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“I trust CTI on my jobsite and recommend them for demanding projects.” – Korie Bishop, The Whiting-Turner Contracting Co.

Concrete Cutting & Robotic Hammering Shortens Ft. Calhoun's "Big Outage"

Engineering Challenge
Bechtel project managers needed to create a 30-feet-by-35-feet opening through the 4-feet-thick reinforced concrete wall of the Ft. Calhoun Nuclear Station containment building to remove and replace the facility's aging reactor head, pressurizer and two steam generators.

The CTI Solution
Cutting Technologies (CTI) began by designing and installing a dust and water collection system that would safely contain all cutting and breaking spoils. Then, a neat line cut that would define the opening's perimeter was created with a wall saw, scoring the concrete and severing the structure's tendon sheathing and #18 rebar. Once this outer cut was done, CTI technicians used Brokk robotic hammering to quickly chip away at the wall, gradually removing each layer of concrete and rebar all the way through the void. Lastly, CTI technicians using chipping guns exposed the remaining rebar surrounding the opening, enabling workers to tie in the replacement rebar when repairing the hole upon completion of the job.

With an aggressive project plan, skilled labor and a consistently proven record of safe operations, CTI completed its scope of work one week ahead of schedule, helping Bechtel save $40 million in overall construction cost.

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brokks robotic hammering breaking containment building wall
Working on a platform 35 feet up, CTI’s Brokks start breaking away at the containment building wall.
roboting hammers on concrete
The robotic hammers reveal a dense lattice work of reinforcing bar within the concrete.
saw cutting with clean edge
A saw-cut neat line defines the clean edge of the emerging hatch.
CTI technicians working at night
As work continues into the night, CTI technicians have progressed more than 2 feet into the void of the hatch.
hand chipping the thin layer of concrete
With most of the hatch cleared, the thin layer of concrete that hides the delicate inner liner is carefully chipped away by hand.
clean edges of the access hatch make for a seamless buildback
The clean edges of the access hatch make for a seamless build-back after the work is completed and the wall is repaired.

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