Concrete Openings - Mar 2009 Reprints

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The Return of

the King King Ramses Begins His Journey to the Pyramids

The WS 440 HF Wall Saw. Husqvarna’s WS 440 HF is setting a new standard for electric high cycle wall saws. The saw is based on a totally new technology, which gives the saw increased power for fast and efficient cutting. The powerful, water-cooled electric motor generates 17 horsepower to the shaft, despite the fact that the saw only weighs 55 pounds.

Husqvarna has succeeded in optimizing the weight/power relationship and developed a saw that is light and flexible but also powerful!

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w w w . c s da . or g CIRCLE READER service CARD NO. 11

Smooth Operators Industry Professionals are Becoming Well-Polished at Their Craft

T

he art of concrete polishing is a relatively recent addition to the concrete industry, a process that was adapted from the ancient method of polishing stone. The adaptation of polished concrete first originated when engineers began looking for a durable finish for industrial flooring. What they discovered was that polishing concrete was a great way to mechanically seal a concrete surface while beautifying it at the same time, thus providing a permanent finished surface.

This innovation led to a growing need to develop and use chemical hardeners, which increased the hardness and density of the concrete to complement the polishing process.

Of course, in order to properly work the newly-hardened and densified concrete substrate, specialized diamond tools were also required. Through years of development, engineers have been able to add several other aspects to the polishing process, including the addition of color to create highly-decorative surfaces with superior wear and abrasion resistance.

Concrete floors and surfaces provide various choices for interior rooms, including an almost limitless range of designs and colors, together with increased health benefits compared with traditional floor coverings. The developments in the concrete polishing industry have led to it becoming the new material of choice for designers and homeowners across the US, with floors and surfaces in stained, colored, painted and personalized designs appearing on a global scale. Retail outlets, warehouses, restaurants REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

F E A T U R E

and office facilities are now displaying polished concrete floors over marble, granite, tile, and other coated surfaces. In addition, homeowners are also discovering the appeal of polished concrete and are actively looking for smooth, high-luster floors that can replicate the look of polished stone for their properties.

One CSDA member, VIC International, has offered technical support and training for grinding, polishing, and prepping terrazzo and concrete floors since 1993. From founding VICCO in 1978, Vic Green has experienced tremendous growth in the business.

The company has evolved from importing stoneworking equipment from Europe throughout the 1980s and ’90s, to now distributing polishing and grinding equipment manufactured entirely in the US. The company now imports from and sells to 27 countries worldwide. During the course of the last twenty years VIC International has hosted many restoration and maintenance seminars for the US natural stone industry, exhibited concrete polishing techniques at World of Concrete, and published numerous guides and specifications for industry professionals. The company was also instrumental in helping CSDA produce the specification CSDA-PC-113: Polishing Concrete.

The process of polishing concrete bears many similarities to sanding wood. Just as sandpaper consists of fine grits of diamond-impregnated segments, so do heavyduty polishing machines that are used to grind surfaces to required levels of REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

shine and smoothness. This technique of grinding concrete is also employed by other sawing and coring equipment to create smooth, clean cuts and cores with a high level of accuracy.

The procedure involved with the polishing and preparation of concrete surfaces consists of several steps, the quantity of which is wholly dependent on the condition of the floor or surface.

This procedure begins with the application of coarse diamond segments to remove minor pits, blemishes, stains or light coatings from the floor in preparation for final smoothing. At this stage of the process the diamond segments are embedded in a metallic matrix, however other materials are bonded to the segments as the process continues. The subsequent steps involve fine grinding of the floor or surface using diamond abrasives, but this time the segments are bonded with a plastic or resin matrix.

Polishing contractors employ ever-finer grits of polishing disks until they have achieved the desired sheen. In order to attain a high-gloss finish to a surface, a final grit of 1,500 or finer may be used. By paying close attention to the floor or surface and observing the amount of material being removed, many experienced polishing contractors are able to determine when to switch to a finer grit. As the final polishing step is being carried out, some concrete polishers spread commercial polishing compounds over surfaces to provide a greater shine to the finish.

These compounds also help to remove residual substances that may remain on the surface, and leave a dirt-resistant finish.

The popularity of polished concrete as a flooring material is due to a number of factors, putting it in a far superior position than other options. Concrete surfaces can be maintained with a great deal of ease, and are ideal for use in geographical areas that have sand or snow. In terms of offices or homes, concrete floors can be an excellent alternative to carpet or other floorings. Many people suffer from allergies that can be collected and harbored in carpets, therefore having a surface made of concrete is an ideal solution to this issue. In addition to the potential health benefits, concrete floors can be easily

changed and decorated. These floors are a great feature when selling a home too, as the potential new owner is able to immediately see the clean, even, smooth condition of the floor. This way they can keep the surface as it is, or confidently cover with carpet or wood, safe in the knowledge that the floor is extremely even and free of defects.

Like in every other part of the concrete sawing and drilling industry, the control and removal of dust, slurry and other waste material is of great importance when preparing and polishing any floor or surface. It is essential that any slurry or dust generated during the grinding and polishing is cleaned away at regular intervals. It is advised that between each step of the grinding and polishing process, a vacuum or other appropriate equipment is employed to clean the area to prevent debris in the slurry or dust creating additional scratches in the slab surface.

Taking all of these factors into account, many manufacturers are producing and improving industrial wet and dry vacuum cleaners to be more lightweight, energy-efficient and eco-friendly machines. Wet vacuums can now be found on the market that have the ability to recycle slurry in order for water to be reused on the job site. The debris and other waste material from the slurry collected can be contained in filter bags for simple handling and disposal. Dry vacuum cleaner designers and manufacturers are continuing to remain ‘ahead of the game’ too, with advancements in the removal and filtration of dust particles from the work area.

A growing number of CSDA member companies are now adding this line of work to their repertoire. Atlantic Concrete Cutting of New Jersey have been involved in floor polishing and preparation projects for approximately six years, and now have employees dedicated specifically to this form of work, “Our polishing system is an economical and ecological flooring solution that is low maintenance, uses no harmful chemicals and is virtually dust-free,” says Nancy Walker, owner.

With all the advantages that polished concrete floors and surfaces have to offer, together with the advancements of equipment required to create them, it is easy to understand why many cutting contractors are ‘adding the polishing string to their bows.’ By doing so, these contractors are attracting a wider client base and can offer polishing as an additional service on their sawing or drilling projects.

You may say they are literally becoming ‘smooth operators’!

REVIEW AND COMMENT ON THIS ARTICLE AT WWW.CSDA.ORG/FORUM.cfm

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2009 RATE CARD

The only magazine specially targeted to the sawing & drilling industry Advertising in Concrete Openings magazine is the only way to reach the specialty market of sawing and drilling contractors who cut concrete, asphalt or masonry because it is the only magazine in the market specifically targeted to this segment of the industry.

Reach 16,000+ Concrete Sawing and Drilling Professionals

Circulation

Each issue of Concrete Openings magazine is sent to more than 9,500 sawing and drilling operators, manufacturers of sawing and drilling equipment and suppliers to the industry and more than 6,500 specifiers of concrete cutting services.

16,000+ minimum, per issue

Best Rates in the Industry

9,500+

Concrete Openings has always offered the best advertising rates in the construction industry targeting sawing and drilling contractors and other industry professionals in this market.

6,500+ general contractors, engineers, architects

and government officials who specify sawing

and drilling

Target Your Message

Reader Response Program

Concrete Openings reaches sawing and drilling contractors, as well as specifiers of sawing and drilling services including engineers, architects, general contractors and governmental agencies. Why waste your message on unnecessary circulation? Advertising in Concrete Openings guarantees a targeted audience of industry professionals.

Advertisers can enjoy our Reader Response Program as a complimentary addition to ad placement. Readers can request information for any advertiser by filling out a reader response form. All sales leads are then emailed to advertisers.

Readership by Location

Readership by Profession

• Cutting Contractors • Architects, Engineers,

42%

43%

member and prospective member companies made up of sawing and drilling contractors, manufacturers, distributors and affiliates

9%

General Contractors, Government Officials Manufacturers, Distributors

8%

•

77% 15%

6%

• United States • Canada, South America • Asia, Africa, Australia • Europe

From left to right: Rupert Marko, Raul Bracamontes, Greorg Rachor, Patrick O’Brien and Tiziano Tondin.

