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A CUT ABOVE
Specialized Terex® Cutting Units Involved in Complex Tunnel Project
Crailsheim (GERMANY), February 2012 – Four Terex hydraulic cutting units played a critical role in the overhaul of the Michaelstunnel, a 2.5 km road tunnel in Baden-Baden, Germany. A total of €27 million was invested in refurbishing and upgrading the busy two-lane tunnel, which included developing a new ventilation system, extra emergency escape routes and installing a fireproof ceiling.
The contract for the structural and operational improvements was awarded to two Austrian firms, Jäger Bau GmbH (Schruns) and PKE Verkehrstechnik GmbH (Vienna). Before the new ventilation system could be fitted, the old ceiling structure had to be removed. This task was subcontracted to Berlin-based Czwikla Spezialfräsen, a company which undertakes construction projects all over Germany and was selected for the Michaelstunnel project due to their wealth of experience and expertise in this sort of intricate operation.
Lothar Czwikla, the owner of Cwickla Spezialfräsen only uses Terex hydraulic cutting units as he finds the technology and the compact cutter design ideal for demolition work in a forward or upward direction. “The compact cutters are incredibly powerful, while being extremely smooth-running for fine profiling work” he explains.
In addition, there is the high standard of service offered by Terex, which Czwikla describes as “exceptional”. He continues, “Every promise was met. Terex exceeded my expectations in terms of customer service.”
This close collaboration and support proved vitally important when it came to carrying out the cutting work in the Michaelstunnel. During the planning stage, it was assumed that the concrete hardness of the abutment was 35 - 45 MPa. In fact, the non-reinforced concrete measured 65 - 75 MPa. As a result, at the end of a 10-hour day the competitor’s 8-tonne excavators with 15 kW cutters had progressed by just 40 m instead of the planned 100 m. At this rate it would be impossible to remove the 2 x 1755 m of abutment at a height of 4.8 m in the time allotted.
The test run using a competitor’s cutters was soon called to a halt. “Too big, too heavy and too inefficient” was the conclusion of Czwikla Spezialfräsen’s Torsten Paegel. But for Lothar Czwikla and Terex, there is no such word as impossible, and after switching to the Terex WS30 cutters mounted on 12-tonne excavators, offering twice the power of the original cutters, the team achieved the necessary rate of progress to deliver the job on time and on budget.
One of the key success factors in the Michaelstunnel project was the fact that the Terex cutters operate at a lower rotational speed than competitor models but have more picks. “We achieve the necessary rate of progress through greater efficiency at the pick tip rather than the rotational speed of the drum,” explains Robert Piasecki, Product Manager for Terex cutting units. This feature makes Terex cutters quieter and less prone to vibration. As Piasecki says, “They don’t impact as hard or rebound as much.”
For fine profiling, the Terex WS15 was the cutter of choice. It also proved that using the 15 kW cutter eliminated the need for manual material removal, which must be retained in order to install the new abutment. Between early August and mid-October 2011 there were up to four Terex cutters in use at any time: two WS30 cutters for the main demolition work and one or two WS15 cutters for the finer work. Jäger Bau was full of praise for Czwikla’s organised approach and complete reliability.
Czwikla Spezialfräsen has also completed projects for customers such as Bilfinger Berger, Bauer Spezialtiefbau and Deutsche Bahn. Past projects have included the approaches to the Waldschlösschen Bridge in Dresden, tunnels for ICE high-speed trains and the Berlin Stadtbahn, and most recently new bank reinforcements for the River Spree on Berlin’s Museum Island. The company specialises in a variety of demolition, profiling, reconstruction and cutting tasks.
Terex Corporation is a diversified global manufacturer of a broad range of equipment that is focused on delivering reliable, customer-driven solutions for many applications, including the construction, infrastructure, quarrying, mining, shipping, transportation, refining, energy, utility and manufacturing industries. Terex reports in five business segments: Aerial Work Platforms; Construction; Cranes; Material Handling & Port Solutions; and Materials Processing. Terex offers financial products and services to assist in the acquisition of equipment through Terex Financial Services. More information can be found at www.terex.com.
Pictures 2274 and 2276
Up to four Terex® cutters were in use at any one time in the Michaelstunnel near Baden-Baden, undertaking demolition and fine profiling work.
Thanks to the Terex® WS15, the smallest cutter in the Terex range, no manual material removal was needed at the separation point.
Pictures 3669, 3720 and 3704
The Terex® 30 kW cutter was used for the main demolition operations. The rugged and powerful WS30 cutters proved their mettle on concrete with a hardness of 65 - 75 MPa.
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