BL.KOREA Concrete Manual Download Page 1

Page: 1 / 39

Rock

Concrete

Splitter

Manual

(Concrete)

(Rock)

== TABLE OF CONTENTS==

TYPICAL APPLICATIONS FOR THE ROCK/CONCRETE
SPLITTING SYSTEM.

Power Rock Splitter

–series Technical

Specification

- Basic Concept
- Advantages of the SP-series Splitters

- Operational Theory
- Comparison with Other Non-Explosive Methods

OPERATIONAL SEQUENCE

Drill the holes.

Cleaning the Drill Holes

Summary of Contents for Concrete

Page 1: ...ATIONS FOR THE ROCK CONCRETE SPLITTING SYSTEM Power Rock Splitter series Technical Specification Basic Concept Advantages of the SP series Splitters Operational Theory Comparison with Other Non Explosive Methods 2 OPERATIONAL SEQUENCE 1 Drill the holes 2 Cleaning the Drill Holes ...

Page 2: ...ower Pack 3 Power Cylinder 4 Hose Sets 5 THINGS TO KNOW 1 Connecting the electric line 2 Oil 3 Pressure limit switch 4 Hose 5 Location of the Power Unit 6 Damaged Hoses or Fittings 7 Supporting the Power Cylinder in vertical holes 8 Maximizing the Power cylinder life 9 Straightness of holes 6 SERVICE MANUAL 1 Sub Component Identification 2 Trouble shooting Rock Splitter fails to operate Transforme...

Page 3: ...or conventional blasting methods ii In downtown core areas where there are by laws regarding noise and dust pollution iii Job sites near to electrical supplies gas mains water mains or other services that can be adversely affected by vibration and fly rock iv Under in or beside historic buildings that can be damaged by less controlled methods v Excavating narrow trenches in rock or concrete dedica...

Page 4: ...hift 115 315 80 220m3 shift Drill by Top Hammer DTH Hammer CORE DRILL Drilling Diameter in 3 504 89mm Technical specifications are subject to change without prior notice due to quality improvement More detailed specifications are available in Appendix 1 ...

Page 5: ...in excess of 1 200 tons 144 000psi There are several mechanical methods available to split rock including the Darda system HRS expansion methods using chemicals Brista gas gun method and Super Wedge insertion by excavator The Power Rock Splitter has demonstrated time and time again that it is the safest most efficient cost effective and productive method on the market today 3 ADVANTAGES of Power R...

Page 6: ...ds of expansion chemicals is expensive and not usable in horizontal holes As a direct result of equipment failure or the introduction of chemicals the potential for environmental damage is increased All of these problems can lead to excessive maintenance costs and lower production rates The Power Rock splitter requires little maintenance uses environmentally friendly oils and replacement parts cos...

Page 7: ...c hammer Expansion Tube is expensive easily broken More down time Increased risk of hydraulic spills Wedges are weak and expensive and are easily broken Lubrication is expensive Increased risk of hydraulic spills Chemical is expensive Long wait times while chemical sets Increased risk of chemical spills Applicable Job Site Medium or Large Site Small or Medium site Small and or Narrow site Narrow s...

Page 8: ... drill of choice although a crawler mounted DTH drill would also be acceptable The other choice would be a Coring Diamond Drill on Excavator especially where noise dust and vibration are restricted The PCD 200 series Diamond Core Drill can be attached to an excavator if there is no available crawler mounted drill or crawler mounted DTH drill Fig 3 1 PCD 200 Core Drill Bits An excavator can also be...

Page 9: ...it or DTH Note If you do not use the recommended bits and the holes are crooked damage and premature failure of the power cylinder will occur This may invalidate a warranty claim 2 Cleaning the Drill Holes The drilled hole should be cleaned out prior to the insertion of the Power Rock splitter power cylinder This can be done using a blowpipe and compressed air or by using the rake supplied with ea...

Page 10: ...linders are properly placed in the selected holes the Oil Directional Control Lever is set to the right hand side The pump supplies oil to the power cylinders and ramps up the pressure in the pistons forcing them to stroke outwards until the rock or concrete is fractured Directional Control lever Fig No 3 5 THIS POINT WILL BE CRACKED THIS POINT WILL BE CRACKED Piston Direction Piston Direction Tur...

Page 11: ...ecreases the ability to create fractures The temptation is to augment the travel by inserting a backing plate in order to shim the power cylinder This has been done before with a high degree of likelihood that the power cylinder body will be cracked and made inoperable Redrilling is the most prudent option Fractured Concrete and Hard Rock Fig No 3 6 Concrete Rock 6 Power Down After cracking the ro...

