F R E S E I D R A U L I C H E

HYDROMILLS F R E S E I D R A U L I C H E

HYDROMILLS The hydromills are designed by Casagrande to match today s demands of diaphragm wall construction. Whenever the challenge of difficult soil condition, high productivity and shear accuracy are made in diaphragm walling, the Hydromills can cope. Versatility Whether in hard or soft soils, a choice of cutters is available to match every condition and demands of different wall width scan be easily met, simply by changing the cutter wheels and the interchangeable guides. All models of the hydromills are designed to work on the principle of reverse circulation. Cutting chains are used enable the equipment to cut through hard strata, to guarantee the cut throughout the wall width and to provide better joints and excellent interlocking. Performance The hydromills utilizes a wealth of engineering expertise gained by Casagrande in many years of geotechnical available for the application of electronics to record depth, verticality and cutting force and to provide with instant information to control performance and maximize on production. The all-round ruggedness of hydromills are complemented by attention to details. The suspension of the hose reels by automatic winches and the fitting of a powerful fl ushing pump to remove cuttings. 2

CASAGRANDE HYDROMILL ASSEMBLY The equipment consists of a heavy steel frame with two drive gears, attached to its lower section, which rotate in opposite directions around horizontal axes. The soil, or rock, is milled by the cutting wheels from the bottom of the trench and continuously moved, mixed with slurry, and removed by a powerful fl ushing pump. Frame Manufactured in heavy duty steel structure consists in the milling unit - lower section - which contains the motors, chain transmission system, excavating wheels and the slurry pump. The guide - upper section - which contains the control instrumentation and the verticality control steering plates. Steering plates 6 hydraulically-driven steering plates to correct verticality at the excavation stage. The steering plates have 4 work positions and are mounted in the upper section of the hydromill to maximise precision and effectiveness of operation. Guides These are elements mounted on the frame to guide it during excavation work. Their thickness varies according to the dimensions of the panel to be built. Sensor Box Accommodates the control instrumentation and the sensors for reading the hydromills verticality. Compensators These are hydraulic accumulators that guarantee balance between the external pressure exercised by excavation fl uids at considerable depths and the inner pressure of the hydraulic components lubrication. Mud Pump The centrifugal pump sucks the excavated slurry mixed with the working fl uids and pumps it to the separation plants. The pump s main parts are made in wear-proof material to maximise their durability. It is driven by a hydraulic motor that assures high prevalence and fl ow capacity. Hydraulic motors Two radial piston motors transform the hydraulic power into torque and rotation speed. The absence of gear-motors increases the system s mechanical efficiency. Their position is such that they are directly subjected to the induced stresses during excavation stages. Chain Transmits the motion of the hydraulic motors to the milling wheels and implements the joint between primary and secondary panels. On each chain element are mounted excavation teeth that guarantee full excavation face. Tensioning system Two independent hydraulic cylinders guarantee the tensioning of the chain for a correct transmission of the motion from the hydraulic motors to the excavating elements. Suction box This is the point from which the suction of the excavated material takes place, entering the piping through specific suction holes. Wheels Excavation units consisting of a hub on which are mounted the wheels. Driven by the chains that move the toothed wheels to transmit torque and speed. They are available in the standard and heavy duty versions according to the characteristics required by the worksite s geology and by the excavation depth. 4

HYDROMILLS 1. MILL S BODY 2. CHAIN 3. STEERING PLATES 4. CHAIN DETAIL 5. MUD PUMP 6. WHEELS 7. SUCTION BOX 1. 2. 3. 4. 5. 6. 7. 5

