Utilicor Minicor 2 User manual

Minicor-2™
Rotary Coring Attachment
And
Utilibond™ Permanent Pavement
Bonding Compound
Operations Manual
2010
Version MC2 1.1
Utilicor Technologies Inc.
36 Densley Avenue, Toronto, Ontario, Canada M6M 2R1
1-800-572-6666 www.utilicor.ca

© 2010 Utilicor Technologies Inc.
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Table of Contents
minicor-2™ at a Glance 2
Introduction 4
Suggested Operator Qualification and Training 6 6
Pre-Trip Procedure 7 7
Pre-Departure Checklist 8
Utilicor Process Pilot Bit and Integral Center Pilot Hole 9 10 11
Tips for a Successful Coring Operation 11
Step 1: Operating Instructions for Utilicor Rotary Cutter 13
Step 2: Coring Process 14
Step 3: Site Clean Up 17
Step 4: Detach Minicor-2 18
Tips for Successful Core Reinstatement 19
Core Reinstatement Procedure with Utilibond™ 21
Core Reinstatement Equipment 24
Cold Weather Procedures 25
minicor-2™Equipment Maintenance 28
Drill Carriage Schematic 30
Pillow Block Assembly 31
Troubleshooting 32
minicor-2™Hydraulic Schematic 33
minicor-2™Electrical Schematic 34
Warranty 35
Utilibond™ MSDS 36
Utilibond™ WHIMIS. 40
Utilibond™ OSHA 41

© 2010 Utilicor Technologies Inc.
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Minicor-2 at a Glance
Up/Down
Control Orbital
Manual Valve
• Wash Pump
• Stabilizers
E-Stop
Cutter
Water
Right Stabilizer
Drum Motor
Pillow Block
Drive Adapter
Core Drum
Beacon
Hydraulic
Quick
Connects
Drum Speed
Adjuster
Water Petcock
Water fill Port

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Minicor-2 at a Glance
Left Stabilizer
Winterizing
Assembly
Core Puller
Holder
Water Filter
High Pressure
Wash Pump
Lockable
Toolbox
Drill Carriage
Adjuster
Door
Bash Plate
holder located
on inside of
door

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Introduction
Utilicor Technologies Inc. (Utilicor)
Utilicor is the exclusive manufacturer and distributor of a field-proven,
keyhole coring and pavement reinstatement system. Our mission is to
develop new, innovative and cost effective technologies for the utility
industry.
Utilicor Process
The Utilicor process, referred to as "Utilicoring", combines the purpose-built,
field proven, truck or minicor-2™ skid-steer mounted, Utilicor Rotary Coring
Unit with Utilibond™, a proprietary bonding compound, that have been
specially engineered for coring and the permanent reinstatement of the
cored coupon in asphalt, asphalt-concrete, concrete and reinforced concrete
road surfaces, and concrete sidewalks. The process has been approved as a
permanent pavement repair by a number of transportation authorities in
both Canada and the USA since 1992, on thousands of keyhole excavations,
with ZERO failures.
Utilibond™, our proprietary core bonding compound is an integral part of the
reinstatement process and has been independently tested and shown to
create a bond (in less than 30 minutes at 70ºF) that is stronger than the
original pavement and is capable of supporting the combined weight of five
transit buses in under half an hour.
The Purpose of The Operations Manual
This manual is intended as a reference guide for operating and maintaining
the Utilicor coring equipment and performing core reinstatements using
Utilibond™. It is designed to familiarize the operator with the main elements
of the process, and to answer common questions, but does not replace
comprehensive, on-the-job training performed by a competent trainer.
Neither should it be considered as a replacement for common sense or a
substitute for the maintenance requirements of the vehicle or equipment on
which your Utilicor unit has been installed or mounted. Most importantly, this
operations manual is intended to be used in conjunction with the internal

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policies, procedures and maintenance schedules already established by your
company, and does not supersede them.
If you feel the information provided in this manual is not sufficient to operate
the equipment or carry out the processes described, Utilicor Technologies Inc.
is available to answer your questions and to facilitate any training needs you
may require. Please contact us directly for more information at 1-888-572-
6666 (toll free), or via email to [e-mail].
For safety reasons, this entire Operations Manual should be reviewed prior to
operation of the Utilicor Rotary Coring Unit. Failure to review the entire
manual prior to commencing operations, or to follow warnings and operating
procedures outlined in this manual, may result in damage to the equipment,
injury, or possibly death.
Always take extreme care when operating or working around all
equipment.

