Pile cropping is an elementary work step in the construction industry, especially in special civil engineering. It involves removing the uppermost part of a cast-in-place concrete bored pile in order to connect it to other construction elements, such as foundations or load-bearing structures. After the concrete and steel have been inserted into the borehole, there are often excess lengths or concrete residues that need to be removed for the connection to the structure. This process is crucial for the quality and safety of the structures.
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Why is pile cropping done?
The process of pile cropping is necessary because concreting often takes place above the planned final level during the production of bored piles. This happens for several reasons:
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Avoiding cavities: Over-concreting ensures that the bored pile is completely filled without cavities.
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Quality improvement: The upper area of a pile can be affected by impurities such as drill cuttings or sludge. Capping removes these unusable areas and creates a clean surface.
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Exact height adjustment: In order to integrate the piles into the planned structure, it is necessary to bring them to the exact construction height.
This step guarantees that the pile reaches its full load-bearing capacity and can be optimally connected to the rest of the structure.
What methods are there for pile cropping?
Pile cropping can be carried out in different ways. Different techniques are used depending on the project requirements and available resources:
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Manual methods: Traditional methods such as removal with chisels or hammer tools are used in smaller projects or in areas that are difficult to access. They are labor-intensive and time-consuming, but offer a high level of control.
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Hydraulic cross-cut systems: These methods utilize powerful equipment specifically designed for pile cropping. The concrete can be removed precisely and quickly using hydraulic cutting tools or tongs. This method is efficient and significantly reduces manual labor.
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Blasting technology: In special cases, such as large projects or extremely hard types of concrete, blasting may be an option. However, this method requires extensive safety precautions and permits.
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Mechanical processes: These include attachments on excavators or special milling systems, which are an automated and scalable solution. These methods combine efficiency and precision, but are particularly suitable for larger projects.
Advantages and disadvantages of the methods for pile cropping
Each method for pile cropping has its own advantages and disadvantages, which must be weighed up depending on the area of application and project budget:
| Method | Advantages | Disadvantages |
|---|---|---|
| Manual | Low investment costs, flexible | High time and labor costs |
| Hydraulic | Efficient, precise, low noise | Higher acquisition costs |
| Blasting technology | Effective for large volumes | High safety requirements |
| By machine (e.g. Brextor) | Fast, economical, scalable | Investment in equipment required |
Pile cropping with an innovative solution
Brextor® is an efficient, safe and high-quality method for pile cropping. With this method, not only single piles, but also all types of pile walls (tangent, secant or contiguous) are processed gently by machine. The work is done by one person and one machine. The weather conditions have no influence here.
Brextor® offers the following advantages:
🏗 Increased construction quality
Perfect pile cropping without cracks in the pile body or spalling on the pile outer skin, no bent or torn reinforcements and a height accuracy of +/- 1cm.
💵 Reduced construction costs
The demolition material consists of 80% gravel 0-30mm and can therefore be reused directly on the construction site. In addition, Brextor® requires less working space than conventional mining methods. This means that not only expenses for transportation and disposal incl. fees are saved, but the purchase and supply of replacement material is also eliminated. Furthermore, the preparatory work eliminates the need for a separating diamand cut at the final extraction level and the cleaning effort is massively lower than with conventional extraction methods.
⏱ Shortened processing time
For example, a pile with a diameter of 1 m and a height of 1 m can be processed within 40 minutes. A daily output of up to 16 piles is possible. In addition, Brextor® provides reliable performance and therefore increased planning security.
♻️ Environmentally friendly
With Brextor®, the demolition material (80% gravel 0-30mm) can be reused directly on the construction site. Brextor® also requires less working space. This saves excavation and replacement material. By reusing the demolition material directly on the construction site and saving on excavation and replacement material, transportation can be saved. In addition, landfills are less polluted.
👷 Increased health & safety at work
No heavy physical labor is required for pile cropping, which massively reduces the risk of health hazards such as HAVS syndrome. Brextor® also avoids working in danger zones.
Find out more about Brextor® here:
Contact us for more information and find out how you can benefit from this revolutionary pile cropping method.
Call us on +41 41 495 05 20 or send an e-mail to info@brc.swiss. We look forward to working with you and taking your projects to the next level.