CASAGRANDE HYDROMILLS FD60 The FD60 is the model that suits the widest range of requests for special foundations. A version is available with special motors to increase the wheels torque. FD100 The FD100 is designed with heavy duty wheel assembly and special hydraulic motors to deal with very thick diaphragms and under very demanding ground conditions. Torque [knm] 70 60 50 WHEEL TORQUE-SPEED 80 120 11140 Torque [knm] 100 80 WHEEL TORQUE-SPEED 11210 40 60 30 20 10 15340 40 20 15400 0 0 0 5 10 15 20 25 30 35 0 5 10 15 20 25 Speed [rpm] Speed [rpm] Head (water) [m] MUD PUMP MUD PUMP 70 70 60 60 50 50 1500 1500 40 40 1400 1400 30 30 1200 1200 20 20 1000 1000 10 800 10 800 4200 Head (water) [m] 4200 0 0 0 100 200 300 400 500 600 0 100 200 300 400 500 600 Nominal capacity [m³/h] Nominal capacity [m³/h] 3150 3150 Length of trench mm 3150 Width of trench mm 700 * 1200 Torque al wheel axle knm 2 x 67 Wheel speed rpm 0 30 Suction pump m³/h 450 Verticality control X-axis wheels + n 2 steering plates Y-axis n 4 steering plates Weight t 33 37 * 660 with special mud pump * 1800 with special arrangement Length of trench mm 3150 Width of trench mm 800 1500 * Torque al wheel axle knm 2 x 99 Wheel speed rpm 0 21 Suction pump m³/h 450 Verticality control X-axis wheels + n 2 steering plates Y-axis n 4 steering plates Weight t 38 45 FIELD OF APPLICATION Trench width 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 2000 mm FD60 FD100 Soil characteristic 20 30 40 50 60 70 80 90 100 110 120 130 140 150 MPa FD60 Unconfined compressive strength FD100 6

FD60 - CRANE ARRANGEMENTS Crane The hydromill is suspended from the crane s winches, while the hydraulic hoses and debris pipe are supported by the two idler wheels activated by two independent tensioning systems. According to the length of the lattice boom, different excavation depth can be managed. Crane Hose Reels The hydromill is suspended from the crane s winches while two winders hold the hydraulic hoses and debris pipe. Each winder is activated by an independent hydraulic circuit in order to adjust the tensioning according to the depth to be dealt with. This configuration allows the reaching of considerable excavation depths with minimum boom length. FD Crane arrangement Base carrier C850 C900 C900 Hose tensioning system Winches Winches Hose reels Depth m 46 36 30 64* 52 42 30 100 Boom length m 24 24 21 33 27 27 21 21 Jib extension m 5 5 5 - Approx. weight t 130 129 128 154 142 141 150 155 Installed power kw 480 Power pack additional ** kw 194 * Special configuration ** The additional power pack powers the mud pump, and allows a productivity increase and to work under extreme environmental conditions 8

FD100 - CRANE ARRANGEMENTS Crane The hydromill is suspended from the crane s winches, while the hydraulic hoses and debris pipe are supported by the two idler wheels activated by two independent tensioning systems. According to the length of the lattice boom, different excavation depth can be managed. FD Crane arrangement Base carrier Hose tensioning system Depth Boom length Jib extension Approx. weight Installed power Power pack additional ** m m m t kw kw Crane Hose Reels The hydromill is suspended from the crane s winches while two winders hold the hydraulic hoses and debris pipe. Each winder is activated by an independent hydraulic circuit in order to adjust the tensioning according to the depth to be dealt with. This configuration allows the reaching of considerable excavation depths with minimum boom length. C900 Winches 40 21 5 150 52* 27 5 162 30 21 149 480 194 C900 Hose reels 100 21 163 * Special configuration ** The additional power pack powers the mud pump, and allows a productivity increase and to work under extreme environmental conditions 10

CUTTING TEETH FOR WHEELS AND CHAIN Type of teeth available According to ground characteristics, two typologies of cutting tools are available: teeth for rock and hard rock teeth soil and medium rock For their dimensions and sturdiness, teeth for hard rock are always suitable for mounting on the chain elements. The teeth are arranged in such a way as to cover the entire excavation surface and to convey the excavated material towards the suction box. The position and inclination of each tooth assures the best cutting angle when in contact with the excavation material. HARD ROCK TEETH SOIL AND MEDIUM ROCK 12