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Suggested Operator Qualifications and Training
Proper training and qualification of operators is a key factor in the success of
any operation or maintenance program. All operators who operate this
equipment should have the appropriate skill set, accreditation, training
and/or certification, as well as a good amount of common sense.
The operator should be a “competent person” whose qualifications include:
•A valid driver’s license for the appropriate class or level of motor
vehicle or piece of equipment being operated.
•Successful completion of a practical, on-site training program and
operating examination for the Utilicor equipment, administered by a
qualified trainer.
•First Aid and CPR training.
•Traffic safety and awareness training for construction sites.
•Safe excavation procedures training
•Underground electrical awareness training.
•Familiarity with ONE-CALL (Call before you dig) local requirement.
REMEMBER: This manual is only a guide. Always consult, and follow your
own company's policies and procedures that pertain to safety and
training and use your common sense.

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Pre-Trip Procedures
Circle-Check
Safe and reliable operation of any piece of equipment starts with a
comprehensive and thorough pre-trip and post trip procedure. Walk around
(circle-check) the Utilicor coring equipment to ensure that the unit is safe to
operate.
Pre-Trip Inspection
The following is a suggestion of some important elements of a pre-trip
procedure. Consult your own company's procedures before continuing.
Before inspection, ensure that the vehicle is positioned on a clean, dry and
level surface, with wheels chocked both front and back.
(1) External:
•Visually inspect the minicor-2™ unit
•Check for hydraulic fluid and other leaks.
•Fill water tank
(2) Skid-steer:
•Check hydraulic reservoir
•Check fuel level

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Pre-Departure Checklist
This checklist is designed to make your job and your day run much smoother.
You may find it helpful to keep a copy of this list in the coring unit. Feel free to
add to it as you see fit.
(1) Has the skid-steer been refueled?
(2) Is the water tank full?
(3) Are all other fluid levels topped up?
(4) Do you have enough Utilibond™ and pea gravel for reinstating the
cores?
(5) Are all appropriate tools and equipment on board, and are they in
good working order? Check that all tools, equipment and other
materials are safely secured for transit.
(6) Are the pilot bit and coring drum in good condition? Examine both for
excess wear and replace if necessary. Check to make sure the truck has
spares of both items.
(7) Do you have all necessary personal protection equipment?
(8) Is the equipment secured to the trailer for transit?
(9) When loading the skid-steer and minicor-2™ on the trailer, ensure that
the minicor-2™ is raised high enough to clear the trailer in loading
forwards or to clear the ground if loading backwards, otherwise serious
damage to the unit may result.
(10) Are your Driver's Licensed, H2S, WHIMIS, First Aid certificates and are
other necessary documents available and current?
(11) Have you completed all other pre-departure checks and procedures
mandated by your company?
(12) Do you have all the required work-orders and paperwork?