Diamond Award Winners Announced at World of Concrete

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orld of Concrete, the commercial construction industry’s biggest, most important event, was the venue for the announcement of the 2009 Diamond Award winners. The award ceremony, organized and presented by the International Association of Concrete Drillers and Sawers (IACDS), was held in the Las Vegas Convention Center on February 4, 2009 and drew great interest from members of the press and industry professionals alike. The ceremony, in fact, drew a standing room only crowd.

The Diamond Award is an internationally recognized competition for concrete sawing and drilling professionals to showcase their most complex and innovative projects, with the aim of being the gold award winner. Entries were judged on the degree of difficulty, planning, complexity, innovation and the quality of the work produced to ensure project success. Following a detailed review of each entry, the judging panel representing members of various country-wide sawing and drilling associations, chose the winning projects.

Since the first awards, presented during BeBoSa 2000, the Diamond Award entries have increased in both quantity and quality.

Previous Diamond Award winners have experienced the benefits of being recognized for the outstanding results of their projects on an international scale.

Entries for the award came from all four corners of the globe, including sawing and drilling projects from Austria, Canada, Egypt, Germany, Italy, Japan, Russia, the UK and the US. Following a detailed review of each entry, the judging panel chose the winning projects.

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Crucible repair project—ADRA.

Bronze Award The third place award was won jointly by CSDA members ADRA Tecnologia en Servicio of Mexico, and Germany’s BWW. Mittal Steel of Lazaro Cardenas, Mexico, one of the biggest steel producers in the world, suffered a major explosion in its furnace, damaging its crucible. Because of the damage sustained, Mittal Steel was losing approximately two billion dollars a day due to lack of production, and so needed its crucible to be rebuilt quickly and efficiently.

The crucible, or melting pot, is a graphite container used to hold metal for melting in a furnace, and is required to withstand extreme temperatures. These crucibles are custom-made and are therefore extremely difficult to replace quickly.

ADRA’s project was to repair the crucible by cutting 114 graphite blocks of different dimensions, using nitrogen gas instead of water, as a cooling agent. The reason for this was that if the graphite block absorbed water, this would create steam as the crucible heated up, creating pressure and cracking the furnace. The contractor also made new handling holes to elevate the pieces uniformly, coring 161 holes measuring 381 millimeters (15 inches) in diameter, 40 holes at 500 millimeters (20 inches) in diameter and two holes at 127 millimeters (five inches) in diameter in the furnace. This came to a total area cut of 70 square meters.

Raul Bracamontes of ADRA was pleased with the win, “I am very happy to be included as a winner along with these other great projects, and happy to be a CSDA member. ADRA worked hard to complete a difficult and demanding job, and this is a great reward for us.”

BWW’s job in Koblenz, Germany, involved a large roll mill replacement project with severe time constraints. The job was to be completed within 120 hours, requiring non-stop operation. The job consisted of extensive alterations to the mill’s base to fit a new hot mill of a larger size. “It is a proud moment for myself and the company to win this award. The project was really hard, and the client was extremely pleased with the outcome. I would like to thank the IACDS

Roll Mill replacement project—BWW.

for the chance to receive the award here at World of Concrete,” said Rupert Marko, managing director of BWW. Various wall sawing and core drilling techniques, together with pressure removal and demolition methods, were used to remove concrete blocks and built-in anchors to create room for the new roll mill. The center of the existing base had a thickness of 4.5 meters (15 feet), where two recesses measuring 4.14 meters (13.6 feet) long, 2.1 meters (6.9 feet) wide and 2.25 meters (7.4 feet) deep were required to position the new roll mill in steel hulls with rolled concrete. Had BWW been allowed to carry out the work under standard shift hours, the process would have taken approximately two and a half weeks to complete.

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Loggia Palace foundation consolidation project—Tondin srl.

Silver Award

Gold Award

Taking second place was another CSDA member, Tondin srl, for its work on a project to consolidate the foundation of the Loggia Palace in Brescia, Italy. Tondin was able to devise a high speed drilling system with micro bits to fit into confined spaces to restore the foundation. The project required the drilling of holes just 26 millimeters (1 inch) in diameter, with a horizontal axis to perform the coring with a safe distance between the foundation and the ground below it. The holes created would be used to fill cavities in the terrain below where the original wooden piles had deteriorated. As work progressed, Tondin had to increase to a 32-millimeter (1.25-inch) bit because of the presence of rocks, stones and other erratic material in the soil. The core drills were custom-made to produce a rotation speed of approximately 1,600 rpm. Tiziano Tondin was thrilled about his successful entry, “I would have been happy to receive any award for the project, so to win the second place Diamond Award is fantastic. To be chosen above so many other outstanding submissions and have the project recognized is a great honor indeed.”

In first place was Braun of Münster, Germany, for the company’s outstanding work dismantling a highly-contaminated steam dryer at a nuclear power plant. “I am honored to win this award, it is a great pleasure. The project specifications were very strict, with no room for mistakes. When the story was written and the entry submitted we were quite happy, as getting the story down on paper was a big task.

Then to be invited to Las Vegas as a winner was an added bonus,” said Georg Rachor.

The project involved putting the steam dryer in a steel formwork for radiation shielding, encasing it with concrete, and cutting it into pieces via remote control using diamond wire sawing techniques.

Remote control wire sawing was a necessity to keep operators at a safe distance from the contaminated material, avoiding exposure to high levels of radiation. The cut parts were dismantled using a special wire saw design by Hilti AG, a WS 30 E type. Wire tensioning was effected through pneumatic cylinders with a pressure of up to 6 bars. The speed of the 10.5-millimeter (0.4-inch)-diameter wire could be REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

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Steam dryer dismantling project—Braun.

progressively adjusted between 0 and 35 meters per second. Once encased in concrete, the steam dryer was cut into 24 segments that were separated using hydraulic punches. These 24 segments were then individually removed and further cuts were performed to break the pieces down into smaller sizes for disposal. The cut pieces were packed in Type IV Konrad containers suitable for final disposal. In total, Braun removed approximately 184 square meters of steel and concrete while maintaining a high level of operator safety.

The winners of 2009 Diamond Awards were presented custommade trophies and certificates by IACDS President Patrick O’Brien.

The winners were notified in advance of the ceremony and arrived in Las Vegas via complimentary flights awarded by IACDS and complimentary hotel rooms by the World of Concrete. Georg Rachor, together with Tiziano Tondin, Rupert Marko and Raul Bracamontes were all on hand to accept their prestigious awards, and their companies now stand alongside the elite group of Diamond Award winners that has been growing since the first ceremony back in 2000.

IACDS is an international trade association of sawing and drilling associations from the concrete construction and renovation industry.

Its mission is to provide an international union and cooperation of trade associations to support and promote professional development of professional sawing and drilling contractors and their methods. This umbrella organization of sawing and drilling associations is composed of associations from Australia, Austria, Germany, Japan, Spain, Sweden, Switzerland, the UK and the US. Formed in 1995, the IACDS’s headquarters in Switzerland and holds meetings annually around the globe. For more information, contact IACDS at info@iacds.org or visit www.iacds.org.

REVIEW AND COMMENT ON THIS ARTICLE AT WWW.CSDA.ORG/FORUM.cfm

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CSDA at the World of Concrete 2009

Right Place at the Right Time with the Right People For four days in February, World of Concrete was the focal point of 65,000 industry professionals from the fields of concrete and masonry construction at the Las Vegas Convention Center.

W

ith 1,700 leading industry suppliers in 880,000 net square feet, the exhibition featured innovative products, technologies, and tools and equipment to give companies new ways to sustain and grow their businesses. In addition, over 150 seminars packed with powerful messages and knowledge provided industry professionals with a wealth of information. Although attendance may have been down, all that attended felt there was an optimistic feeling in the air due to the fact that many decision-makers and buyers were present. One other noticeable feature of the show for sawing and drilling contractors was an increase in exhibitors representing floor preparation and polishing, together with an increased amount of interest in this service.

OSHA / CSDA Alliance For the third year running, OSHA had a presence at the CSDA booth and also was part of the seminar program. CSDA has been a co-sponsor of the World of Concrete (WOC) since 1977 and the affiliation with OSHA has increased in importance with each passing year. Rob Swick of OSHA’s national office was pleased to be at the booth, “The Alliance with CSDA has a great deal of benefits for SLURRY ROUNDTABLE both organizations. By sharing the CSDA booth at World of Concrete, we (OSHA) are able to meet and converse directly with CSDA members, cutting professionals with years of experience in the industry and non-members alike,” said Swick.

