BL.KOREA Rock User manual

Rock & Concrete Splitter
Manual
(Concrete) (Rock)
== TABLE OF CONTENTS==
1. TYPICAL APPLICATIONS FOR T E ROCK/CONCRETE
SPLITTING SYSTEM.
Power Rock Splitter–series Technical Specification
- Basic Concept
- Advantages of the SP-series Splitters
- Operational Theory
- Comparison with Other Non-E plosive Methods
2. OPERATIONAL SEQUENCE
1) Drill the holes.
2) Cleaning the Drill Holes

3) Insert the Power Cylinder
4) Powering Up
5) Failure to Crack Rock or Concrete
6) Powering Down
7) Removing the Power Cylinder
8) Secondary Breaking
3. DRILLING PATTERNS
1) Hole Spacing.
2) Horizontal Drilling
3) Trenching
4) Tunneling
4. COMPONENTS of the Power Rock Splitter
1) Electric Power Supply Unit
2) Hydraulic Power Pack
3) Power Cylinder
4) Hose Sets
5. T INGS TO KNOW
1) Connecting the electric line
2) Oil
3) Pressure limit switch
4) Hose
5) Location of the Power Unit
6) Damaged Hoses or Fittings
7) Supporting the Power Cylinder in vertical holes
8) Ma imizing the Power cylinder life
9) Straightness of holes
6. SERVICE MANUAL
1) Sub Component Identification
2) Trouble shooting
• Rock Splitter fails to operate
• Transformer works but the motor does not.
• Odor from Motor or Transformer
• Oil Pressure suddenly drops.
• Pump is not working

• High Pressure doesn’t go to upper limit
• Internal leakage of Power cylinder
• Internal leakage in the oil direction control valve
• Check Valve is damaged
• Oil leaking at the piston cap
• The piston does not return.
7. SPARE PARTS LIST
8. WARRANTY POLICY
Appendix A: DATA of Power Rock Splitter: SP-80 Power Cylinder
1. TYPICAL APPLICATIONS FOR T E ROCK /CONCRETE
SPLITTING SYSTEM.
1.1 What are some applications for the Power Rock Splitter series Rock/Concrete
splitting system?
i) On sites where there is a restriction or ban on the use of hydraulic impact
hammers or conventional blasting methods.
ii) In downtown core areas where there are by laws regarding noise and dust
pollution.
iii) Job sites near to electrical supplies, gas mains, water mains, or other services that
can be adversely affected by vibration and fly rock.
iv) Under, in, or beside historic buildings, that can be damaged by less controlled
methods.
v) E cavating narrow trenches in rock, or concrete, dedicated to service lines such as
gas, electricity, water and sewage.
Power Rock Splitter– Technical Specification
Chart 1.1
Model
Items
Unit Sp-80
Applications
(concrete or hard rock)
Power Cylinder Weight lbs 66.1 (30Kgs)
Power Cylinder Length in 29.5 (750mm)
Power cylinder dia. in 3.15” (80mm)
Piston max. stroke in 8.87” (225mm)
Working Pressure psi 17,068 (1,200Kgs/cm2)

Rock Splitter Force ton 259x4=1,036
Productivity y³
³³
³/shift
115 - 315
(80 – 220m3/shift)
Drill by Top ammer
DT ammer
CORE DRILL
Drilling Diameter in 3.504” (89mm)
* Technical specifications are subject to change without prior notice due to quality improvement.
* More detailed specifications are available in Appendix 1.

