Category: Media reports

Smart Trenching with KEMROC EK 40
Cosmoforça Unipessoal Lda | Carvoeiro, Algarve | Portugal

In Carvoeiro, Algarve (Portugal), Cosmoforça Unipessoal Lda faced a demanding trenching project requiring excavation of 20 km of trench in limestone with an estimated compressive strength of ~30 – 50 MPa. The project involved trenches 50 cm wide and 2 meters deep, to be completed over 2 months.

The job site presented significant challenges: limited access space near the sea, medium-hard limestone rock, and a confined working environment where heavy equipment could not be used effectively. Early attempts with hydraulic breakers and larger attachments failed to deliver results.

The Right Solution: KEMROC Chain Cutter EK 40

In search of an efficient solution, Tierri Correia, Owner of Cosmoforça, turned to the local KEMROC dealer in Portugal. The team recommended the KEMROC EK 40 Chain Cutter mounted on a Develon excavator, a combination perfectly suited for the site’s constraints.”Big attachments couldn’t access the site. Even a smaller breaker failed. That’s when we discovered KEMROC,” said Tierri Correia.

Once mounted, the EK 40 Chain Cutter delivered immediate results. The chain cutter was able to penetrate and steadily cut through the previously unbreakable limestone. Continuous cutting enabled smooth and precise trenching, which was not possible with previous solutions and equipment. “It was a game-changer. The stone we couldn’t break, we could now cut through cleanly with KEMROC Chain Cutter EK 40. Trenching became manageable again,” Tierri added.

Project Impact

Prior to using the EK 40 Chain Cutter, the project was at a complete standstill. Productivity was lost, and project delays were accumulating. With the EK 40 in place: Trenching progressed continuously, Idle time was eliminated, No more equipment failures, and higher productivity was achieved. “We were blocked. Once we used EK 40 Chain Cutter, no more idle time, no more failures. It solved the problem—plain and simple.” said Tierri Correia.

Ease of Use & Operator Experience

KEMROC Chain Cutter EK 40 excavator attachment was easy to integrate and operate. The site operators adapted quickly, thanks to their background with asphalt attachments. A short training session from the KEMROC dealer ensured that the team was fully prepared. “Our operators adapted easily and felt confident using EK 40, it was really easy to manage.”

Customer Support & Trust

Tierri Correia praised the KEMROC dealer in Portugal – DUROMIN for their responsive customer support and involvement throughout the project. “100% satisfied. They were with us from day one, stayed involved, and supported us until everything was running smoothly.”

Why Choose KEMROC Again?

Cosmoforça evaluated various brands and technical options before selecting KEMROC. The decision was reinforced by on-site support and superior technical performance. “We compared the market and KEMROC stood out, both technically and through their support. That’s why we chose them, and we’ll choose them again.”

Conclusion

For Cosmoforça Unipessoal Lda, the KEMROC Chain Cutter EK 40 delivered a highly effective and easy-to-use solution for complex trenching in medium-hard limestone. Backed by strong local support and proven performance, KEMROC earned the trust of another satisfied customer in Portugal.

KEMROC KDS Diamond Saw Powers Tunnel Cutting in SNCF Project, France BROKK 180E with KEMROC KDS 20 | Vertical Cuts in Limestone Rubble and Concrete

In a recent SNCF (French National Railway) tunnel project in France, ALSACIENNE DE MINAGE ET DEMOLITION were tasked with executing precision cutting in a confined and challenging underground environment. The project involved cutting through a combination of limestone rubble and concrete with compressive strengths ranging between 15 and 20 MPa.

The client selected the KEMROC KDS 20 diamond saw, equipped with a concrete blade (800 mm diameter), and mounted it on a BROKK 180E machine with an extendable arm, an ideal setup for operating within narrow tunnel profiles.

The project spanned a duration of 2 months, requiring cutting a total of 400 meters along the vertical tunnel walls. The target cutting depth varied between 10 and 15 cm, with an expected production rate of approximately 40 linear meters per day, adjusted for non-continuous operation cycles dictated by site logistics.

Tunnel Cutting Application Challenges

Tunnel environments present significant operational limitations:

1. Space constraints limited the use of larger hydraulic equipment.
2. Dust suppression and cooling were critical; water supply was available onsite to enable wet cutting
3. The site required vertical cuts, demanding high stability and precise control.
4. In addition, the material composition, a mix of concrete with embedded limestone rubble, presented a variable cutting profile, placing additional demands on tool performance and wear resistance.

Why KEMROC KDS Diamond Saw?

Faced with these challenges, the project team evaluated multiple cutting options. The KEMROC KDS 20 was chosen for its: High productivity in confined spaces, ability to achieve precise, clean vertical cuts, minimal vibration and noise compared to impact tools, proven performance on BROKK electric demolition robots, which offer superior maneuverability in tunnels, and efficient blade consumption, only 1 diamond disc was used over the entire 400-meter scope.