“We can listen to any safety related issues or concerns they may have and provide advice and

guidance.” CSDA and OSHA teamed up again at the event to cosponsor a seminar on the subject of Concrete Safety, Standards, Citations and Best Practices Presented by Danezza Quintero, which also proved to be popular with attendees.

CSDA Seminar and Roundtable Due to increasingly stringent federal and state controls of slurry handling and disposal, CSDA held a roundtable at WOC that gave 60 participants the opportunity to voice both their opinions and concerns regarding this subject, and to also share knowledge and experiences.

This way, fellow attendees were able to learn from the successes, and sometimes mistakes, of others. Moderators of the roundtable represented a variety of viewpoints from within the industry, from cutting contractors to representatives from slurry recycling equipment manufacturers. By discussing in an informal, yet structured manner, issues such as methods of decanting/filtering, individual state regulations and restrictions and familiarity with DEP standards, including acceptable PH levels for slurry, all participants were able to acquire a greater understanding of the subject that will ultimately benefit their businesses.

Also at the event, Rick Norland, CSDA lead trainer, held a seminar on the subject of Ground Penetrating Radar (GPR): Real Time, Non-Destructive Testing. This was Norland’s fourth WOC presentation, and proved to be as popular as ever as the event was sold out. The seminar gave great insight into this section of the industry.

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F E A T U R E

Husqvarna DXR 310 breaker robot

DITEQ provided live demonstrations of a range of Shibuya TS Blu-Drills. The TS range of core drills operate between 10 and 27 amps, have core diameters from 6 to 34 inches and have speeds ranging from 150 to 1,750 rpm. The Blu-Drill models feature low noise motors together with right and left hand feed positions to aid all operators.

James Instruments showcased the V-Meter Mark IIITM, an advanced ultra-sonic test system widely used and accepted for quality

New Products This year’s World of Concrete did not disappoint in terms of new products and technologies to enhance the efficiency and safety of cutting contractors, and many CSDA member companies were in attendance to show just that.

Husqvarna was proud to announce its new DXR 310 breaker robot to the WOC attendees. The 29.5-hp DXR 310 has an 18-foot reach and can contract to just 31 inches in width to fit through most standard-sized doors. This remote-controlled model also features front-mounted LED lights for working in areas with limited visibility and a 4.7-inch color display on the remote unit. However, the most innovative part of the DXR 310 is the use of Bluetooth® technology for remote communication between the control unit and the robot.

Unlike traditional radio control, multiple units can be used in close proximity without causing signal disruption due to the individual properties of each Bluetooth® signal. This demolition robot also comes equipped with breaker and crusher attachments and a bucket.

The highlight of the ICS booth was the new chain wall saw due for release later in 2009. This new track-mounted saw utilizes the flagship Force 4 chain chassis, and is capable of performing ICS chain wall saw 4-foot horizontal cuts through 12-inch reinforced concrete in approximately three minutes.

Unlike traditional wall saws, the chain wall saw can be rotated to make contact with the concrete at an angle. The saw is designed with confined spaces in mind, and will cut specialty openings in various walls and floors with thickness in excess of six inches.

The company also continues to promote its flagship 880F4 saw, which features a Force 4 chain chassis with 50% greater tensile strength than a standard chain.

Operator safety is an area that Hilti are looking to enhance with the release of the new TE 60 ATC-AVR combihammer. The new product has been specifically designed to reduce vibration, and its Active Torque Control (ATC) has been implemented to provide protection for operators. Aside from these features, the TE 60 ATC-AVR also has a theft protection system to offer peace of mind for operators. The SFH 18-A CPC hammer drill/driver was also highlighted at WOC, with emphasis on its increased charge life and charge life indicator to improve drilling potential.

DITEQ Shibuya TS Blu-Drills

control and inspection of concrete. The unit features a direct digital read out of transit time, a built-in wave form display and comes in a rugged, splash resistant case. The V-Meter conforms to ASTM C-597, BS 1881-203 and other international standards.

It was pleasing to find that even the current economic climate could not deter many CSDA member companies from exhibiting or attending a great show, and the optimism and forward-thinking displayed will no doubt prove to be invaluable in the future. As the old saying goes, it’s all about being in the right place at the right time that can make all the difference.

World of Concrete is the industry’s only annual international event dedicated to the commercial concrete and masonry construction industries. The event is now in its 35th year, having grown exponentially since first taking place in 1975. For more information, call 972-536-6423 or email contactus@worldofconcrete.com.

CSDA MEMBER BOOTHS

REVIEW AND COMMENT ON THIS ARTICLE AT WWW.CSDA.ORG/FORUM.cfm

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The Return of the

King

King Ramses Begins His Journey to the Pyramids With Help From This CSDA Member

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C O N C R E T E

T

C A S E S

he Statue of Ramses II is a red granite representation of King Ramses II of Egypt, showing the pharaoh in a standing position.

The statue was discovered in 1820 by Giovanni Battista Caviglia

at the Great Temple of Ptah of Mit Rahina, near Memphis, Egypt. King Ramses II ruled Egypt for 67 years during the 19th Dynasty (1279-1212 BC). The statue measures approximately 67 feet in height and weighs approximately 85 tons.

Following the Egyptian revolution of 1952, President Nasser requested the statue be moved from Mit Rahina to Bab El Hadid Square, the main railway station square in Cairo, in 1956. The statue was transported to its new location, which was renamed Ramses Square, and is one of the most famous statues of the Egyptian pharaohs. Since this time, the square has undergone significant development including the construction of waterfalls and colored lighting around the statue, together with the building of road infrastructure and bridges around the square in the 1980s. Unfortunately, all this has led to Ramses Square incurring increased noise, pollution and high vibration levels.

In 2005, the Egyptian Ministry of Culture, afraid the statue may be damaged by the constant vibrations and environmental conditions in the square, took the decision to relocate the statue approximately 30

Diamond wire saws cut through the statue’s base.

miles away to the Pyramids close to Giza City. By early 2006, the project was announced and tendered internationally. The winning bid was submitted by Arab Contractors Co. (Public Egyptian Contractors Co.), who approached several European companies to provide their ideas on how to dismantle and move the statue. Three ideas were presented. The Arab contractors asked Dr. Ahmed Hussein of the Engineering Faculty of Ain Shams University to submit a risk analysis. He found that the three ideas provided were too risky, and so came up with a completely different one. Arab Contractors were pleased with this new concept,

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Did You Know?

Pyramids During the earliest period of the 3rd and 4th dynasties, pyramids were constructed wholly of stone. Locallyquarried limestone was the material of choice for the main body of these pyramids, while a higher quality of limestone quarried at Tura, near modern Cairo, was used as the outer casing. Granite, quarried near Aswan, was used to construct some architectural elements, including the porticullis and the roofs and walls of the burial chamber. Occasionally, granite was used in the outer casing as well. In the early pyramids, the layers of stone forming the pyramid body were laid sloping inwards. However, this configuration was found to be less stable than simply stacking the stones horizontally on top of each other.

One of the major problems faced by the early pyramid builders was the need to move huge quantities of rock. Some illustrations show 172 men pulling an alabaster statue of a pharaoh on a sledge. The statue is estimated to weigh 60 tons and it is estimated that 45 workers would be required to start moving a 16,300-kilogram lubricated block, or eight workers to move a 2,750-kilogram block. Many archaeologists surmise that it took tens of thousands of skilled workers to build the pyramids, particularly the Great Pyramid of Giza. These workers camped near to the site and would work for a salary or as a form of tax payment (levee) until the construction was completed.

As the stones forming the core of the pyramids were roughly cut, especially in the Great Pyramid of Giza, the material used to fill the gaps was a problem. Huge quantities of gypsum and rubble were needed. The filling has almost no binding properties, but was necessary to stabilize the construction. To make the gypsum mortar, it had to be dehydrated by heating, and this required a lot of wood. Some findings suggest that Egypt had to strip its forest and scrap every bit of wood it had to build the pyramids of Giza. Workmen probably used copper chisels, drills and saws to cut softer stone, such as most of the limestone. The harder stones, such as granite, granodiorite, syenite, and basalt could not be cut with copper tools alone.

Instead workers used time consuming methods like pounding with dolerite, drilling and sawing with the aid of an abrasive, like quartzite sand. Blocks were transported by sledge likely lubricated by water. Leveling the foundation was accomplished by use of water-filled trenches.