There are many other sizes of power cylinder available depending on your application but
the two units shown are the most often used and the most economical for general
purposes.
In a basement digging jobsite where the e cavation is in bedrock, we recommend use of a
special drill of diamond drill coring type.
2. BASIC CONCEPT
The Power Rock Splitter is an advanced method of mechanically breaking rock or concrete
using hydraulic power. Utilizing a state-of-the-art design the Power Rock Splitter uses
hydraulic power and specially designed hydraulic rams to split the concrete or bedrock.
This method is useful and efficient and is a more than acceptable alternative at urban job
sites or near industrial plants, historical buildings and municipal facilities where blasting
methods or impact breakers are severely regulated due to vibration, noise, dust or
environmental concern.
The Power Rock Splitter is lightweight and the durable power cylinder (ram) makes it easy
to operate.
Reduced Vibration Reduced Noise Reduced Dust
The Power Rock Splitter uses hydraulic pressure in 9~12 small pistons to gradually e pand
across the diameter of the drilled hole until the material fractures. The breaking force can
be in e cess of 1,200 tons (144,000psi).
There are several mechanical methods available to split rock including the “Darda” system,
“HRS”, e pansion methods using chemicals (Brista), gas gun method and Super Wedge
insertion by e cavator. The Power Rock Splitter has demonstrated time and time again that it
is the safest, most efficient, cost effective, and productive method on the market today.
3. ADVANTAGES of Power Rock Splitter.
(1) Reduced Vibration –Reduced Noise
With the Power Rock Splitter, vibration and noise are virtually eliminated (E cept
for the noise generated by the Core Drill, Crawler Drill or DTH Hammer). Noise
levels can be reduced to between 90-95 Dba utilizing the latest Hydraulic drilling
technology. It can be further reduced to 85 Dba using electric core drilling
technology. As there is little impact involved in the hydraulic drill, and none in the
core drill method there is anything vibration generated.
(2) Precise Control
The equipment is simple and easy to use, shearing clean faces and break is
limited to very e act specifications. No over break occurs and no micro fractures are
created in the host rock that might later result in “loose sloughing off”.
The power cylinder is lighter than other types of hydraulic jacks and the operator
/worker can manage the power cylinder fairly easily. This contributes to increased
productivity as the operator / worker is not as prone to physical fatigue.
- High Efficiency

Only two operators per rock splitter are required to achieve the daily production of
35-100 Cubic Yards per shift. No other competitive systems can offer this level of
production efficiency. We recommend using two crawler drills, diamond core drills
or DTH Hammer with one Power Rock splitter, as this will create the most efficient
and productive workforce.
- Low Breaking Costs and Maintenance Costs.
The Power Rock Splitter is designed to operate with most electrical power supplies
including generator, city electricity and industrial electricity. In most cases the step-
up or step-down voltage requirements are managed by the power pack, but the best is
to specify the voltage available to factory before ordering a unit of Power Rock
splitter.
With other rock splitting equipment, a number of potential problems e ist:
• With the DARDA System, wedges brake frequently and the system
requires special grease to lubricate the leaves
• With the HRS System, e pansion tubes burst easily and must be replaced on a
regular basis.
• Chemical (BRISTA or other brands of e pansion chemicals) is e pensive
and not usable in horizontal holes
• As a direct result of equipment failure or the introduction of chemicals,
the potential for environmental damage is increased
All of these problems can lead to e cessive maintenance costs and lower
production rates. The Power Rock splitter requires little maintenance, uses
environmentally friendly oils, and replacement parts costs are negligible.
- Versatilit
The Power Rock Splitter is lightweight for efficient mobilization, has few
moving parts and is easily maintained. It can be moved into narrow site
applications including tunnels and used in building demolition as well as for cement
or rock breaking jobs.
4. OPERATION T EORY
As with blasting or impact breaking, force is required to split the rock. In the first
two methods, e cessive force is applied resulting in ancillary damage to the host rock in
the form of micro-fractures that create weakness in the host rock and encourage splitting.
With the Power Rock Splitter force is applied directionally and under tight control.
With a 1” stroke on the cylinders, the force applied is adequate to cause splitting along
the fracture plane in the rock or concrete without causing further damage to the host
material.
<Fig. 1-1>

Cracked Area
ROCK or CONCRETE
Piston
andle Power Cylinder
750 mm
Drilled OLE 1.5~ 3m
5. COMPARISION vs NON-EXPLOSIVE SYSTEMS
<Chart 1-2>
SYSTEM
ITEMS
NON EXPLOSION MET OD
COMPARISION
ROCK
SPLITTER
.R.S.
MET OD
DARDA C EMICAL
Productivity 115-315 Y
3
/shift 10—50 Y
3
/shift 15—30 Y
3
/shift 30 –40 Y
3
/shift
Advantage ighly productive
Low operating cost
Low maintenance
Controlled power
Multi-purpose
Light weight
Useful in
trenching or in
confined spaces
Useful in trenching
or in confined
spaces
Useful in trenching
or confined space
applications where
movement is
severely restricted
Disadvantage
Second breaking
costs by hydraulic
hammer.
Expansion Tube
is expensive &
easily broken.
More down time.
Increased risk of
hydraulic spills
Wedges are weak
and expensive and
are easily broken.
Lubrication is
expensive.
Increased risk of
hydraulic spills
Chemical is
expensive.
Long wait times
while chemical sets
Increased risk of
chemical spills
Applicable
Job Site.
Medium or Large
Site
Small or
Medium site
Small and / or
Narrow site
Narrow site
Type of Drill
Rig and
Secondary
Breaking
Equipment
Diamond Core Drill
Crawler Drill
DT ammer
ydraulic Breaker
Crawler Drill
DT ammer
Impact Breaker
Crawler Drill
DT ammer
Impact breaker
Crawler Drill
Leg Drill
The PowerRock splitter compares favorably with other methods in all categories and
it’s high productivity, low operating cost and convenience, clearly show it to be the
method having the greatest versatility.

