LATEST PROJECTS: MILLING
NO MORE ROLLING AWAY
SHOPPING TROLLEY RETENTION SYSTEM
|Total length||approx. 900 m|
|Width approx.||5 cm|
The solution to a very common problem
Shopping trolleys rolling away in one supermarket car park in Vilshofen is a thing of the past. Using our special cutting machinery, we milled a profile into the asphalt in order to create a shopping trolley retention system measuring approximately 900 metres long. This was a really simple solution to a problem that we are all familiar with. The rear wheel of the shopping trolley fits neatly into the recess that is approximately 5 cm, holding the shopping trolley in place.
We mostly worked at night to prevent any disruption to ongoing operations.
HALL MILLING WORK
Special solution for indoor milling
Dust-free and low-vibration milling indoors – we are the specialists. Our video shows exactly how we create cable ducting or profiles in a closed hall.
We filmed the work performed at our customer PRÜM-Türenwerk GmbH in Weinsheim. All the measures were discussed in advance with the customer and adapted precisely to their needs. This enabled us, for instance, to work in halls that still contained warehouse goods, as no dust emissions were created.
Milling work in building structures: fast, clean, precise and cost-effective with KUTTER.
MOBILE COLD MIXING PLANT
A MOBILE PLANT
Independent and versatile
A mobile plant that replaces lorry journeys between the mixing plant and remote construction sites: KUTTER’s mobile cold mixing plant. Thanks to the separate diesel motor, it can operate independently of the public power supply. The cold mix that is created is suitable for a wide range of different construction projects: motorways, high-quality bearing layers for road and path construction, reinforcement of car parks and parking areas. Watch the video to learn out the diverse applications.
IN THE BLACK FOREST
A uniform substrate
Uniform and sufficiently load-bearing substrates are the prerequisite for the permanent and damage-free foundation of structures. In the event that the in-situ ground does not have these properties, it can be prepared so that it can be built upon and bear loads, by incorporating limestone and/or cement.
KUTTER carries out a wide range of ground improvement and ground hardening activities, such as in the construction of roads, car parks, industrial premises, airports and rail tracks. We can perform diverse earthwork, such as the creation of dams, embankments or backfilling. The soil stabilisers are also ideal for creating seals in landfill construction.
Thanks to this fast and environmentally friendly procedure, there is no need for time-consuming and costly replacement of soil.
RENOVATION OF A COUNTRY ROAD IN RADEGAST
Ecological and economical
As many roads in Germany are severely damaged several layers deep, for some time now it has no longer been possible to just replace the surface over and over again. KUTTER are the specialists for the job: we repair the entire structure of the road and permanently increase its load-bearing capacity. KUTTER are pioneers of cold recycling, and we have devoted ourselves to this ecological and economical procedure. The technological leadership acquired in this complex area enables us to maintain the functional properties of roads in the long term.
We renovate traffic areas with as little logistical effort as possible. And we do this with asphalt recycling. Our video shows you exactly how it works and what machines are used.
Green light for the airport
|Construction period||04/2021 - 05/2021|
|Material||350,000 m² concrete/hydraulically bound mixture|
Renovation of the runway in Leipzig/Halle
The large project to renovate the northern runway at Leipzig airport started with the deployment of a special construction milling machine.
The work included building 9,375 metres of rain run-off channels, among other things. The ideal machine for this is the special construction milling machine from Kutter Leipzig with side-mounted milling drum. The milled material was extracted using suction excavators and disposed of professionally.
Over the next few days, another form of milling was used. This milling work was recently carried out in collaboration with Wirtgen and our workshop at the Leipzig branch.
In addition, ten W250 large milling machines were used to mill a total area of 307,000 m² of concrete and hydraulically bound mixture.
This equates to a total volume of 350,000 tonnes, or the equivalent of around 12,400 loaded semi-trailer tippers!
Bridge demolition on the B37
|Construction period||05/2020 - 07/2020|
|Total surface area||10,000 m²|
|Milling machine used||radio-controlled W 50 milling machine|
The overall process
After noticing the damage on the bridge, the City of Ludwigshafen closed the bridge and surrounding area to all forms of traffic.
As this is a traffic intersection, it caused major disruption for the entire population.
In order to remove the partly contaminated coating without having to dispose of the entire demolition material, a radio-controlled milling machine with a maximum weight of ten tonnes needed to be used.
Up until this point, our company did not have a radio-controlled milling machine, therefore within a very short time, the milling specialists at KUTTER developed a W 50 milling machine offering all the required functions, which were converted to radio control.
Special feature: The machine operator remained on a part of the bridge that was not being worked upon and was held secure by a safety harness on a truck-mounted crane, from where they could operate the machine via remote radio controls.
The material was placed down on the bridge deck and picked up separately during the demolition work.