FULL EXCAVATION FACE The massive weight of the transmission motors and the lower blocks supporting the wheels concentrated in the lower part of the Hydromill frame, plus the utilization of the transmission chains system insure the distribution of the weight of the machine in the entire width of the excavation. The operator then, managing the balance of the weight of the rig will use the hydromill as a reverse pendulum system controls the verticality while optimizing production. The configuration of the wheels teeth together with the position of the chains teeth are designed to insure the cover of the entire trench section to have the FULL EXCAVATION FACE - and the proper transfer of the entire weight of the rig during excavation. JOINT FORMATION Based on the excavation s depth specified, the project geology, the site logistic and sensibility the dimensions of the primary panels can range from the minimum 3150 mm (single byte) to a 7600 mm length (triple byte). The panels joints are formed without the use of end-stops while instead milling a portion of the concrete on the primary panels. The thickness of the concrete milled is based on the required excavation s depth and the capacities of the vertically recording system. OVERLAPPING PRIMARY SECONDARY PRIMARY 3150 210 260 120 120 FD60 FD100 Because of the use of the transmission chains technology the Casagrande hydromills can create, during the installation of the secondary panels, a concrete joint system that produce, above the standard grooved joint a key extended into the primary panel. 14

PANELS INSTALLATION HYDROMILLS PRIMARY PRIMARY PRIMARY L Max L x 2.4 Max L x 2.4 1. Pre-excavation (4-5 m) and excavation of primary panel 2. Excavation of second byte of primary panel 3. Excavation of middle byte of primary panel SECONDARY PRIMARY PRIMARY PRIMARY PRIMARY Max L x 2.4 Max L x 2.4 SECONDARY PRIMARY 4. Installation of reinforcement and concreting 4. Excavation of secondary panel 4. Installation of reinforcement and concreting 15

INSTRUMENTATION Operator s cabin The control instrumentation, installed in the operator s cabin, allows checking of the correct operation of all basic machine functions and those of the hydromill. Over and above the basic machine controls, there is a simple panel of controls dedicated to hydromill control. 12 display The 12 colour touch screen display allows settings and provides information about the machine condition; moreover it allows and assists fault diagnostics. All machine functions are controlled by a PLC network. 1 3 Instrumentation The verticality of the hydromill is constantly monitored by the control system and the corrections are applied by activating the fl aps for directions X, Y and for the rotation on Z, or by selectively controlling the wheels on the X direction. The FULL EXCAVATION FACE solution with the control instrumentation adopted allows an excavation verticality precision of more than 0.1% (e.g. for a 100 m deep diaphragm this means less than 100 mm deviation on the theoretical vertical). Y 1 12 DISPLAY 2 HYDROMILL CONTROL PANEL 2 X 3 MONITORING AND RECORDING DEVICE CONNECTION BOX Z Measured and recorded data Deviation axis X, Y, Z Depth of excavation Cutting wheel speed Press. cutting wheel Speed of suction pump Flow of suction pump Hydromill weight on ground Min./Max. oil level compensator Two press. switches for chain tensioner Hydraulic oil contamination sensors SENSOR BOX MONITORING AND RECORDING DEVICE 16