2. OPERATIONAL SEQUENCE
1. Drilling
The first step is to drill holes of the proper diameter to accommodate the selected
SP-series cylinder diameter. In a large e cavation where noise levels under 95 dB are
acceptable, and where there is adequate room for a crawler mounted top hammer this
would be the drill of choice, although a crawler mounted DTH drill would also be
acceptable. The other choice would be a Coring Diamond Drill on E cavator
especially where noise, dust and vibration are restricted.
The PCD-200 series Diamond Core Drill can be attached to an excavator if there is
no available crawler mounted drill or crawler mounted DTH drill
<Fig 3-1> PCD-200 & Core Drill Bits
An excavator can also be used to mount a small DT drill if a crawler mounted unit is
not available.
<Fig3-2> Low Noise P D-30

The PHD-30 DTH Drill is very useful in small areas and where there are restrictions limiting
noise pollution. The DTH hammer, and more rigid drill string, cuts a straighter hole than the
crawler drill.
(We have found that there is a strong correlation between straight holes and extended
power cylinder life cycle.)
When using a crawler top down drill, it is recommended to use a reaming it or a retrac it to
ensure that the hole is straight. The diameter of hole should e 3/8” wider than power
cylinder in order to ensure easy insertion of the power cylinder in the drilled holes.
<Chart 3-1>
PROPER DRILL BIT FOR SP-80 Splitter
Dia
odel
Sp-80
Bit Dia in “in” 3.504”
Remarks Reaming
or Retract
Bit
or DTH
Note: If you do not use the recommended its and the holes are crooked, damage and
premature failure of the power cylinder will occur. This may invalidate a warranty
claim.
2) Cleaning the Drill Holes
The drilled hole should e cleaned out prior to the insertion of the Power Rock
splitter power cylinder. This can e done using a lowpipe and compressed air, or
y using the “rake” supplied with each splitter. When cleaning multiple holes, plug
the collar of the hole after it has een cleaned, to avoid recontamination from adjacent
holes eing cleaned.
3) Insert the Power Cylinder
Insert the power cylinders into the cleaned holes with the pistons facing toward the
free face. Never use support plates at the ack of the power cylinder, as our experience
is that this may cause damage to the power cylinder. In case of using support plate,
please use it at the front face of power cylinder.

<Fig No. 3-3>
Power Cylinder Placement in Vertical Holes
(Correct Direction) (Wrong Direction)
Power Cylinder Placement in Horizontal Holes
<Fig No.3-4>
(GoodAlignment)
(
(Wrong Alignment)
4) Powering Up
Once the power cylinders are properly placed in the selected holes the Oil Directional
Control Lever is set to the right hand side. The pump supplies oil to the power cylinders
and ramps up the pressure in the pistons forcing them to stroke outwards until the rock or
concrete is fractured.
Directional Control lever
<Fig. No.3-5>
THIS POINT
WILL BE CRACKED
THIS POINT WILL BE
CRACKED
Piston Direction
Piston Direction
Turn Right

5) Failure to Fracture the Concrete or Rock
If the rock or concrete fails to fracture then you will have to redrill the holes ensuring that
they are the correct diameter for your Power Rock splitter. The Pistons in the Power Cylinder
have a 1” stroke, which is more than adequate to reak even the hardest rock encountered to
date. Oversized holes increase the distance etween the piston face and the hole wall, there y
increasing the amount of travel for the piston efore it engages the hole wall and decreases
the a ility to create fractures. The temptation is to augment the travel y inserting a acking
plate in order to shim the power cylinder. This has een done efore with a high degree of
likelihood that the power cylinder ody will e cracked and made inopera le. Redrilling is
the most prudent option.
Fractured Concrete and Hard Rock
<Fig. No.3-6>
(Concrete) (Rock)
6) Power Down
After cracking the rock or concrete, turn the Directional Control Lever to the left hand
position. Low pressure oil goes through the low pressure oil hose to the piston and
retracts the pistons ack into the power cylinder.
Note: The lever moves to three directions, High Pressure or Extend, Low Pressure or
Retract and neutral

<Fig 3-7>
(Turn the Directional Control Lever to the left side for piston retraction)
7) Removing The Power Cylinder
As soon as the pistons are retracted into the power cylinder, the power cylinders
may e pulled out from the cracked holes and move to the next set of holes to e
roken. If portion of the roken rock or concrete o struct you from pulling the
power cylinder out of the hole do not pull it out y force. Clean out the roken
material and then pull out the power cylinder smoothly.
8) Secondary Breaking
If the roken material is too large and ulky to e removed, either the material must
e roken with an impact hammer or drilled and roken up using the splitter. If
this is a continuing pro lem, then the drilling pattern should e reassessed and
adjusted for fewer urdens.