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Utilicor Process, Pilot Bit and Integral Center Pilot Hole
The central pilot bit and related pilot hole, are unique to the Utilicor process,
and perform four important functions in Rotary Coring and Reinstatement:
(1) Accuracy: The 2 3/8" diameter bi-cone central pilot bit, which is
integral to the Utilicor coring process, acts as a concentric guide for the
coring drum, centering and stabilizing it to ensure a fast and accurate
cut. It is the same type of robust, high-performance bit that is used in
the drilling industry to quickly and accurately cut through rock and
other tough materials.
(2) Access and Handling: The central pilot hole, created by the pilot bit,
provides a convenient access for the core-puller by which the core or
coupon is removed from the pavement and by which it is repositioned
back into the pavement during reinstatement after completion of the
repair. Other coring processes which do not employ an integrated
central pilot bit must either drill a separate bar hole in the core, insert a
separate lifting ring into the core or use some form of clamping
mechanism or other device to lift the core out of the hole after cutting
and to accurately refit the core back into the hole after the repair. This
involves an extra step and adds more complexity to the coring process.
(3) Strength and Stability: The central pilot hole, when filled with
Utilibond™ increases the bonding surface of a typical 12" deep 18"
diameter core by almost 100 square inches (a 13% increase in bonding
surface area) and adds strength to the reinstatement process. In
addition to increased surface bond strength, this central column of
Utilibond™ acts as a continuous stabilizing link between the replaced
core and the Utilibond™ impregnated bed of pea gravel at the base of

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the hole, increasing the vertical stability of the core as well as adding
to the overall strength of the reinstatement process.
(4) Coring Guidance: Because the pilot bit cuts slightly deeper than the
coring drum, it can provide the coring operator with an audible and
sensory cue as to when the coring drum is about to core through the
bottom of the pavement. When the pilot bit breaks through the
pavement into the sub-grade there usually is a noticeable change in
the sound and the feel of the coring process, which can alert the
operator to the fact that the coring drum is about to cut through the
full pavement depth.

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Tips for a Successful Coring Operation
(1) Mark the area to be cored with a paint slash across the core area before
beginning to core. This will help to properly orient the core when it
comes time for reinstatement.
(2) Before the coring process begins, manipulate the tilt controls on the
skid-steer to make sure the minicor-2™ is level and flush to the ground.
(3) Using either the left or the right stabilizer level the minicor-2 to the
horizon.
(4) Ensure that the appropriate rate of water is flowing through the pilot
bit and the adapter plate inside the drum. Periodically check for water
flow during the coring operation. If the hole in the pilot bit becomes
blocked with asphalt or other debris, remove build-up by inserting a
thick gauge wire into center hole to clean it out. Do not core without
adequate water flow to the centre pilot bit.
(5) Let the diamond tipped cutting drum do the work of cutting without
excess pressure being applied. Slow, continuous turning of the orbital
control wheel will allow the coring teeth to work and cut through the
pavement without experiencing drum kick back, or stalling of the
hydraulic motor. You are applying too much downward pressure if the
drum stops turning, or if the minicor-2™ lifts off the ground.
(6) When cutting through asphalt, after you have scored the surface to a
depth of ½” or so, raise the coring drum and position the Pavement
Protection Plate within the cored circle. This plate will protect the
asphalt surface if the core sticks in the drum and it is necessary to use a
spud-bar to dislodge it (see # 9 below).
(7) Remember to raise the coring drum completely out of the cut area
periodically during the coring operation. This will help to remove any
build up of suspended solids and cutting debris that can cause the
core to become lodged in the drum. Keep the cut space surrounding
the core or “kerf” clean and free of debris.
(8) You will know you are through the concrete / asphalt pavement when
the slurry changes color, and begins to include roadbed materials such

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as sand, gravel, etc. The sound emitted by the bi-cone pilot bit
(typically a "rumble") will change, and not be as noticeable when it
cuts through the bottom of the pavement. Core for another 1"-2"
more to compensate for the additional length of the pilot bit and for
any slant or unevenness in the core bottom.
(9) To ensure that the core is completely cut through, raise the drum and,
with a spud-bar in the pilot hole, gently rock the core back and forth.
(10) If the core should become stuck in the drum, use the holes in the top
of the coring drum to insert a push rod or spud-bar to tap the top of
stuck core, remembering to rotate the drum a quarter turn after each
tap. Never tilt the drum to the horizontal position if a core is stuck in
the drum or you could bend the shaft. Keep the drum perpendicular,
and push the core out first.
(11) Check the coring teeth on the drum regularly for wear. You will save
time by cutting with sharp teeth, and reduce the chance of the core
becoming stuck inside the drum, which tends to happen once the life
of the teeth has been used up.