The 120-ton statue took six hours to be removed from its base.

and contracted Dr. Hussein to complete the design, follow-up steps and transportation requirements. Hussein created a special design that allowed the statue to be transported in its standing position. Mohamed Labib of CSDA member Market Leaders was the consulting engineer for the core drilling and wire sawing of the statue’s concrete base which was a major part of the planned project.

Market Leaders began testing the concrete using several core-drilled test holes and wall and wire sawed cuts in various locations, away from the main base of the statue. The main concrete base under the statue measured approximately 16 feet in length, seven feet in width and stood 13 feet high. In addition, radar scanning and vibration sensing equipment, including 27 sensors around the statue’s base, was fitted.

This equipment was monitored for two weeks prior to work commencing to record the live vibrations of the statue and to ensure all cutting work did not exceed typical street vibration levels.

Two hydraulic systems were employed to cage the statue, consisting of four hydraulic cylinders, mounted on the four corners of the statue with a supporting steed structure. Another four supports for the basket carried the part of the concrete base located underneath the statue.

A one-inch-thick steel plate was placed around the concrete base, using one-inch-diameter core holes and threaded steel bars to hold this part of the concrete base in one piece. The base was then injected with high-strength concrete to make this part of the base more robust.

Seven 10-inch-diameter holes were created below the steel plate, and REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

C O N C R E T E

C A S E S

Many local people gathered to see the statue begin its journey.

seven steel reinforcement supports were fixed in place to form the basket bottom that carried the statue with part of the base. In addition, the whole cage system was fitted with two large bearings to allow movement back and forth while the frame carrying these two bear-

amounts of damage or even caused the statue to fall. Such were the dangers of having the statue placed on such a narrow base.

Market Leaders began wire sawing the upper level of the concrete base 10 inches below the generated basket base carrying the statue, using two wire saws. A wire

ings was carried on another two large bearings to

saw was set up at each side of the statue after dividing

allow independent movement side to side. The

the concrete base into two equal parts. Wire sawing

whole suspended basket, with the statue inside, could then have gyroscopic freedom on top of

commenced from the middle of the base to the outer edges with both machines running in parallel. The

the supporting structure. The suspended weight

robust part of the base acted as a simple supported

was approximately 135 tons, including the bas-

beam. The basket carrying the statue was carried

ket, the statue and the remaining part of the

through the basket suspension structure on

base. This ensured the statue could absorb some

the four inside supports. After each 30-minute

movement and vibrations while in a vertical position during cutting and transportation, enabling

period of sawing, steel platelets were inserted, each measuring approximately 0.5 inches thick, eight inches

the convoy to traverse humpback bridges or the

wide and 20 inches long, replacing the wire cutting

road super elevation.

clearance. The wire cutting took approximately six hours

Wire sawing elements were the most danger-

to complete.

ous part of the work because of the 67-foot height

Following the successful sawing of the upper level,

and 135-ton weight of the statue, carrying basket

two other levels at the middle and at the bottom of

and the remaining part of the base. It was criti-

the remainder of the base were also wire sawed. Once

cal to ensure there was minimal movement of the

cutting was completed, concrete jackhammers were

statue during the cutting process, as even a one

employed to break the concrete under the base and

degree lean in any direction could have caused large

remove it. Only then could the general contractor use REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

Following a 10-hour journey, King Ramses arrived in Giza.

their hydraulic jacks to lower the statue from just over 13 feet high to around 4.5 feet from street level for transfer onto the trailer.

The basket containing the statue was secured on both sides and

COMPANY PROFILE

transported using two specially designed, flat-bed trailers. The trailers

Market Leaders recently became CSDA members in

enabled the statue to be moved freely suspended in a vertical position.

September 2007 and are based in Cairo, Egypt. The company

Each trailer had eight axles, with eight wheels on each axle. In total, a

has been operating for 15 years, and specializes in diamond

weight of 180 tons was being carried. King Ramses’ journey began at

drilling, sawing and controlled demolition. Market Leaders

1:00 AM on the night of August 25, 2006, passing through the down-

has a team of eight operators and carry out sawing and

town streets where more than half a million Egyptians gathered to say

drilling jobs in and around Egypt and other Arab countries.

farewell to the King. The convoy reached the outer ring road bridge at 5:30 AM, traversing the ramp bridge before driving eight kilometers until they passed the Pyramids, finally reaching Giza at 10:00 AM. Upon arrival, the statue was greeted by the Egyptian minster of culture, minster of tourism and several ambassadors to officially welcome King Ramses II to his new home.

The project was a great success, and Mohamed Labib was pleased to have been a part of it. “It was a great opportunity to be the consulting engineer for the coring, floor, wall and wire sawing of such a large and prestigious job. Market Leaders is very proud to have played an important role in this project.”

RESOURCES

General Contractor: Arab Contractors, Co. Sawing and Drilling Contractor: Market Leaders, Cairo, Egypt Phone: 20-2 2453 0917 Fax: 20-2 2453 0917 Email: mleader2000@hotmail.com Methods Used: Core Drilling, Wire Sawing, Wall Sawing

REVIEW AND COMMENT ON THIS ARTICLE AT WWW.CSDA.ORG/FORUM.cfm

REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

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Coffee Break

Concrete Cutting Specialist Removes Storm-Damaged Sections of Coffee Warehouse A storage warehouse of Maximus Coffee was damaged due to a recent tropical storm that blew through Houston, Texas. Cotton Restoration, the General Contractor, was called upon to remove the damaged areas and rebuild. Cotton contracted CSDA member Holes Incorporated to perform the saw cutting, demolition and removal of the affected areas.

T

he job scope was to remove four wall panels that had been damaged by the collapse of the roof, saw cut 24 openings in the slab so new roof support columns could be added, and lastly the

demolition of a two-story block building inside the warehouse. Holes Incorporated was selected for this job because their sawing and drilling methods would help maintain the integrity of the building that would remain, which had not been damaged by the storm.

Wall sawing with diamond blades was used to cut and separate the four damaged concrete wall panels from the existing building. The methods employed by Holes ensured vibrations to a minimum and helped maintain the integrity of the remaining wall panels. The walls had been forced out at a 25-degree angle, therefore they all had to be shored in place before saw cutting could begin. Holes Incorporated decided to REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

C O N C R E T E

C A S E S

Left: Four panels were removed due to storm damage.

Right: A Holes Incorporated operative carrying out wall sawing on the project.

Below Left: All panels were shored and braced until removal.

Below Right: The panels were cut in half and lowered by crane onto trucks.

3-foot by 6-inch areas. The existing roof columns were broken and had left the slab damaged, so Holes Incorporated sawed around the area and broke out the sections using a skid steer with a hoe ram attached. Once the section was broken, the team dug out the area to allow Cotton to insert new columns to support the new roof.

Holes Incorporated also used a GDM wall saw to cut a 10-foot by use a GDM wall saw and 60-foot boom lift to cut the four 45-foot-tall by

10-foot by 8-inch overhead door opening that the owners wanted

14-foot-wide by 8-inch-thick panels. All panels were shored and braced

to allow additional deliveries to the warehouse. Before demolition

until removal. Two 6-inch by 8-inch holes were drilled into each panel to

of the two-story building could commence, Holes had to detach a

rig the panels for removal. The panels were cut in half due to their size,

wall which the building shared with its warehouse. Due to limited

and were lowered by a 110-ton crane onto Holes’ flat bed haul trucks.

access, a Stihl Saw was used to perform the cut. An ICS chain saw

Once the panels were down, the interior of the building was exposed

was then used to cut 16 9-inch by 6-inch by 8-inch-deep openings

and the team was able to use a Core Cut diesel saw for the 24 3-foot by

for roof scuppers. This was performed so that the roof would not fill with water and collapse again. Once the building was detached, the team used a backhoe and skid steer with a hoe ram to break up

REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

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Rebuilding work can now begin on the coffee warehouse.

and demolish the two-story CMU block building. Holes also performed concrete demolition of a 12-foot by 4-foot by 5-foot concrete staircase.

Holes Incorporated is actively taking steps to become a ‘green’ business, therefore all crushed and broken concrete was transported

COMPANY PROFILE

to a recycling plant for crushing and reuse throughout the Houston

The Holes Companies are service companies, specializing

area. The wall panels were sent to Holes so that they could be used for

in concrete sawing, drilling, breaking, lifting, demolition,

hands-on training.

scanning, load and haul and specialty wire sawing. The Holes

The job took eight days to complete and was on time and within

Companies primarily work for commercial and industrial

budget. This was Holes’ first job with Cotton Restoration, and due to

contractors, state highway departments and municipalities.

their success on this job have been awarded two additional projects.