CONSTRUCTION OF A NEW BYPASS
Project Adelsdorf bypass
KUTTER is working on the construction of a new bypass in Adelsdorf. During the initial phase, 3,500 cubic metres of limestone were removed using heavy equipment (see images).
The asphalt junction at the existing traffic lane is currently being milled. Over the coming weeks, a further 1,100 cubic metres of rock will be milled for the second section of the bypass.
IN BERLIN MITTE
|Construction period||11/2019 - 11/2019|
|Total area||10,000 m²|
|Milled area||7,500 m²|
|Milled depth||0-12 cm|
|Material||concrete without reinforcement|
|Controller||Trimble tachymeter controller|
|Milling machine used||Wirtgen W 100 CFi|
MILLIMETRE PRECISION WORK IN BERLIN MITTE
In November 2019, the milling specialists at KUTTER GmbH & Co. KG milled the challenging profile of a drainage channel into a concrete surface.
A 3D system was used for the levelling work. Special feature: The project was for the Senate Administration for the Environment, Urban Mobility, and Climate Action on Karl-Marx-Allee in the heart of Berlin, under which runs an underground train line. For this reason, it was not possible to use large milling machines. Instead, KUTTER performed the 3D milling using a compact device with 1 m milling width, and developed an innovative solution that can safely discharge rainwater.
Work to redesign Karl-Marx-Allee, an avenue in the heart of Berlin measuring up to 72.5 m wide in parts, has been ongoing in several stages since the summer of 2018. In future, there will be less room for cars. Instead there will be wider cycle paths as well as attractive walking paths and open spaces. After removing the bituminous road surfaces, the drainage points and the pavement were replaced.
Drainage channel in the concrete surface
The next step – to create a profile in the concrete surface beneath the asphalt – was challenging from a construction point of view. The profile of a drainage channel was required in order to later ensure the drainage of rainwater along a length of approx. 800 m and a width of 5.75 m. The plans stipulated that the slope had to vary between 2.5% and 3% at distances of 3-5 m. On the remaining 9.25 m width of the road, the profile needed to have a cross slope of 2.5% from the centre to the edge of the road. Based on this geometry, this resulted in a milled depth that constantly varied between 0 and 12 cm. But what’s more, the Berlin underground railway runs beneath parts of Karl-Marx-Allee. Therefore, due to load restrictions, large milling machines could not be used on around 75% of the construction area.
3D milling with a compact machine
In light of this task, the team of milling specialists at KUTTER developed a concept together with the main contractor Matthäi GmbH & Co. KG for the precise profiling of concrete. The machine of choice was a compact milling machine with a 1 m milling width, equipped with a 3D levelling system. This is rather unusual as normally only large machines with a milling width of at least 2 m are used for 3D milling.
Tried and tested for many years
“For almost a decade, we’ve been successfully creating new profiles by means of 3D levelling and have tried out different systems. The variants
incorporating a Totalstation have proven to be the best for a wide range of tasks. Therefore, we were certain this method would be successful for the project in Berlin Mitte,” explains Roland Schmid, Head of Milling at KUTTER in Memmingen. This meant that the milling specialists were able to confidently deliver the required precision of ± 5 mm in accordance with additional technical terms of contract, and create the best conditions for laying the asphalt top structure.
|Project||Oberau tunnel bypass|
LIGHT AT THE END OF THE TUNNEL
The overall process
Swiss company Marti AG was awarded the contract to build Oberau tunnel.
The tunnel is essentially constructed using underground excavation with blasting. Once the rough removal of the tunnel cross-section was complete, our specially adapted mining milling machines were deployed to profile the tunnel invert to the exact height level required.
Our machine operators were guided by defined survey points and transferred the data by means of a laser controller which engages directly with the machine controller.
The milled material is loaded directly onto the transport vehicle on site via the integrated loading conveyor. The steep belt conveyors are reinforced with solid steel inserts to prevent damage caused by sharp-edged stone.
Our machines and their performance capacity
The performance capacity of our machines is generally based on the type of stone. This project involved dolomite stone and limestone with associated single-axial compressive strength values.
A further indicator for performance capacity is the fissurisation of the material to be removed, which can be naturally inherent or due to damage caused by stone blasting.
The special task
Another key area of this project was the creation of utility trenches within the tunnel invert. To complete this special task, we used the W 2200 milling machine with lateral milling device, which we had modified in-house and has a milling width of around 65 cm. This way we were able to create trenches that were approximately 70 cm deep.
The benefit of this technique is the fact that the milling machine with an entire operational weight of more than 40 tonnes is positioned centrally above the milling drum.
Quality thanks to years of experience
We have many years of experience in both surface and profile milling and can produce cost-effective results through optimised applications, even in extreme conditions.
The tunnel builders in Central Europe are familiar with the opportunities presented by milling technology, and are already incorporating our technology in the planning and costing phases of their projects.