Page 12: ...ion of the broken rock or concrete obstruct you from pulling the power cylinder out of the hole do not pull it out by force Clean out the broken material and then pull out the power cylinder smoothly 8 Secondary Breaking If the broken material is too large and bulky to be removed either the material must be broken with an impact hammer or drilled and broken up using the splitter If this is a conti...

Page 13: ...tion Rock splitting direction For very Hard Rock Caution Generally you will drill the holes to a depth 5 6 longer than the Power Cylinder length When the Power Cylinders are inserted into the holes they must be suspended so that they do not drop too deeply into the hole An 8 rebar or drill steel would be appropriate Another consideration when orienting the pistons of the power cylinder is to look ...

Page 14: ...ll speed and drill accuracy than it is on the splitting time Avoid problems with jammed power cylinders and down time due to cracked power cylinder bodies by drilling holes accurately and to an established pattern 2 Horizontal Drilling Breaking The Power Rock Splitter can also be used in applications where the material must be split horizontally In this type of application it is acceptable and mor...

Page 15: ...t hole length in each particular application When breaking reinforced concrete the hole spacing should be fairly close 12 15 especially if there is a tight rebar pattern It is important to ensure that any intersection with the rebar in the concrete is recognized as even the slightest deviation in the accuracy of the hole will have an adverse effect on your ability to insert the power cylinder End ...

Page 16: ...to drill the holes to their full depth and split in 31 increments Trench Rock Digging Fig 4 5 Where there is top access and a free face to break to it is more productive to drill from the top down and split the material to the open face A wide variety of trench profiles can be easily achieved with clean smooth sides and flat bottoms minimizing the need for added leveling materials in the trench bo...

Page 17: ...ragmentation is not a problem The Power Rock Splitter offers very precise control of what is to be broken and to what specifications The most difficult part of this type of work is to create a free face or void allowing the drill and breaking pattern to be expanded Here are two methods and patterns to create that free face The first method is to drill a large diameter hole with a crawler mounted D...

Page 18: ... an electric motor and various pieces of instrumentation such as a directional control lever oil filter accumulator limit switch oil pressure gauge and oil tank Electric Power Supply Unit Then standard motor supplied with the unit is a 3 phase 60 cycle 220 Volt electric motor The unit comes equipped with a phase converter that allows the operator to accept single phase power and change it to three...

Page 19: ...e the broken material is cleaned out of the newly created slot successive lines of holes can be broken above and below and to the left and right of the slot Fig 4 8 Power cylinder insert Using a larger diameter bit allows the pattern to be expanded more easily and quickly and the breaking to proceed at a faster pace Insert the SP power cylinder Drilled using a larger diameter bit 4 6 ...

Page 20: ...ler diameter holes with tighter spacings have proven to be the best combination The Power Rock Splitter is designed and manufactured using the very best grades of specialty steel to allow the unit to be robust yet light enough to be easily managed by one worker Additionally the unit had to be capable of withstanding very high hydraulic pressures without cracking or leaking Through 12 years of test...

Page 21: ... valve to the distribution manifold The longer hoses come in 13 lengths and in situations where longer runs of hoses are required can be connected together Due to the very high pressure in the high pressure hoses it is recommended that the end user inspects the hose regularly for damage or signs of deterioration and replaces the hose with only the hoses recommended in the Parts List Section 7 of t...

Page 22: ...pears to be dirty the lines and tank should be purged and cleaned thoroughly before replacing the oil and filter Oil should be replaced every 6 months or 1000hrs Use the hydraulic oil 32 for four seasons Where component failure is the result of insufficient oil in the tank or dirty oil or a plugged filter any damage or failure of power pack unit will not be covered by warranty 3 Pressure Limit Swi...

Page 23: ...n block and install a proper and close the oil path hole of oil distribution block with blind Nut for working with remaining power cylinders as temporary The damaged Power cylinder or hose should be repaired immediately to make it work in normal condition 7 Supporting the Power Cylinder in Vertical Holes When splitting rock or concrete on the vertical plane it is important to ensure that the power...

Page 24: ...he factory pre set pressure of 15 600 PSI Do not reset this switch to a higher pressure for better force as you are exceeding the safety factors are creating a hazard to the workers and could cause serious damage to the equipment Oil cap Access to the hydraulic tank to add oil High Pressure Line This is a line from the high pressure side of the hydraulic pump to the distribution manifold e Directi...

Page 25: ... hydraulic pump to the distribution manifold Oil Filter The oil filter is inside of this steel case If it is time to replace of the oil filter when oil begins to leak from the cap of this case Pressure Gauge Instantaneous pressure readout during breaking operations The needle will drop when the rock or concrete is fractured and then go up until the full stroke of the pistons have been achieved ...