Holes Incorporated, Holes Golden Triangle, LLC and Holes

Kellie Vazquez, administrative vice president of Holes Incorporated, is

Technology, LP have built a solid track record through 36

very satisfied with this project and pleased with her team’s performance,

years of experience and reliability. The company has been a

“We pre-planned the sequence of each task, and reviewed the job scope

CSDA member since 1976.

and necessary safety requirements daily to successfully complete each day’s work. We followed this format throughout the project.” Vazquez continued, “Our estimator and 20-year veteran, Lee Aitken, performed the job walk-through with our senior load and haul operator, 30-year veteran Mark Stepanski, prior to bidding the job. Mark performed safety audits every morning with the other members of the Holes team, and the crane operator when present. All safety concerns were addressed during the morning safety audits prior to commencing work.

This job was completed without any lost time, injuries, incidents or recordables during the project.” Hard hats, steel-toed work boots, hearing protection, gloves, safety glasses and fall protection was worn throughout the project.

In total, Holes wall sawed 400 feet of 8-inch-thick concrete, slabsawed 288 feet of 6-inch-thick concrete and hand sawed 12 feet of CMU blocks. The team core drilled 18 6-inch by 8-inch holes, and also chain sawed 40 feet of 8-inch concrete. This adds up to approximately 13,000 square feet of concrete removal.

RESOURCES

General Contractor: Cotton Restoration Sawing and Drilling Contractor: Holes Incorporated, Houston, Texas Phone: 281-469-7070 Fax: 281-469-6207 Email: kvazquez@holesinc.com Website: www.holesinc.com Methods Used: Core Drilling, Wall Sawing, Hand Sawing, Slab Sawing, Demolition

REVIEW AND COMMENT ON THIS ARTICLE AT WWW.CSDA.ORG/FORUM.cfm

REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

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Dock’s Owners Turn to CSDA Member for Precision Cutting

I

t has almost been a hundred years since civil engineers Easton, Gibb and Son started

construction of Rosyth Dockyard in Scotland in 1909, strengthening the Royal Navy’s presence along the East coast of Great Britain. In 1984, Rosyth was chosen as the sole location for refitting the Royal Navy’s nuclear submarine fleet, a role in which it was already specializing, and in 1986 extensive rebuilding commenced to facilitate this position. However, in 1993 the then-Conservative government switched the refitting role to Devonport.

Aerial view of Rosyth Dockyard, circa 1919.

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The huge caisson required cutting in order to be widened.

REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

Diamond wire sawing ensured a clean and precise cut through steel and concrete.

The caisson is used to dry dock vessels entering Rosyth Dockyard.

“Thanks to our expert staff, we managed to successfully complete the job on time and on budget.”

Babcock Thorn, a consortium operated

Early last year, as part of the Rosyth

by Babcock International and Thorn EMI, was

Dockyard infrastructure upgrade, Babcock

awarded the management contract for Rosyth

Marine approached CSDA member Core

Dockyard in 1987, after which they were a

Cut Ltd. of West Lothian, Scotland with the

government-owned, contractor-run facility. In

challenge of cutting a huge caisson in two.

1993, the Ministry of Defense announced plans

The caisson, already measuring 33 meters wide,

to privatize Rosyth. Babcock International

5.8 meters deep and 15.5 meters high, needed

(who had bought out Thorn’s share of the

to be widened and a new piece welded in

original Babcock Thorn consortium) was the

place. Therefore, an accurate and clean cut

only company to submit a bid, and after

was paramount. An extension piece had been

protracted negotiations purchased the yard

prefabricated to fit exactly between the two

in January 1997.

sections of the existing caisson, and required

REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

Did You Know?

The HMS CHURCHILL Currently, there are seven decommissioned nuclear submarines stored at Rosyth Dockyard, one of which is the HMS Churchill.

HMS Churchill was the first of three Churchill-class nuclear fleet submarines that served with the British Royal Navy. The three nuclear-powered fleet submarines served with the Royal Navy from the 1970s until the early 1990s, of which the lead ship was named after the former British Prime Minister and First Lord of the Admiralty, Winston Churchill. The Churchill-class was based on the older Valiant-class, but featured many internal improvements.

The Churchills carried a crew of 103 and had a full load displacement of 4,900 tons when submerged. They were 86.9 meters long, had a beam of 10.1 meters, a draught of 8.2 meters and could achieve a maximum speed of 28 knots when submerged. The submarines were fitted with one Kelvin-type 1008 surface-search radar and a type 2001

The setting up and cutting process took ten days.

sonar array, which was replaced in the late 1970s with a type 2020 array and a type 2026 towed array. Weapons included Mark 24

welding together without the need for any infill

and guided into position. Water is then

Tigerfish torpedoes and sub-harpoon, anti-

metal. Being specialists in the fields of drilling

pumped into tanks to sink it and form

ship missiles. Six 21-inch (533-mm) torpedo

and cutting, Core Cut were keen to accept this

a watertight seal. The caisson is then

tubes fired from the bow.

challenge.

used as a walk and roadway. The water

Like all nuclear powered submarines,

In a dockyard, a caisson performs a similar

in the dock is pumped out, with the ves-

the Churchill-class could remain submerged

task to lock gates on a canal. The big difference

sel being docked on oak blocks at the

almost indefinitely, with supplies of food

is that a caisson is moveable and floats like a

same time.

being the only limiting factor. The HMS

ship. When a vessel needs to be dry docked, the

The structural makeup of the caisson

Churchill evaluated both the American Mark

dock is first flooded and the caisson is removed

meant Core Cut needed to make two dis-

48 torpedo and the UGM-84 harpoon missile

by pumping out the water inside of it. When

tinct cuts. The first was to the lower bal-

during its service, though only the latter

afloat, it is moved by capstan and cables to the

last section standing 3.5 meters high that

was adopted by the Royal Navy. The HMS

outside wall leaving the entrance to the dock

included concrete and steel. The second,

Churchill was decommissioned in 1990 at

clear. The vessel is then towed into the dock

and much larger cut, was of the remain-

Rosyth and is currently awaiting disposal.

and the caisson is returned to the entrance

ing 12 meters. Additional concerns of

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Core Cut were that the interior of the caisson

ing to be the fastest and most versatile means

outcome of both the cuts and the project as a

contained various ballast tanks and internal

of cutting heavily-reinforced concrete and

whole, “Thanks to our expert staff, we man-

bracing, all of which had to be cut with the

steel. The wire saw easily handles the thickest

aged to successfully complete the job on time

same degree of accuracy as the mass concrete

sections of all construction materials with cut-

and on budget.”

ballast to the keel section. The cuts also had

ting rates in excess of one square meter-per-

In addition to these works, Core Cut was

to be wedged as the team progressed to pre-

hour achievable, and the ability to cut circular

awarded a separate job on the same project,

vent the natural expansion and contraction

openings up to 2.5 meters in diameter leaving

and was subcontracted by Edmund Nuttall to

of the steel affecting the cutting process by

clean, straight and smooth cut surfaces with no

help with the dock-widening program. Core

snagging the wire.

damage to the remaining structure.

Cut’s job was to make preparatory cuts of the

For Core Cut, cutting the caisson in two

The work was carried out over ten days

was not going to provide any problems, but

during July 2008, in which time the cutting

cutting it accurately to allow for a success-

team mobilized, set up the equipment, per-

ful weld was going to be the real challenge.

formed the cut and broke out the mass con-

Fortunately with 30 years in the sawing and

crete ballast from the keel section. Since Core

drilling industry, and a team of highly skilled

Cut completed their work, Babcock Marine has

workers, Core Cut’s director Finlay Crocker was

now successfully welded in the extension piece

confident of success, “Like most jobs it was all

to the caisson. Crocker was pleased with the

concrete and granite to facilitate the easy and tidy removal of the alters (large dock steps).

in the setting up and our skilled operators are known for their attention to detail no matter how large or challenging the task.”

Core Cut spent over 24 hours setting up and preparing the task, checking and re-checking using a Hilti PR25 rotating laser to ensure accuracy before commencing the wire sawing.

They employed a Hilti WS 15E 15 kW electric wiresaw system. Hilti also supplied the 10 and 4 noise-reducing pulley sets required for the

COMPANY PROFILE

Core Cut joined CSDA in 1996 and is based in Broxburn, West Lothian, Scotland. The company is a family owned and run business celebrating 30 years in the concrete drilling and cutting industry. During this time, Core Cut has built an enviable reputation within the UK construction industry and is a specialist in diamond drilling, sawing and controlled demolition.