3. DRILLING PATTERNS
1) Distance between Holes
The spacing between the holes depends on the
“breakability” of the rock or concrete. As a rule of thumb, in hard rock,
all perimeter holes (holes defining the rock/excavation contact) should be
at 6” centerline to centerline, to ensure clean shearing on the contact line.
The next line of holes can have a spacing of 12” centerline of hole to
centerline of hole. After that the pattern can be expanded to 18” center to
center. This pattern will produce chunks that weigh about 50-125 lbs. with
little or no secondary breaking required.
Preferable Hole Distance
<Fig 4-1>
--------------------------------------------------------------------------------
Free face
Rock splitting direction Rock splitting direction
( For very Hard Rock )
Caution
Generally you will drill the holes to a depth 5-6” longer than the Power
Cylinder length. When the Power Cylinders are inserted into the holes, they
must be suspended so that they do not drop too deeply into the hole. An 8”
rebar or drill steel would be appropriate.
Another consideration when orienting the pistons of the power cylinder is to look
for fractures, or small fault planes in the material to e split. These are indicators of
weakness in the “in situ” rock. The splitting force should e applied along the
fault or fracture, as this is the easiest and weakest plane.
If there is no defina le plane of weakness, you may have to experiment with the
placement of the power cylinder and pistons to esta lish the est plane for reaking the
particular rock on your project.
18”
12 “

Texture of Rock and Splitting Direction
Fig 4-2
(Rock Texture & Splitting Direction)
When reaking the reinforced concrete, the hole spacing should e fairly close
(12”-15”) especially if there is a tight re ar pattern.
. It is important to ensure that any intersection with the re ar in the concrete is
recognized as even the slightest deviation in the accuracy of the hole will have an
adverse effect on your a ility to insert the power cylinder. Although it is time
consuming, it is far etter to move over and redrill the hole, than it is to damage the
power cylinder ecause the hole is not straight.
In a well planned operation, the total working time should e far more dependant on
the drill speed and drill accuracy, than it is on the splitting time. Avoid pro lems
with jammed power cylinders and down time due to cracked power cylinder odies,
y drilling holes accurately and to an esta lished pattern.
2) Horizontal Drilling & Breaking
The Power Rock Splitter can also e used in applications where the material must e
split horizontally. In this type of application, it is accepta le and more efficient to drill a
longer hole (generally the length of the drill rod) and split the material in 31” increments,
cleaning the holes efore re-inserting the power tu es. This method saves time in that
there is no need to set up a drill after the first splitting cycle has een completed. It is not
recommended that the holes e drilled any deeper than one rod as hole deviation may e
introduced, and it will then e difficult to insert the power tu es.
Texture of Rock
Piston Direction

Horizontal Cutting Pattern
<Fig 4-4>
These are only guidelines ased on past experiences, however, and depending on local
conditions, ground type, and the amount of fracturing in the material eing roken, you will
develop a sense of what is the est hole length in each particular application.
When reaking reinforced concrete, the hole spacing should e fairly close (12”-15”)
especially if there is a tight re ar pattern. It is important to ensure that any intersection with
the re ar in the concrete is recognized as even the slightest deviation in the accuracy of the
hole will have an adverse effect on your a ility to insert the power cylinder.
End Line
Horizontal Cutting Pattern
1
st
2nd
3rd

3) Breaking a Trench
Breaking a trench for pipelines in edrock is another excellent application for the Power
Rock splitter. This is especially true where fly rock, and lasting would e a pro lem.
Again in this application, it is advisa le to drill the holes to their full depth and split in 31”
increments..
Trench Rock Digging
Fig 4-5
Where there is top access and a free face to reak to, it is more productive to drill from the
top down and split the material to the open face. A wide variety of trench profiles can e
easily achieved with clean smooth sides and flat ottoms, minimizing the need for added
leveling materials in the trench ottom.
Trench Drilling Pattern
Free face