Page 26: ... off to the electric motor for the hydraulic pump When starting up this switch is turned on first and then the magnet switch in the motor side of the cabinet is turned on When you finish operation please turn off the magnet switch first and then the main switch to protect the motor If not the motor might be burnt out Input Connector Block Incoming power is connected here If the incoming power is s...

Page 27: ...witch beside the electric motor and push the small button with a screw driver if the motor runs then the Oil Pressure Switch is out of order Replace the terminal of the oil pressure switch If the electric supply is lower than 220V irregular sound comes from the Motor magnet If so turn the round type electric voltage switch clockwise till voltage reaches 220V If the electricity is still lower than ...

Page 28: ...place it Oil Pressure suddenly drops Cause Corrective Action A hose connection is disconnected A hose or nipple connection is loose and oil is leaking at the connection Replace the hose Tighten the nipple or connector and check the oil lines Pump is not working Cause Corrective Action Pump is not working because of a motor trouble Motor magnet is burnt out when the electric supply is lower than 22...

Page 29: ... Valve lever to the right High Pressure mode If oil leaks out of the low pressure hose then the cylinder is bypassing which means that one or more seals are damaged on one of the pistons in the power cylinder If no oil leaks from the hose but a small amount of oil leaks from the low pressure connection nipple then there is a problem with the directional control valve If neither the hose nor the di...

Page 30: ... cylinder is bypassing which means that one or more seals are damaged on one of the pistons in the power cylinder If no oil leaks return the lever to the neutral position reconnect the first low pressure hose then disconnect the next low pressure hose and urn the Directional Control Valve lever to the right High Pressure mode Continue this process for all four cylinders and note which cylinder it ...

Page 31: ...nd for diagnosis of which piston is B O and for testing the power cylinder upon completion of the procedure Place the power cylinder in the vice with the pistons facing upwards Connect the hoses to the cylinder and move the control lever to the high pressure mark noting which piston is not performing as expected Extend all pistons to there limit and then move the control lever to the low pressure ...

Page 32: ...lar attention to the piston shoulder and use emery cloth to take out any scratches Once the piston has been cleaned install a new seal and copper ring Reassemble the piston and tighten down the cap on the repaired piston Reconnect the hydraulic hoses and test the unit Clear all material from the shoulders and inspect for damage ...

Page 33: ...r to the neutral position Turn off the magnet switch Turn off the main power to the pump Open the oil Direction Control Valve Caution Do not stand directly over the valve as it may still be under pressure Remove the direction control lever by unscrewing the cap screw holding it in place Loosen and remove the four cap screws on the valve cover Remove the valve spool and examine it for scratches or ...

Page 34: ...should be polished on a fine polishing stone using the same technique as was used on the valve face Once the valve face valve body and spools have been polished re assemble the directional control valve Check the oil level in the tank Top it up to the full mark Put the directional control valve in the neutral position Switch on the magnet switch then the motor switch and run the pump in neutral fo...

Page 35: ... secure it so that you can safely work on the unit Start the motor and pump to have oil circulation in the system Carefully observing the check valves for leakage If any oil is leaking from any check valve or valves then it or they must be replaced Oil leaking at the piston cap Valve Block Plate Overflow Low Pressure Intake Check Valve Connection Pipe Bearing Exhaust Check Valve High Pressure Inta...

Page 36: ...d replace the seal If oil continues to leak from the crack around the piston cap then the power cylinder body should be discarded The piston does not return Piston seal in the Power Cylinder is broken Open the cylinder cap and replace the seal of piston ...

Page 37: ...e pressure Hose 300m m one 4 Hose Connecting Nipple High pressure 4 pieces Low pressure 4 pieces 5 Manual Valve Spool 3 pieces Spool O ring 6 pieces Back up Ring 6 pieces Spring 3 pieces 6 Drilling hole cleaner 1 piece Note The above lists of parts are subject to change due to up dates and improvement on the machine ...

Page 38: ... year Exceptions Failure caused by substituting defective or non standard parts will not be covered by warranty Problems due to operator error are not covered by warranty Consumable goods for the machine such as hoses filters etc will not be covered by warranty If holes are drilled without using a reaming or retract bit as recommended by the manufacturer and the power cylinder is inserted into a c...

Page 39: ...bject to Continuous Improvement studies Model Items U O M SP 80 PURPOSE Rock or Concrete Power Cylinder Diameter in 3 15 Piston Diameter in 1 97 Piston Quantity ea 10 Power of each Piston ton 27 Power of each Power Cylinder ton 302 Power of one unit of Rock splitter ton 1 209 Power cylinder Quantity for each Rock splitter ea 4 ...

Search results

Summary of Contents for Concrete

Reviews:

Related manuals for Concrete

Brands by name

Popular brands

BL.KOREA Concrete, Manual

Search results

Summary of Contents for Concrete

Reviews:

Related manuals for Concrete

Brands by name

Popular brands