The company is proud to have achieved ISO9001 accreditation.

project, and Core Cut made some modifica-

RESOURCES

tions that would allow the position of the pul-

General Contractor:

ley wheels to be adjusted without the need for

Babcock Marine

repeated set-ups. Power was supplied by a 70

Sawing and Drilling Contractor:

KVA Super Silent 145-volt mobile generator.

Core Cut Ltd., West Lothian, Scotland

The set up was overseen by Finlay Crocker and

Phone:

Ernst Siegenthaler, Hilti’s global key account

44-1506 854710

manager of the Diamond Systems Business

Fax:

Unit, and carried out in conjunction with engi-

44-1506 853068

neering staff from Babcock Marine.

Email:

Core Cut’s wire sawing was accomplished

finlay@corecut.co.uk

using a 50-meter length of 100% specifica-

Website:

tion steel diamond wire supplied by Hilti Great

www.corecut.co.uk

Britain. Core Cut has found diamond wire saw-

Methods Used: Core Drilling, Wire Sawing and Controlled Demolition

REVIEW AND COMMENT ON THIS ARTICLE AT WWW.CSDA.ORG/FORUM.cfm

REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

Kentucky Fired

Charcoal Cutting Contractor Takes Part in Explosion Vent Installation Project

The team had to drill through a quarter-inch of medium strength steel to start.

REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

C O N C R E T E

C A S E S

Holes were required at the plant to prevent pressure build-ups.

S

awing and Drilling projects, big or small, come with many com-

duces charcoal briquettes, and Madison Smith had been contracted by

plex elements that must be overcome by the cutting contrac-

Kingsford to install nine “explosion vents” at the plant. The installa-

tor to get the job done. People may think that the difficulty

tion would require nine clean, round holes to be located in an exterior

of a project is directly proportionate to the size. However, this is not

wall. The new explosion vents would provide a safe release of pressure

always the case. There are just as many small, complex projects being

should an explosion occur.

undertaken by relatively small cutting and coring companies—one of

The project called for nine, 20-inch-diameter holes to be located

which is CSDA member company Taylor’s Concrete Cutting Services of

in an exterior wall. The wall had a total depth of only two inches, but

Franklin, Kentucky.

was constructed of an outer layer of quarter-inch medium strength steel

Taylor’s has been asked to tackle many unusual projects during its

and an inner layer of inch and a half refractory material. The refractory

time in the industry, but in July of 2008 they were asked to participate

material consisted of a concrete-like material embedded in a horizon-

in one of its most unusual yet. Jeff Blanton, project manager for gen-

tal and vertical grid of 3/16-inch stainless steel flat bar. What made the

eral contractor Madison Smith Machine & Tool Company, contacted

project difficult for the general contractor was that the holes had to

Ron Taylor to discuss a project he was working on at Kingsford Products

penetrate both the steel and refractory material. Using a torch was not

Company’s charcoal plant in Summer Shade, Kentucky. Kingsford pro-

an option, as a torch would cut through the outer layer of steel but not the refractory material. The solution had to involve core drilling, and that’s where Taylor’s came in.

There were three basic criteria for the project: First of all, the general contractor required nine 20-inch-diameter, clean, round holes in the wall. Secondly, no holes could be drilled in the wall for drill mounting purposes. Thirdly, the holes had to be drilled from the outside of the wall, which meant that drilling had to begin on quarter-inch medium strength steel.

REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

The contractors carefully maintained drilling speed and pressure to achieve success.

The cutting team worked with Diamond Products to satisfy the first part of the criteria by designing a core drill bit that would penetrate the steel as well as the refractory material. Diamond Products designed a 20-inch-diameter,12-inch-deep bit with 32 segments. The segments were formulated with a bond that would allow the bit to efficiently cut the steel.

Once the bit was designed, Ron Taylor worked with Dave Gillespie, Madison-Smith’s site supervisor, to design a drill mounting system. The second project criteria stated that no mounting holes could be drilled in the wall, therefore a machinist from the general contractor fabricated a steel plate that contained threaded rods on which to mount the drill.

Gillespie tack-welded the steel plate at the hole location and the drill was mounted to the plate. The mounting system allowed the drill to be mounted without drilling additional holes in the wall.

The third criteria stated by the general contractor was that holes had to be drilled from the outside of the wall, meaning each hole had to begin on the surface of a quarter-inch medium strength steel panel.

Core drill bits have a tendency to “walk,” that is to move vertically and Nine 20-inch diameter holes were drilled by Taylor’s.

horizontally when beginning a hole on a flat steel surface. Since the project called for clean, round, 20-inch-diameter holes, something had to be done to keep the bit from “walking.” The core drilling team’s solution was to use guide rollers to stabilize the bit. The machinist at MadisonSmith installed the guide rollers on a plate that they designed and fab

REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

It took Taylor’s six days to complete the six holes.

ricated. The site supervisor tack-welded the guide roller plate underneath each hole location to stabilize and support the bit as it turned.

Ron Taylor, along with his cutting team, began drilling at Kingsford

COMPANY PROFILE

Taylor’s Concrete Cutting Services, LLC, are based in Franklin,

on September 18, 2008. The team used a Diamond Products Char-Lynn

Kentucky, and have been a CSDA member since 2006. The

hydraulic drill, powered by a Diamond Products model CB24XL gaso-

company has been operating for nine years, and specializes in

line powered hydraulic power pack. A 30-foot lift provided them with

diamond drilling, sawing, and controlled demolition. Taylor’s has

access to the wall. Drilling through the refractory material was espe-

a team of seven operators and carry out sawing and drilling jobs

cially challenging as the bit had a tendency to get hung on the stainless

in the Middle Tennessee and Southern Kentucky areas.

steel mesh. Taylor had to ensure the correct drilling speed and pressure was maintained to guard against hanging the bit. Taylor’s team spent the entire day drilling the first hole, but as the drilling progressed, the cutting team experimented with speed and pressure, perfecting their technique.

It took Taylor’s Concrete Cutting Services approximately six hours to drill each hole, two hours to drill through the quarter-inch steel plate and four hours to drill through the 1.5-inch-thick stainless steel and refractory material. All nine holes were completed in six days. The custom-made bit, drill mount and guide roller plate worked as expected, a testament to the innovative approach and excellent planning executed

by Ron Taylor, Jeff Blanton and their respective teams. By working on the principles of mutual trust and cooperation, the cutting contractor was able to overcome the challenges of a most unusual small project.

RESOURCES

General Contractor: Madison-Smith Machine & Tool Company Sawing and Drilling Contractor: Taylor’s Concrete Cutting Services, LLC, Franklin, Kentucky Phone: 270-598-9400 Fax: 270-598-9020 Email: info@taylorsconcretecutting.com Website: www.taylorsconcretecutting.com Methods Used: Core Drilling

REVIEW AND COMMENT ON THIS ARTICLE AT WWW.CSDA.ORG/FORUM.cfm REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

The Business of Business

How to Survive and Thrive in a Tough Economic Climate

By Chip Webster

I

t’s likely that booms and busts have been part of the business world ever since the first shell jewelry was exchanged 100,000 years ago.

For businesses that successfully weather this tough economic climate,

the silver lining is a relatively open market when the economy begins to rebound.

Over the past 35 years, working with companies ranging from Fortune 500 firms to start-ups that are still a gleam in their founders’ eyes, I’ve identified three key areas where CEOs should focus their attention to ensure that their company comes out on top.

First, of course, is cash. Businesses that have it will survive, those that don’t, won’t. Unprofitable businesses with positive cash flow can stay in the game, while a profitable company with negative cash flow will go broke. Here are some key points for a CEO to consider: •

Cash ain’t cash unless it is cash. You need daily reports on all

•

Receivables and inventory aren’t cash. Look at every unpro-

bank balances and weekly cash flow projections for 90 days out. ductive asset to see if you can convert it to cash. Invest in cash bonuses to employees who help turn those assets into cash.

•

Paper profits don’t count—and never, ever get caught in the “we’ll take this one to break even” trap.

•

Work with both vendors and customers to increase available cash.

Personally visit big customers who are slow payers and work out payment plans. Ask suppliers for better pricing and/or terms, and consider consolidating suppliers to get the best deal. Increase your price on small accounts.