Performance on Site

Once mounted, KEMROC Diamond Saw KDS 20 delivered excellent results:

1. The Tunnel cutting process was stable and smooth, with operators able to maintain consistent depth and line across all wall sections.
2. The BROKK 180E’s extendable arm provided the reach and positioning flexibility required for vertical cutting along the tunnel walls.
3. Water cooling effectively managed dust and blade temperature, ensuring safe and efficient operation.

Productivity averaged 40 linear meters per day, aligned with the project’s targets, a testament to the reliability of the KDS Diamond Saw as a smart solution under continuous use.

Results & Customer Feedback

The project team reported high satisfaction with the KEMROC KDS solution: “The KDS 20 proved to be an excellent choice. We completed all vertical cuts as specified, with minimal blade consumption and without the vibration issues associated with conventional cutting methods. The setup with BROKK 180E was ideal for our confined work area.”

Conclusion

KEMROC’s KDS Diamond Saw once again demonstrated its value in a critical infrastructure application, enabling safe, precise, low vibration, and efficient cutting in a challenging SNCF tunnel environment.

The success of this project reinforces KEMROC’s position as a trusted partner for smart cutting solutions in railway, tunnelling, demolition, and civil engineering sectors across Europe.

To install underground services, an EK 150 chain cutter and an EKT 220 rotary drum cutter are used for low-vibration removal of solid dolomite rock.

At a project to demolish and re-construct the Ludwig-Uhland-Halle in Gärtringen (Baden-Württemberg, Germany), the company Peter Gross Bau was awarded the contract for the complete renewal of the pipeline layout in order to integrate the future building into the municipal infrastructure. Included in the tender was the low-vibration removal of around 3,000 m³ of dolomite rock. Using unconventional equipment – a 35-tonne excavator with a KEMROC EK 150 chain cutter and a 75-tonne excavator with a KEMROC EKT 220 drum cutter – the project was almost fully completed by the winter break …

Using a KEMROC DMW 220 cutter wheel on a 32-t excavator, a massive concrete weir wall was cut into individual segments.

A disused weir in Stadtilm (Germany) was demolished to allow fish to pass through this section of the Ilm River again. To break down the massive weir wall, demolition contractor, JeFra Bauservice GmbH & Co. KG used a KEMROC DMW 220 cutter wheel on a 32-ton hydraulic excavator. This made it possible to dismantle the concrete body precisely, economically and without harmful vibration …

A KEMROC KDS 30 diamond saw on a compact excavator cuts out concrete cable ducts from the floor of the tunnel to make room for a new tunnel lining.

The Elleringhauser Tunnel in Germany’s Hochsauerland region is being completely renovated. To install new tunnel lining, concrete cable ducts had to be removed from the bottom of the tunnel wall. Specialists from the EET consortium (Max Bögl/Marti DE/Marti CH) chose an 8-tonne compact excavator and a KEMROC KDS diamond saw to cut the concrete ducting into manageable pieces …

Using a Powertool KRX 70 drive unit with milling attachment, recesses are made in bored piles, into which reinforced concrete spurs are poured at a later date.

Near Osterode in the Harz Mountains (Germany), the intake section of the Söse dam is being renovated. In the process, the holding dam had to be resealed using a new bored pile wall. This wall is strengthened at the top and bottom with two reinforced concrete belts. To excavate recesses in the bored pile wall to attach the reinforced concrete spurs, Umwelttechnik & Wasserbau GmbH uses one of their own 24-tonne excavators with a KEMROC KRX 70 Powertool drive unit with longitudinal milling attachment. As a result, the project was completed within the required specifications and on schedule …

A KRC 140 Bullhead milling attachment excavates trenches in hard sedimentary rock to connect new elevated tanks to the drinking water grid.

In the district of Neundorf in the municipality of Rosenthal am Rennsteig, two new elevated tanks will supply water for the future. A large pit had to be excavated in bedrock before trenching for foundations and pipelaying could start. Mounted on a 26-tonne excavator, a KRC 140 Bullhead milling attachment from KEMROC completed all excavation work and trenching within expected tolerances and within expected timeframe …

To underpin a building, rock below the façade is carefully and precisely milled out by using a 25-tonne excavator with an EKT 100 drum cutter attachment.

To underpin a building in Paderborn, the construction company Karl Immig used a 25-tonne crawler excavator with a KEMROC EKT 100 rotary drum cutter. This was used to excavate rock from underneath a building with precision and with little vibration to create space for the necessary foundations. Thereafter the excavator-milling combination excavated trenches for services – and thanks to a 3D excavator grade control system, it was extremely fast and accurate …

A KEMROC KR 120 rotary drum cutter and an EK 40 chain cutter complete site preparation work efficiently and accurately.

The “Königsteiner Höfe” is a new residential and commercial quarter being constructed in the middle of Königstein im Taunus in the German state of Hesse. Acting as a subcontractor to the Köster Group, the company Höfling Erdbau was engaged to complete the site preparation work. Using two excavators with cutter attachments from KEMROC, the contractor put all the bored pile walls in place and put in the drainage systems efficiently and to the required accuracy …