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Operating the minicor-2™ Coring Attachment
Step 1: Attaching the minicor-2™
(1) Position the skid-steer behind the minicor-2™, and slowly raise the
Quick Attach or Bob-Tach™ locking arms into the recessed area on the
minicor-2™. Once in place, secure the coring unit to the skid-steer by
locking the arms on the Quick Attach system. Please refer to the
attachment guide that comes with the Quick Attach system on your
skid-steer, as failure to achieve proper coupling may result in damage
to the coring attachment and/or injury to the operator.
(2) Attach the flat face quick-connect hydraulic couplers from the skid-
steers auxiliary hydraulic system to the quick-connect couplers on the
coring unit. If the quick connect couplers on the coring unit are not the
proper configuration, contact Utilicor directly before proceeding. Do
not use high flow connection. This will result in blown seals on the
hydraulic motors.
(3) If there is any back pressure in the hydraulic system on the minicor-2™
or skid-steer, engaging the quick connect hydraulic couplers may be
difficult. Refer to the operation manual of your skid-steer to determine
how to de-energize the hydraulic pressure in the auxiliary lines. (If the
pressure was not released from the pressure hose before the unit was
disconnected you will have to loosen the hydraulic fitting on the hose
and bleed off some oil to relieve the pressure in the line.)
(4) A 12-volt power supply for the water pump is required. The minicor-2™
coring attachment comes with a two pronged wire leading from the
back of the attachment. The easiest place to plug this in is the cigarette
lighter if your unit is equipped with one. A cigarette lighter adaptor
piece will be required, and is not supplied, but can be easily obtained
at any automotive store. The other alternative is to run power off one
of the front lights of the skid-steer, as long as the light will not be
required for night use. Contact Utilicor if you do not have the correct
connection pins to safely accomplish this.

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Step 2: Coring process
(Follow the “Tips for a Successful Coring Operation”)
(1) Fill the unit with fresh clean water, through the fill port located on the
back of the unit. The water level indicator (sight tube) is located inside
the core drum enclosure.
(2) Position the cutter over the area to be cored using the skid-steer
controls. Lower the back end of the coring unit first, feathering the
back half of the base down until the unit sits level on the pavement.
Slowly lower the front of the attachment until it is level on the
pavement. Do not apply too much down force on the coring unit (i.e.
DO NOT lift the skid-steer wheels off the ground) otherwise the
settling of the hydraulics of the skid-steer over time will result in an
altered angle of approach of the core drum, and cause the coring drum
to bind or stick as you cut. IMPORTANT: Make sure that all 4 feet of
the minicor-2™ unit are in direct contact with the pavement and that
the unit is resting firmly on the pavement.
(3) Engage hydraulics on the skid-steer, turn skid-steer throttle to full, and
turn on hydraulic override. Refer to skid-steer operations manual for
details regarding these procedures. This process will allow you, the
operator, to safely dismount while the hydraulics remain engaged to
power the coring process.
(4) Lower either the left or right leveling stabilizer to level the minicor-2™
to level the unit.
Left and Right Stabilizers

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(5) Turn on water pump switch on minicor-2™, establish and adjust flow
rate of water to cutting drum and pilot bit assembly.
(6) Remove the bash plate and close the cutter guard door. The door
should be closed and latched during the coring operation.
(7) Turn the cutter on. In the event of an emergency or hydraulic failure
push the Estop in and all flow will be diverted back to the skid-steer.
(8) You may have to adjust the flow control depending on the hydraulic
flow of the skid-steer. The core drum should spin at approximately:
12” Core Drum – 200 to 225 RMP
18” Core Drum – 175 to 200 RPM
24” Core Drum – 100 to 130 RPM
Cutter water petcock
Water Pump
ESTOP
Cutter Drum
Drum speed flow control

