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AK2 CUTTER METHOD

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EXISTING CAST-IN-PLACE PILES CAN BE CUT UNDERGROUND 『AK2 CUTTER METHOD』

The social capital of Japan has been greatly improved since the record period of economic growth, the number of buildings and public facilities built over 50 years ago has been increasing. In order to pass on the benefits of infrastructure development to the next generation, an appropriate renewal plan is necessary. Looking at cities, the lack of vacancies in office buildings and accommodation facilities is on the rise, due to the increase in the number of foreign visitors to Japan and the highly concentrated of large company headquarters across Japan metropolitan areas. However, while satellite cities around metropolitan area are becoming desolate, cities are progressing redevelopment. From now on, cities, with the desire to develop and use land resources effectively, need to conduct reconstruction of infrastructure.
Along with the renovation of cities, old buildings are being dismantled, leading to the removal of old pile foundations. In particular, eliminating existing large-diameter cast-in-place pile by using an all-rotation excavator to cut vertically along the length of the pile. In this case, because the pile is vertically cut along the length, the weight may be too large to be removed from the ground. If it cannot be taken out, the pile will be crushed into small pieces, however, because the size of the shredded pile in the casing cannot be predicted in many cases, it often exceeds the crane lifting capacity. For these reasons, work progress was often unstable, and the removal of existing cast-in-place piles from the ground also faces environmental, safety and cost problems.
To solve this problem, a construction method that can cut existing piles horizontally has been desired.

Features This method uses a large rotational force of an all-rotation excavator to cut existing piles horizontally so that they can be taken out with a safe length and weight. By this method, we can safely remove existing piles, with reduction in construction time, vibration and noise. In addition, damage to the cutting edge of the casing is small, and the load applied to all-rotation excavator, so it can be expected as an environmentally friendly method.
  1. Existing pile can be cut at any position.
  2. Vibration and noise due to free fall of chisel are reduced.
  3. Cut piles can be taken out with a safe weight.
  4. Safer than other construction methods.
Work Process The system consists of a horizontal blade and an inclined sliding rail mounted inside the first casing, the blade will move up and down thanks to hydraulic pressure through a connecting rod. It is possible to cut the existing reinforcement by rotating the casing and pressing the blade.
  1. Rotate and press the casing tube to the specified depth with the all-rotation excavator set up at the pile position.
  2. Attach the hydraulic unit on top of the casing, connect the rod to the horizontal cutting blade. The hydraulic unit is operated by a remote controller. Rotate the casing while moving the horizontal cutting blade (Figure 2).
  3. Pull up the casing and the main rebars will be cut.
  4. After returning the horizontal blade to its original position, remove the hydraulic unit, and cut the pile with a chisel. (Figure 3)
  5. Insert the grab hammer into the casing, take the cut pile out of the casing. (Figure 4)
  6. Continue rotating and pressing the casing to the specified depth.
  7. Repeat steps 2 to 6.

Equipment Introduction

Horizontal Cutting Blade

It has a simple structure with a hydraulic cylinder for pushing and pulling the horizontal cutting blade. Figure 1 shows the horizontal cutting blade.

Hydraulic Unit

The hydraulic pressure source supplied to the hydraulic cylinder is located at the top of the casing. The hydraulic unit is fixed on top of the casing and has a structure in which the unit will rotate with the casing. The hydraulic unit is equipped with an engine, has its power source, and can operate independently without depending on other devices. Figure 2 shows the appearance of the hydraulic unit.

Construction Case

Figures 3 and 4 show the status of a pile cut section being removed and the cross-section of the pile. Figure 5 shows the cutting status of rebars.

For Practical Use

Scope of Application

The equipment used for the AK2 cutter method is a Ø2,000 mm type all-rotation excavator. Suitable for the removal of piles with a diameter of Ø1,500 mm. Since the horizontal cutting blade is attached inside the Ø2,000 mm casing, the excavation hole is protected by the casing from excavation to backfilling, so it may prevent the collapse or loosening of the ground from occurring. The removal work that does not affect surrounding structures is possible. Further, with this configuration, the removal length of the existing pile can be set arbitrarily, so that only the necessary part can be removed.

In addition, since the excavated hole is protected throughout the hole by the casing, for backfilling after removal, it is possible to choose methods of filling the hole with excavated soil or cement mortar.

The purpose of AK2 horizontal cutting blade is to cut main reinforced steel bars. After the cutting is completed, only the concrete remains inside with poor cutting resistance, so it can be easily cut by inserting a chisel and rotating the casing. This method reduces the time required for cutting.

APPLYING AK2 METHOD TO PRACTICE

Visualize Control Panel

By attaching a stroke sensor to the hydraulic cylinder, a numerical value is displayed on the control panel monitor, from which we can know the displacement of the blade in the ground. Control the blade by the radio system. Figure 6 shows the operating status of the monitor on the control panel.

Simple Operation

Operation on the control panel is actually only 2 buttons: shrinking and stretching the cylinder, so manipulating the blade is relatively simple. Later, as we continue to develop, we will aim at semi-automation by taking in the data of the rotational torque from the all-rotation excavator. (Figure 7 - Control panel)

Improve The Durability Of Cutting Blades

If the durability of the horizontal cutting blade is further improved, the cutting speed can be expected to increase. Currently, we are developing the shape and hardness of the cutting blade. Figure 8, showing the state and speed of rebars cutting when changing the shape and hardness of cutting blades.

AK cutter

For pile diameters of Ø1,000mm and Ø1,200mm, there is a fixed horizontal cutting blade without a hydraulic unit. Horizontal cutting AK cutter can be easily attached to the equipment of the conventional all-casing method as shown in Figure 9.

Construction Example

Removing existing cast-in-place pile for a high-standard dike maintenance

With the improvement of a high-standard dike in the city’s rivers renovation project, existing condominiums were demolished, accompanied by the removal of the foundation piles. Also, the protection dike is close to an operating railway line, as well as a factory in operation, so an environmentally friendly construction method was necessary.
The cast-in-place pile (Ø1,600mm x 23.0m) was removed by the AK2 cutter method. Figure 10 - the entire pile were removed.

IN CONCLUSION

The idea of a horizontal cutting method for existing cast-in-place piles was developed around 2005, and the developers obtained a patent in 2008.
After that, it was put into practical use, and our AC group made further improvements.
In October 2014, the AC Group which includes companies and manufacturers with bases in major cities nationwide such as Hanshin Kensetsu Co.,Ltd., Shinmei Gikou Co.,Ltd., Marui Jyuki Kensetsu Co.,Ltd., Mitsuwa Kougyo Co.,Ltd., Sougou Kiso Co.,Ltd., Sanyo-Doboku Co.,Ltd., Miyazaki Kiso Kensetsu Co.,Ltd., Asahi Giken Co., Ltd., Eiko Co., Ltd., and 2 other companies, have been established, aiming to develop the construction industry and contribute to society.
In the future, the AC Group will continue to make technical improvements to the AK2 cutter method, in order to create a safe and environmentally friendly construction method.
[Patent No. 4106374] << Patent Related To AK2 Cutter Construction Method >>
Name of Invention: Demolishing Method for Existing Piles
[Patent No. 3683229] << Patent Related To AK Cutter Construction Method >>
Name of Invention: Existing Pile Removal Method And Equipment

VIDEO ABOUT AK2 CUTTER METHOD

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