•

Develop alternative sources of cash and draw down credit lines if necessary—but make sure you understand every word of bank covenants first.

•

Finally, keep an eye on the future. No one knows just how long this recession will continue, but many demographics show that certain states will become economic powerhouses in the near future as signs of recovery emerge. Be ready to take advantage of pent-up demand when this recovery occurs by: •

Don’t stonewall bankers, creditors or landlords. Communicate with them often and tell them the truth.

Second, corporate is more important than ever. CEOs need to be leaders not managers. Leaders are out in front, managers hide in their office and send emails and memos. Your first job as a leader is to make sure that every employee is pulling his or her weight. Systematically review every employee’s skills and attitudes and get rid of weak, underperforming people today.

Create a team culture with the high-performing people that remain.

Have ‘town hall’ meetings, communicate constantly and look for positive news to announce. If you have to cut top-notch people, put your staff in a room and let them decide if they want to go to a shorter work week instead of laying off co-workers. Then, if you have to cut hours or pay, cut your own pay even more.

Personally calling lost customers and doing whatever you need to do to get them back. Calling on your top accounts to ask how you can help them survive this downturn.

•

Leaving unprofitable business on the table for your competition.

• Picking up market share whenever possible, and considering buying weak competitors who will make your business more profitable.

As frustrating as the current economic climate is, always remember: tough times never last, tough people do.

Chip Webster is president of TEC Florida, an affiliate of Vistage International and the state’s leading organization for CEOs. For more information, visit www.tecflorida.com or email info@tecflorida.com.

REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

Tech Talk Tech Talk is a regular feature of Concrete Openings magazine, focusing on equipment, maintenance and operational issues of interest to concrete cutting contractors. Readers wishing to have a particular subject addressed can call or email CSDA with their suggestions at 727-577-5004 or rhitchen@concreteopenings.com.

The Evolution of Synthetic Diamonds

By Robert Hodson

M

anufactured diamonds have

are recovered and sorted by size, shape, and

been commercially available

purity. Particle toughness is directly related

for over 50 years, but were

to purity—the higher the purity, the higher the toughness.

not used extensively by diamond blade manufacturers until about the mid-seven-

Diamonds manufactured by the cobalt

ties. The main reasons for this were that

matrix method generally have inclusions

suppliers of natural (mined) diamonds

called dendrites, which resemble tree

convinced manufacturers for many years

branches. These inclusions have an effect on

that their natural material was better, and

crystal “friability” or resistance to fracture.

simply because manufactured diamonds

Friability is determined by subjecting the

were more expensive.

crystals to a crushing action using standard

From a technical viewpoint it was easy

loads for standard time periods, then

to see that the manufactured variety may prove to be better than

measuring the weight loss. Diamonds manufactured by the iron-nickel

the natural alternative, because the former were block-shaped, single

matrix method also have inclusions, but usually not the dendritic variety.

crystals with far fewer internal flaws than the natural type. However,

However, these inclusions also affect friability of the diamond.

this remained undemonstrated on a large scale until the mid-seventies

Over the years, diamond makers have been working on ways to

when, due to political upheaval in Africa, natural diamonds became in

increase the yield of high purity particles in every batch of diamonds

short supply and their price skyrocketed. Now, manufactured diamonds

produced, with relative success. This has given diamond blade

were not only less expensive, but were almost the only type of diamonds

manufacturers another direction to take when the need to alter blade

available.

performance arises.

Diamond blade manufacturers launched fast-track development

Another important development in manufactured diamond

projects to learn how to use the manufactured variety in their saw blade

technology is the recent progress being made in coated diamonds. The

segments. These projects required changes to process parameters in

purpose of using coated diamonds is to improve diamond retention in

order to minimize exposure of the diamonds to high temperatures and,

the metal bonds so that diamonds are not lost before they can be fully

in some cases, changes in metal bond chemistry. Overall, manufacturers

used. In the past, single layer coatings on diamonds were not effective

found that the conversion was easier than expected. Once the changes

due to incompatibility with either the diamond particles or the metal

were made, results were astonishing. Suddenly, hard materials were

bond. The newer coatings now available are multi-layered, having one

easier to cut, cutting rates went up and in many cases blade life

material in contact with the diamond particles and another material

improved.

in contact with the metal bond. These new coatings are being used

Today, manufactured diamonds are used almost exclusively in metal-

successfully in many applications.

bond diamond saw blades. It is well known that man manufactures

In conclusion, out of necessity and the innovation of pioneering

diamonds in a similar way as Mother Nature does, that is, by subjecting

scientists, today’s synthetic diamonds are harder, stronger and less

carbon to high temperatures and ultra high pressures. At the

expensive than those produced 50 years ago. These diamonds are

temperatures and pressures used, the carbon atoms are squeezed so

designed more for the specific purposes of concrete cutting, including

closely together that new atomic bonding occurs and the atoms are

increased blade life and more aggressive cutting techniques. These

locked into the diamond crystal structure. The transformation from

synthetic diamonds are more than capable of standing up to the ever-

carbon to diamond occurs within a molten metal matrix of either cobalt

growing needs of the concrete sawing and drilling industry.

or iron-nickel alloy. The product recovered from the press is an odd shaped nugget of metal with diamond particles protruding all over.

The metal is then leached away with acids and the diamond particles

Robert Hodson is the research director of Sanders Saws, Inc., a division of Multiquip, based in Honeybrook, Pennsylvania. Sander Saws can be contacted at 800-486-0797 or by email at cpriest@multiquip.com.

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Insurance CornER

Are Your Managers Really Managing?

By Bill Crimmins

M

any of us feel we do not have time to think about the

Following the results of the OSHA investigation, the events leading

‘what ifs’ out there. Our time is spent dealing with problems

to the incident were painstakingly reviewed by the managers and

in a reactive, day-to-day way, sometimes not thinking

OSHA’s citations were discussed at length. During the review and

about every possible eventuality associated with any given problem

discussions, a number of issues that had contributed to the incident

or situation. This thought process is similar to the Pareto principle, also

were highlighted, and it became increasingly apparent that these issues

known as the 80-20 rule, the law of the vital few and the principle of

had been overlooked during the planning and mobilization stages of

factor sparsity. Many businesses focus on the twenty percent of their

the job. However, the omission of these issues is not the focus here, but

clients or workload that produces eighty percent of their income.

the subtle misunderstandings that led to these omissions are.

Unfortunately when it comes to OSHA, this rule can cause

The project team assigned by the contractor was typical for

contractors to focus all their attention on OSHA regulations that attract

such a job—a foreman and several operators. It was assumed that

frequent attention such as fall protection, hazard communication or

members of senior management would carry out site visits on a weekly

silica exposure, and overlook other regulations that may be of equal

basis to monitor progress and provide further instructions where

importance. With this in mind, it is imperative that managers are aware

required. This arrangement is not uncommon in the industry, and

of all applicable regulations for a given job, and that they are working

is an arrangement that works successfully when each person’s role

together to adhere to them. There are several scenarios that could

is well defined and understood. Unfortunately in this instance, the

happen and leave owners and managers exposed to liability. Although

foreman did not have a solid understanding of his responsibilities.

these scenarios may not fall into Pareto’s twenty percent, it is important

In addition, senior management was under the assumption that the

to be diligent and fully aware of them.

foreman was responsible for the successful completion of the project,

Recently a cutting contractor encountered such problems while on

as well as meeting all training and safety requirements. The result of

the job site, where compliance with OSHA regulations was questioned.

these misunderstandings and lack of communication was over $40,000

An incident had occurred where an employee of the client had been

in OSHA citations.

seriously injured on the site. OSHA was notified and representatives

It transpired that the foreman had only accepted his position

arrived to carry out an investigation into the possible cause of the

based on an assumption that he would run the job site with little

accident and the injury. A series of citations were issued regarding the

actual reign, yet collect a higher rate of pay. Basically, he would be a

conditions the workers were being exposed, and to what level they

‘paper foreman’ and would hold the position in name only, making

were protecting themselves from potential hazards. The contractor was

him devoid of responsibility in terms of decision-making or safety and

cited for several violations, including not being in possession of material

health compliance. This, however, was not the case. This is a common

safety data sheets, failure to have various written policies in place and

misconception made by operators who are given supervisory roles. Their

having no documentation to certify employee training.

technical proficiency has helped in elevating them to a supervisory status, but a number of additional skills are required and must be applied in order to succeed in this role. One of the most important being an awareness that they are now responsible for the activities and safety of their operators. In this case, the foreman had not understood that he was a manager, and bore such responsibilities.