4) Tunneling
Tunneling is another area where there is a good application for the Power Rock splitter.
This is especially practical for instances where lasting is not an option, due to security issues
or ecause the smoke or noise would interfere with normal and continuous use of existing,
connected operations. Where new tunnels have to go under existing operations or where
they must reak into existing tunnels there is no safer method than the Power Rock Splitter.
The roken material can e easily contained and fragmentation is not a pro lem. The
Power Rock Splitter offers very precise control of what is to e roken and to what
specifications. The most difficult part of this type of work is to create a free face or void,
allowing the drill and reaking pattern to e expanded. Here are two methods and patterns
to create that free face.
The first method is to drill a large diameter hole with a crawler mounted Down-the- Hole
(DTH) drill creating an opening for additional holes to reak into. The second method is
to drill a series of holes, which when roken in sequence creates an ever expanding void, into
which the remaining holes are roken.
Large Center Hole ethod
<Fig 4-6>
Drilled center hole Power cylinder
Large
center hole

4. COMPONENTS OF PowerRock S litter
The Power Rock splitter has been designed with three main component groups.
The whole concept was to design a unit that was easy to use, was robust, and had
interchangeable major component groups.
When the Power Rock plitter was designed, the most importantly considerations were
simplicity of design for easy operation, robust construction for low maintenance requirements
when on site, and compatibility of component groups between all P series splitters. There
are three major component groups in each P series splitter. They are the POWER PACK,
CONNECTING HOSE LINES and POWER CYLINDERS.
The POWER PACK is composed of two sub components; an electric power supply unit,
and a hydraulic power generation unit.
Electric power supplies vary from country to country. For this reason, you were asked to
specify whether you wanted 50 Hz or 60 Hz, 110 Volts, 220Volts, 380 Volts, or 440 Volts, and
whether it was to be 1 phase or 3 phase.
The Hydraulic Power Pack consists of a hydraulic pump powered by an electric motor and
various pieces of instrumentation such as a directional control lever, oil filter, accumulator,
limit switch, oil pressure gauge and oil tank.
Electric Power Su ly Unit
Then standard motor supplied with the unit is a 3-phase, 60 cycle, 220 Volt electric motor.
The unit comes equipped with a phase converter that allows the operator to accept single
phase power and change it to three phases. It also comes equipped with technology to accept
voltages ranging from 110 volts to 440 volts and step up or step down the voltage to 220 volts
to make the voltage compatible with the electric motor.
It is however advisable when ordering the P series splitter, to request that it be set up for
local power supplies to avoid any problems at your site.
If a generator is used as the primary power source, you will need a 220V, 3 phase, 10Kw
capacity unit.
Hydraulic Power Pack
Hydraulic Pump and Oil Tank
The hydraulic pump, supplying oil to the power cylinders is located inside the oil
tank. It is connected directly to the electric motor located on top of the tank. The hydraulic
pump is a modified piston pump, with oversized pistons, designed to generate more power
and supply higher pressures to the power cylinders.

Series of Holes Method
<Fig 4-7>
The splitter is inserted in the top row of
holes and when force is applied, the rock is fractured creating a slot more than twice the
width of the hole. Once the broken material is cleaned out of the newly created slot,
successive lines of holes can be broken above and below, and to the left and right of the slot.
<Fig 4-8>
Power cylinder
insert
Using a larger diameter bit allows the
attern to be ex anded more easily
and quickly, and the breaking to
roceed at a faster ace.
Insert the SP ower cylinder
Drilled using a larger
diameter bit 4”-
6”

The type and grade of oil to be used will vary with the ambient temperature and the
specific requirements of the customer. Any hydraulic oil used in equipment on the job site
is suitable for use in the Power Rock plitter.
The oil tank should be filled to the upper mark of the oil sight gauge (full tank) and it
should be checked daily.
If a hose breaks and is replaced, add more oil, once the lines have been charged, in
order to maintain maximum efficiency of the pump. Oil should be replaced periodically as
should the oil filter. A dark color to the fluid is a good indicator that the oil needs to be
changed.
Hydraulic Power Cylinder
In order to increase the productivity and increase the breakage rate, smaller
diameter holes with tighter spacings, have proven to be the best combination.
The Power Rock plitter is designed and manufactured using the very best grades of specialty
steel, to allow the unit to be robust yet light enough to be easily managed by one worker.
Additionally the unit had to be capable of withstanding very high hydraulic pressures without
cracking or leaking..
Through 12 years of testing and countless re-designs, Power Rock plitter has arrived at a
reliable, efficient, environmentally friendly power cylinder that meets and exceeds customer
expectations.
The most common, all-purpose units in the Pock plitter series is the sp-80(international
standard).
These units utilize 3.503937”(89mm) holes to achieve production rates that exceed any non-
blasting methods.
The sp-80 utilizes 4 power cylinders over a body length of 30.3 inches, generating 1280 tons
of force to split the material.
HOSE SET