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(9) Slowly turn the orbital control wheel clockwise to engage the
pavement with the pilot bit and begin the coring process. Slowly turn
the wheel keeping the drum feed gauge to a maximum of 750 PSI.
Too much down pressure will stop the drum and result in the hydraulic
system going to bypass or begin to lift the unit off the ground. If this
occurs, back the drum up and resume cutting.
Follow the “Tips for a Successful Coring Operation”.
(10) Once the slurry changes color, and the resistance on the orbital control
is reduced, the core should be detached from the pavement and you
are finished cutting. Before moving the minicor-2 verify that the core
has been cut all the way through the pavement.
(11) Raise Drum, turning the control orbital counter clockwise until the
drum is raised to its maximum height. Using the Skid steer lift the
minicor-2 off the ground to a safe transport height and move skid-
steer and the coring attachment away from cut core. Lift the core out
using core puller. Relocate the core to safe place for reinstatement
later.
CAUTION: Some cores are VERY HEAVY. Depending on diameter,
composition and thickness, cores can weigh more than 200 lbs. Small cores
weighting less than 80 lbs. (18” in diameter and under 6” deep) can be moved
by one individual. Cores weighing up to 160 lbs. (18” in diameter between 6”-
10” deep) can be lifted by two men using a spud bar through the eye of the
core-puller. Heavier cores should be lifted and positioned with the assistance
of a core lifting device. Cores can also be carefully tipped on their side and
rolled to the side of the roadway.
Drum feed Pressure Gauge

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Step 3: Site clean up
(1) Uncoil the pressure hose and connect the gun and wand. Open the
high pressure petcock.
(2) Turn water pump on.
(3) Detent the valve handle towards yourself to engage the high pressure
pump.
(4) Wash down site and minicor-2™ of all slurry and debris.
High Pressure Wash Petcock
Water pump switch
High Pressure Wash Pump
ON/Off

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Step 4: Detach minicor-2™
(1) Disconnect 12 volt connection.
(2) Relieve pressure in the skid-steer’s hydraulic system. (Consult skid-steer
operations manual). The hydraulic hoses attached to the skid-steer
should go limp. (Failing to do this will make it virtually impossible to
reconnect the couplings.)
(3) Disconnect the couplers.
(4) Unlatch minicor-2™ attachment.

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Tips for Successful Core Reinstatements
(1) Make sure the backfill is properly compacted to a level two inches
below the base of the pavement.
(2) Line the bottom of the hole with 1”-2” bed of pea gravel. Undercut the
bottom of the existing pavement 1” around the circumference of the
hole to allow the pea gravel to infill under the pavement.
(3) Dry fit the core before reinstating. The core should sit approximately
1/8" below the pavement surface once it is properly dry fitted.
(4) Clean the areas to be bonded (the inner surface of the hole and the
outer surface of the core), removing any loose debris. Proper
preparation and fit are crucial to a proper reinstatement and a good
bond.
(5) Add the exact amount of water (2 liters) to the pail by filling to the
bottom of the indicator line; then pour and mix in the dry Utilibond™
powder. DO NOT ALTER THE RATIO OF WATER TO UTILIBOND™.
(6) Mix Utilibond™ using a portable drill powered mixing tool for at least 3
minutes until it reaches a creamy consistency.
(7) Gently pour Utilibond into the hole, do not disturb base.
(8) Carefully lower the core into the hole. Keep in mind that set times are
dependent on temperature. Utilibond™ achieves bond strength of
50,000 pounds, -- five times the AASHTO standard -- in just thirty
minutes at 70° F. Colder temperatures will result in proportionately
longer setting times, and higher temperatures will reduce setting
times. Contact Utilicor for cold weather reinstatement procedures.
(9) To achieve even coverage of the Utilibond™ around the entire core,
using the core puller, rock the core back and forth and from side to
side until Utilibond™ is seen to ooze out around the complete
circumference of the core. This indicates that the entire kerf is filled
with Utilibond™. Remove the core puller, and allow the pilot hole to
completely fill with Utilibond™ and overflow on to the surface of the
core.