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When OSHA interviewed the operators on site, they discovered that

subject to a variety of citations. Foremen need to be knowledgeable of

the foreman had allowed the use of unauthorized Personal Protective

site safety requirements and should engage in regular communication

Equipment (PPE) which required appropriate selection, fitting tests,

with senior management. Adopting habits such as looking the other

training, sanitary conditions, routine inspections, medical evaluations

way, or failing to understand and learn about the appropriate laws, is an

and a written program. OSHA found that operators were using half-face

unacceptable management method. Should a foreman be unwilling to

respirators with no program in place. Furthermore, OSHA reviewed the

adopt the responsibilities of a management position, then they should

job site and concluded that operators did not actually require respirators

not be considered for such a position.

for that type of environment. When questioned, the operators said they

While there were several factors in this particular example, the

wore the respirators simply for comfort, opening the contractor up to

issue of management failing to communicate with each other and not

further scrutiny. The foreman thought nothing of this, thinking that

providing adequate supervision, led to a serious injury and subsequent

showing OSHA his operators were taking steps to protect themselves

citations. In addition, focussing too much on the twenty percent can lead

would be nothing but a good thing in their eyes, and would show he

to significant losses elsewhere. All CSDA contractors are encouraged to

was doing the right thing.

assess their current and upcoming jobs to ensure that operator safety

This line of communication, together with a lack of understanding

is appropriately managed.

and appropriate supervision, lead to significant citations. The fact that

The CSDA insurance program can assist in providing training for

the respirators were not provided by the contractor had no effect on

employees and provides members with routine instruction regarding

the proceedings. The foreman had the responsibility of evaluating the

safety related matters. Bi-monthly safety conference calls and safety talks

safety of the operators, and was aware that respirators were available

are just one part of the process, where many subjects are discussed and

and in use. Subsequently, the fact that the foreman knew about the

contractor concerns are addressed to prepare them for any eventuality.

respirators meant that management was aware of their use, and should have triggered the implementation of the required program. This was the case, in spite of the fact that the operators had supplied their own

Bill Crimmins is the president of Titan Risk Management LLC, based in New Lenox, Illinois. Bill also acts as a consultant for the CSDA insurance program.

He can be reached at 815-405-8448 or by email at crimminsb@comcast.net.

respiratory equipment.

Senior management argued that they had no knowledge of the respirators, and that the citations should not have been issued. This argument could not stand, as the foreman had allowed the use of the respirators, and he represented management. Neither the foreman or senior management had a full understanding of the foreman’s role.

Needless to say, the citations held.

This example demonstrates exactly why sawing and drilling contractors must communicate to foremen that their position represents a level of management, and ensure that the foremen act accordingly.

If on site managers do not understand the responsibilities of their role or follow prescribed safety procedures, then the contractor may be REPRINTED FROM CONCRETE OPENINGS | VOL.18 | NUM.1 | MARCH 2009

Safety CountS

Avoiding Lockout Tagout Violations

By Mark A. Lies, II

Introduction

the equipment for production.” However, if

Application

As all employers should know, employees must

Lockout tagout (LOTO) applies to the

an employer relies upon this exception, they

be protected against the hazards of “unexpected

control of all energy (e.g., electrical, hydraulic,

must develop and utilize alternative measures

energization” when performing certain functions

pneumatic, gravity) which may be encountered

that will provide effective protection. Finally,

with electrical, hydraulic, pneumatic or other

during servicing or maintenance of machines

there is one additional, limited exception.

applicable equipment. Despite the fact that the

in the general industry sector. The regulation

When the sole source of energy is electrical,

OSHA regulation, Control of Hazardous Energy, 29

can be confusing to employers because it does

and the equipment utilizes a “plug and

CFR 1910.147 (also known as lockout tagout) has

not cover normal production operations, thus,

cord” connection which can be unplugged to

been in effect for many years, employers continue

servicing and maintenance which occurs during

completely de-energize the equipment, and

to receive frequent, and in many cases significant,

normal production operations is only covered

providing the employee maintains control over

monetary citations for non-compliance. However,

if it requires:

the plug and cord, then this would also be an

it is prudent to mention that this regulation does

•

not currently apply to construction or other sectors.

Nonetheless, it is recommended that contractors

An employee to remove a guard or safety device, or

•

Place part of their body into a point

are made aware of this regulation and follow the

of operation area or a danger zone

guidelines to ensure a safe working environment.

during a machine operating cycle.

More importantly, failure to initially imple-

There is a further exception. This exception

ment or to comply with an employer’s lockout

includes the performance of minor tool

tagout procedures has led to numerous fatalities

changes, adjustments or other minor servicing

and serious injuries due to equipment energiza-

activities which take place during the normal

tion during servicing or maintenance. This article

production activities, providing they are

is a brief overview highlighting certain high pro-

“routine, repetitive and integral to the use of

file aspects of the regulation that have occurred recently, and the potential liabilities involved.

exception.

Process In order to develop an effective LOTO program, the employer must first determine if and when LOTO applies and develop specific written procedures for each piece of equipment, identifying each and every energy source as well as the specific means and methods for de-energizing the equipment. This must also include the various energy control switches or devices for utilizing locks that are individually issued to “authorized” employees.

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Authorized employees are those who have been

Enforcement

If the periodic inspection reveals that

trained and authorized by the employer to

Once a LOTO program has been developed

perform LOTO using the appropriate written

the LOTO procedure is no longer effective

and employees have been trained, the program

procedure. Other employees, identified as

due to equipment or process changes,

must be enforced with ongoing observation by

“affected” or “other,” must generally be trained

the procedure must be rewritten and

supervisors and discipline for violations, up to and

to recognize and be aware of LOTO procedures.

employees retrained. If the authorized

including termination. If employers fail to develop

These employees must not in any way attempt

employee is unable to perform the

a LOTO program, train employees and utilize

to start or re-energize machines that have

procedure properly, the employee must

aggressive enforcement, the employers cannot

been locked out, or to tamper or remove LOTO

be retrained. In all cases, the training must

avail themselves of the “unavoidable employee

devices while LOTO is being performed by

be documented. It should also be noted

misconduct” defense which can be an absolute

authorized employees.

that if an employer prepares certification

legal defense to liability for an apparent violation.

of an inspection that is falsified, there are

After initial training, refresher training must be conducted whenever there is a change in job

potential criminal penalties against the

Periodic Inspections

employer and the individual employee

assignments, machines or processes that may

A recent developing area of significant liability

create or present a new hazard, or if changes

involves the duty of an employer to conduct a

have been made to the actual LOTO procedures

periodic inspection under 29 CFR 1910.147(c)(6) of

themselves.

each energy control procedure at least annually;

As the regulatory climate changes

to verify that the procedure is still effective for the

within OSHA to a more aggressive

equipment and that the authorized employees are

enforcement structure, there is no

competent to perform the procedure (that is, their

question that LOTO compliance will be

training is still effective). Basically, the employer

more closely evaluated by the agency,

must observe an authorized employee performing

with increasing citation liability. In

the procedure at least annually. The employer must

any regulatory inspection involving an

then certify in writing, under 29 CFR 1910.147(c)

employer in general industry, where the

(6)(ii), that the periodic inspections have been

employer utilizes any type of equipment

performed by:

or machinery, OSHA will request to inspect

•

who prepared the false certification.

Conclusion

Identifying the machine or equipment on

the LOTO program, procedures, training,

which the energy control procedure was

periodic inspection certifications and

being utilized,

records of any disciplinary action taken

•

The date of the inspection,

for violations. An employer who develops

•

The employees included in the inspection,

and administers an effective program will

and

reduce the potential for employee injury

The person performing the inspection.

as well as regulatory liability.

•

Unfortunately, many employers are completely unaware of the obligation to conduct periodic inspections and prepare the certification or they risk allowing the annual periodic inspection requirement to lapse beyond a year. Recently, OSHA has begun to issue willful citations, which can carry penalties up to $70,000 per violation, or to separately cite each machine or piece of equipment

Mark A. Lies, II is a labor and employment law attorney and partner with Seyfarth Shaw LLP in Chicago, Illinois. He specializes in occupational safety and health law and related employment law and personal injury litigation. In addition, Mark has worked with CSDA members in their businesses. He can be reached at 312-460-5877 or at mlies@seyfarth.com.

for which a periodic inspection was not conducted, resulting in significant monetary penalties.

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