Category: Media reports

KEMROC KDS Diamond Saw Powers Fibre Optic Trenching Project in Asphalt, Italy CAT 306 with KEMROC KDS 30 | Horizontal Cuts in Asphalt and Concrete

One Saw. Endless Applications. Meet KEMROC KDS Diamond Cutting Solution

The KEMROC KDS range of diamond saws is the smart choice for contractors tackling a wide spectrum of cutting tasks. Whether you’re working on fiber optic installations, demolition, recycling, or sawing through wood, concrete, steel, or aluminum, the KDS delivers unmatched performance and precision.

Ideal for compact machines, the KDS 20 model is perfectly suited for 2 to 4-ton excavators, making it the go-to excavator attachment for confined spaces and specialized job sites. Designed to handle the toughest materials, the KDS saws can cut through concrete, stone, and GRP (glass fiber reinforced plastic), commonly found in wind turbine blades. Thanks to high rotation speeds and a wide selection of blade types, KDS diamond saws excel across multiple applications. Available saw blades include options for natural stone, granite, concrete and reinforced concrete, asphalt, plastics, wood, foil, and aluminum.

From urban trenching to precision demolition and high-performance recycling, the KDS Diamond Saw offers a rugged, reliable, and cost-efficient solution for today’s demanding contractors.

Project Overview: Urban Trenching Challenge in Pordenone, Italy

In Pordenone, Italy, a micro trenching contractor faced the demanding task of cutting 15 meters through a complex mixture of asphalt, concrete, rock, and light backfill. The jobsite required shallow yet precise horizontal trenching with minimal disruption to the surrounding area, especially given the variability in material strength ranging from 10 to 170 MPa.

The Smart Choice: KEMROC KDS 30 Mounted on CAT 306

To meet the challenge, the team selected the KEMROC KDS 30 excavator attachment, mounted on a CAT 306. The combination offered an ideal solution for tight urban environments, enabling fast, efficient trenching without the high noise and vibration associated with traditional equipment like floor saws or asphalt milling machines.

Game-Changing Blade Technology

KEMROC introduced a prototype diamond rock cutting machine blade, 800 mm in diameter and 20 mm wide, perfectly tailored for microtrenching. The blade allowed horizontal cuts at a depth of 300 mm, with productivity hitting an impressive 18–20 linear meters per hour. Even more notable was the blade’s durability, estimated at 1.5 km lifespan per blade, with minimal wear during the entire project.

More Flexibility, Less Overhead: KEMROC’s Economical Alternative to Traditional Trenching

To ensure minimal environmental impact and enhanced safety, water was actively used on-site to suppress dust during the trenching operation. Operators quickly recognized the advantages of the KEMROC KDS 30 Diamond Saw, particularly its low-vibration and low-noise performance, features that are often only associated with indoor floor saws.

What truly sets the KDS 30 apart is its unmatched ability to deliver high performance in challenging outdoor trenching conditions, while significantly reducing project costs. Compared to conventional cable trencher machines and asphalt removal tools, KEMROC Diamond Saw KDS 30 offers a cleaner, quieter, and far more economical alternative. The cost difference is not just noticeable, it’s tremendous. For contractors who prioritize efficiency, the KDS 30 dramatically cuts down overall project expenses, thanks to its reduced maintenance needs, minimal wear on the host machine, and extended blade life. With exceptional cutting precision and lower operational costs, KEMROC Diamond Saw has quickly become the go-to smart solution for operators and project managers seeking both performance and profitability.

In fact, the KEMROC KDS Diamond Saw proved to be a game-changer on site. Its innovative design and cutting-edge technology allowed for efficient horizontal trenching in mixed materials, including asphalt, concrete, and light rock, without the disruption, downtime, or excessive maintenance associated with traditional methods. For contractors seeking high productivity, low environmental disturbance, and long-term operational savings, KEMROC truly stands out as the ‘smart’ solution in the world of excavator attachments.

Why KEMROC? Faster, Smarter, Cost-Effective

Contractors cited several reasons for choosing KEMROC over other brands:

• Lower maintenance and higher utilization
• Significantly improved productivity
• A revolutionary new way of microtrenching in Italy
• Consistent, precise results through hard rock, asphalt, and concrete
• Low price per linear meter
• Versatile hydraulic attachment designed for multiple applications, minimizing operational costs while maximizing return on investment
• Simple hydraulic attachment for multi-use reducing the costs and increasing ROI

KEMROC KDS Diamond Saw proved especially valuable for pipeline construction, stone cutting, and trench excavation, outperforming alternatives like floor saws, concrete breakers, or big quarry machines in terms of cost-efficiency, jobsite safety and low noise in urban areas with houses and schools.

The Future of Microtrenching

The KDS30 attachment not only delivered exceptional performance, it redefined what’s possible in urban trenching. With its superior design and operator-friendly performance, KEMROC has positioned itself as a pioneer in smart excavation attachments, from auger drills to cutting wheels, and now, microtrenching. Whether your next job involves cable trenching, asphalt cutting, or excavation of a trench in mixed ground conditions, the KDS30 proves that KEMROC means control, quality, smart, and cutting-edge results.

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 …