy the concrete pile head is strictly prohibited, due to the fact that the impact energy of the peaks of the hydraulic hammer is not controlled clearly enough. An unskilled approach to solving this issue and the use of other tools may lead to the formation of longitudinal cracks in the protective layer of concrete of the pile. The solution to all emerging issues is the use of specially designed pile cutting equipment, which can be installed on an excavator, hydraulic manipulator, crane and connected to its hydraulic system. The design of special equipment allows you to control the force and level of pile incision at all stages. The equipment also automatically solves the issue of baring the reinforcement and preparing it for further concreting into the grillage. Even a preliminary analysis of the feasibility of using the equipment shows that the efficiency of piling equipment can significantly reduce the time for construction projects at the stage of piling, and the economic effect can reduce costs by several times. It should also be noted that the mechanization and automation of all workers operations, allows use a much smaller number of workers, which allows noticeably improve safety at the construction site.

At the moment, the construction market offers several models of pile cutting equipment from various manufacturers: Pilemaster, Delta, Kinhan, Taets, Exten. Let's consider them in more detail.

"Equipos especiales Pilemaster S.A" Spain- has become widespread not only in Spain but also in other European countries. In Russia, this company is represented by OOO Stroymost (www.stroy-most.ru). A company that keeps pace with the times, together with the company "Equipos especiales Pilemaster S.A", launched the production of modern equipment for solving special construction problems. This step made it possible to offer modern equipment to Russian construction companies at attractive prices. The required time for one cycle of tooth extension and retraction is 8-10 seconds, which allows cutting 1 m.p. piles in one minute, not counting the time of moving and transporting the felled head. The resource of welding cutting equipment is from 4000 to 5000 pieces. pile heads, after which an revision is made with the replacement of teeth (4 pieces - 30,000 rubles). Synchronization of the operation of the teeth is ensured by an active extension synchronization system or, in simpler versions, by a ring circuit for connecting power cylinders. This system allows you to increase the speed of work due to the fact that the cutting of piles is carried out evenly and without distortion of the felled pile head. The system is installed only on modern and high-quality equipment.

Installation of one tooth takes 15-20 minutes. Does not require complete removal of the working cylinders. Replacement can be done right on the construction site. Equipment warranty - 12 months. Warehouses of consumable components in all major cities of Russia (Moscow, St. Petersburg, Novosibirsk, Yekaterinburg, Krasnoyarsk).

"Taets" Holland– the company was founded in 1978, is one of the leaders in the production of welding equipment. Has many positive reviews however, the excessively high price of the equipment nullifies all its advantages. and acquisition opportunities for small construction companies. The payback of TAETS welding cutting machines will be more than one year, which significantly slows down the development and distribution of this equipment among foundation construction companies. Taets manufactures a wide range of piling heads, with 9 different models. For the Russian construction market, according to GOST 19804-2012, only 2 models are relevant for the types of standard piles manufactured; all other standards for driven piles in Russia do not apply! Cutting speed 1 r.m. piles is no different from "Pilemaster". The resource of the equipment is 4000-5000 pieces. pile heads, after which the teeth need to be replaced (4 pieces - 200,000 rubles). Replacement can only be done in the factory, because the procedure for heating and cooling the tooth is required to fix it. Cylinder synchronization is ensured by an active extension synchronization system. Equipment warranty - 12 months.

Nozzle Taets Holland

"Delta" (Italy), which was based on the equipment of a Chinese manufacturer, at the moment the equipment is produced under the domestic brand Impulse SV400. Previously, the equipment manufacturer stated that it was allegedly made in Italy, but even with a shallow comparison, it turns out to be very similar to the Chinese manufacturer Kinhan, therefore, in the future, this equipment will be positioned as manufactured in China. The resource of the equipment is 3000-4000 pieces. pile heads, after which the teeth need to be replaced (4 pieces - 120,000 rubles). Replacement can only be done in the factory, because the procedure for heating and cooling the tooth is required to fix it. Warranty for equipment - 12 months. Those who meet this equipment for the first time will say that outwardly the equipment practically does not differ from PILEMASTER or the same Taets. But experts will immediately notice the differences in that power hydraulic cylinders have a significantly smaller diameter than other manufacturers, which means that the equipment cannot deliver the same force and show high performance compared to Pilemaster or Taets. To perform the same amount of work, you will spend much more time and fuel using non-professional solutions. This is written in the technical specifications on the dealer's website, the figure is 160 piles per shift, which is 20% less than that of PILEMASTER and Taets. The synchronism of the operation of the power cylinders is not ensured in any way. The tip of the cutting tooth does not have an offset cutting axis, which increases the minimum cutting height from the design mark. These parameters should be taken into account when choosing a supplier!

There are also many offers from other manufacturers of garage production on the construction market. These models have a fairly budget price category, but not always the price is their advantage. The quality of the materials used is directly related to the performance and service life of the equipment. The negative side of such equipment will be the thoughtless fastening of the cutting tooth - it is carried out with a screw in the center of the tooth (it will be extremely difficult or impossible to unscrew such a screw after felling the first pile, since the screw head with this design will work for wear along with the tooth and perceive everything created hydraulic cylinder force). Also, a restrictive valve is installed on the body, which protects the hydraulic cylinders from pressures of more than 240 bar, which indicates that the hydraulic cylinders are made of low-quality materials that are not capable of operating at high pressure, as on modern imported excavators. High pressure hoses run outside the equipment and any falling tip can damage them and no amount of armor on the hose can protect it from damage and leakage of hydraulic fluid. The front flange, which acts as a tooth guide, is welded tightly or is part of the frame. This part is subject to wear and tear and is not designed to be replaced in the photos below. The teeth are not heat treated and are subject to wear, which leads to the failure of the entire installation. Handicraft slings do not have a stamp (GOST 25573 each manufactured load-lifting mechanism and other components sling must have marking (stamp) on passing tests, as well as the presence of a manufacturer's passport). Any of the above parts will sooner or later turn into a malfunction and downtime at a construction site. Many customers of these products often had to return to jackhammers and compressor. An example of such companies can be: Stroymekhanizatsiya, Novosibirsk, Navigator, IntegroSteel.

Hydrotooth - has the following design flaws: a restrictive valve is installed, high-pressure hoses are located outside the equipment, the tooth is fixed directly on the cutting part, non-replaceable tooth guides. Lack of synchronization system.

The Hydrotooth installation and some Chinese suppliers have a small window under the pile. This causes difficulties for the excavator driver when installing equipment on a pile. At the same time, additional personnel are involved in order to set the installation in the desired position along the edges.