CONTROLS HYDROMILLS Verticality of the Hydromill All information on the orientation of the Hydromill and the deviation from the correct trajectory are shown on the control panel. The operator can correct the direction of excavation by using the controls of the steering plates. Each plate can assume four different positions. After having corrected the excavation trajectory, fully retract the guide plates. X: 0.5 0.8% Y: 0.0 0.0% X: 0.0 0.0% Y: 0.0 0.0% Verticality deviation along X-axis Activation steering plates for correction along X-axis Feed - selection of speed and direction The load applied to the ground by the mills depend on ground conditions. The operator can control the feed (0-40 m/h). The load applied to the surface by the mill is indicated on the terminal by a percentage fraction of the weight of the Hydromill. Verticality deviation along Y-axis X: 0.0 0.0% Y: -0.5-0.8% X: 0.0 0.0% Y: 0.0 0.0% Activation steering plates for correction along Y-axis Wheels Selection of speed and direction is independent for each wheel, in order to control the verticality of the hydromill. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 X (20 cm) 0 Y (20 cm) 0 (1+2 3+4 5+6 ) Rot. (10 d ) 0-0.4 cm +0.2 cm +0.6 d +1.8 cm -1.2 cm -0.1 cm +1.3 d +3.9 cm -2.1 cm +0.3 cm +1.5 d +4.4 cm -1.3 cm +0.6 cm +2.1 d +6.2 cm -1.9 cm +0.7 cm +2.2 d +6.7 cm -1.8 cm +0.9 cm +2.7 d +8.0 cm -1.9 cm +1.1 cm +2.7 d +8.0 cm -1.5 cm +1.3 cm +3.3 d +9.8 cm Axis AD Axis BC (1%) (1%) (1%) (1%) A B D C -0.4 cm -0.7 cm -4.0 cm -4.0 cm -5.1 cm -5.2 cm -7.0 cm -6.9 cm -8.4 cm -0.1 cm -1.6 cm -0.2 cm -2.1 cm -0.5 cm -1.9 cm +0.2 cm -2.1 cm +0.1 cm -2.4 cm +0.4 cm -3.4 cm -0.5 cm -3.3 cm +0.1 cm +1.0 cm +4.1 cm +4.7 cm +6.5 cm +7.0 cm +9.2 cm +9.1 cm +11.2 cm Velocità di avanzamento (m/h) (1/351) 0 100 200 300 400-8 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24 25 25 26 26 27 27 28 28 29 29 30 30 31 31 32 32 33 33 34 34 35 35 36 36 37 37 38 38 39 39 40 40 41 41 42 42 43 43 44 44 45 45 46 46 47 47 48 48 49 49 50 50 51 51 52 52 53 53 54 54 55 55 56 56 57 57 58 58 59 59 60 60 61 61 62 62 63 63 64 64 65 65 66 66 67 67 68 68 69 69 70 70 71 71 72 72 73 73 74 74 75 75 76 76 Deviazione X (cm) -4 0 4 8-8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 Deviazione Y (cm) -4 0 4 8 Example of output record 17

BENTONITE TREATMENT PLANT The desander plants are used to treat the slurries used for support in foundation engineering. The typical use is in excavation with hydromill or grabs in bentonite where the slurry from the excavation is treated in order to separate the soil from the bentonite. Some plant solutions are available depending of geological features and layout of the job site: D500 plant has one cycloning stage and is suitable for slurry with rocks, gravels and sands. The D500 con be completed with one additional desilter plant with secondary cycloning stage and desilter dewatering screen to increase the separation rate; D500.500 + Desilter plant has two cycloning stages and one additional desilter dewaterer screen is used to increase the separation rate of the soil from the bentonite. The plant is suitable for slurry with contents as clays and silts. The plants are completed with full package system, with access stairs and walkways, that gives the following benefits: reduced dimensions easy installation safe transport in a minimum number of package make available a minimum volume for desanded bentonite. DESANDER WITH FULL PACKAGE SYSTEM D500 D500.500 DESILTER Nominal capacity m³/h 500 500 Feed density t/m³ 1,18 1,2 1,18 1,2 Production of solids* t/h 15 200 15 200 Separation µm 60 30 Installed electrical power kw 185 335 Overall dimensions m 9 x 6,2 x 7,7 9 x 9,5 x 7,7 Approx dry weight kg 33000 47000 * Depending of particle size 18

TYPICAL PLANT LAYOUT HYDROMILLS Pump C400XP Concreting Service crane FD100 Excavation using FD hydromill B200XP D500.500 Compressor Mixer Pre-excavation using Kelly KRC Betonite Silos Generator Pump 450 m³/h 19

All data contained in this brochure are indicative and does not take power losses into account. All data can be changed without notice. Tutti i dati riportati su questo catalogo sono indicativi e non considerano perdite di carico. Tali dati possono variare senza preavviso. PRESTAMPA E FOTOLITO VISUAL STUDIO STAMPA ELLERANI 01/2015 CASAGRANDE S.P.A. Via A. Malignani, 1 IT 33074 Fontanafredda Pordenone Italy Tel. (+39) 0434 9941 Fax (+39) 0434 997009 www.casagrandegroup.com info@casagrandegroup.com