Suction excavator


A suction excavator or vacuum excavator is a construction vehicle that removes materials from a hole on land, or removes heavy debris on land.

Description

Suction excavation is a new and innovative solution to traditional excavation methods. The technology allows high powered fans to safely excavate up to 43metres depending on configuration. A small surface area hole of 250mm  is created and then the suction excavator hose removes below surface materials. The compressed air fractures the ground for the suction excavator to remove material safely and no hand tooling is used.
The benefits of suction excavation include: eliminating underground utility strikes, minimising traffic disruption, reducing reinstatement costs and less manpower and equipment needed for each job. There are several different industries that can benefit from suction excavation: rail, civil, highways, plant, water, gas, power, construction and telecoms to name a few.

History of fan-based suction technology

The RSP GmbH have been making suction excavators and stationary suction units since 1993. Since 2000, RSP developed a new suction principle, the ESE Series. These vehicles work with the internationally patented suction principle which guarantees the highest degree of gravity separation, lowest contamination of the filters and thus consistently high suction performance.
Since 1998, the MTS Mobile Tiefbau Saugsysteme GmbH is making another type of suction excavator. It is said to have a new designed air flow principle, and thus a considerably improved suction performance compared to MTS previous designs.

Design and operation

RSP GmbH – GmbH

The RSP GmbH produced since 1993 suction superstructures mounted onto two, three and four-axle vehicles, stationary suction units as well as custom-made machines.

The suction unit is roughly rectangular-block-shaped, about 2.5 metres wide and 3.6 metres high, and is usually mounted and used on the back of a truck, which must have power takeoffs to run the suction unit's air impeller and hydraulics. When it is emptying its load out, the spoil tank lid hinges off to the right, then the spoil tank tips about 90° over to the left to tip its load out.
Possible applications include:
Suction excavators eliminate the need for costly and time-consuming manual labour. Buried pipe systems do not suffer damage. Output is up to sixteen times of that achieved by conventional excavation.
In the ESE 32/7:
Materialm3/hourTime for 1 m3.
heavy soil with buried cables and pipes1.666636 min
dry heavy soil2.524 min
wet heavy soil or clay320 min
moderately heavy soil with buried cables and pipes415 min
muddy soil, gravel, crushed rock610 min
sandy soil106 min
water302 min
heavy soil with buried cables and pipes
excavated by hand		0.254 hours

MTS Mobile Tiefbau Saugsysteme GmbH

MTS GmbH in Germersheim, Germany is making since 1998 these types of suction excavators:
ModelFanAir movementSuction pressureSpoil capacityMax. suction depthMax. suction distanceSuction hose diameterInfo linkNotes
Suction Box SBO1-2m3Can be carried by excavators etc. In 22, 32, 42 kW versions.
MINI-VACSingle turbine6,944 m3/s0.1974 bar1,5-2m35m25mbuildup on 7.5 ton truck, compact for difficult-to-reach sites
DINO 2–5Single or
double turbine		6.944 – 10 m3/s0.335 bar4m3 – 12m320m+100m+with telescopic boom or hydraulic boom
MEGA-VACQuadruple turbine10 m3/s0.493 bar9m330m+200mbig for big jobs



With the MEGA-VAC the suction power across a 9.84-inch-wide hose entry would be about half a ton.

Saugmaster

Saugmaster is a RSP ESE model; it can suck 8 m3/s of air, and its suction tube is wide inside.

History of vacuum-pump-based suction technology

Pacific Tek

Pacific Tek was founded in 1993 and went into the valve exerciser and vacuum excavator industry. Pacific Tek founders have created innovations, such as the Angled Vacuum Excavator Tank and 180° Swivel Mount Valve Operator.

Ditch Witch

The American firm Ditch Witch makes 4 models of suction excavators: FX20, FX25, HX30, HX50, FX50, FXT50, FX65, FXT65, and HX65; the number is its approximate horsepower. It is mounted on a semitrailer or rigid truck. It has its own engine. Its spoils tank is cylindrical with somewhat rounded ends. Its suction hose is 3 to 4 inches diameter inside. Its spoil tank can be supplied various sizes from 150 gallons to

Airex

Airex GB Ltd in the UK make two current models of vacuum excavator: AX-68 and AX-180. Both systems are mounted on the back of rigid 7.5-ton trucks, designed for use in inner-city streets. The smaller design of these trucks gives less impact on their surroundings. The AX-68 uses a 4-inch hose but the AX-180 uses an 8-inch hose which can remove a tonne of earth in six minutes.

Ring-O-Matic

Ring-O-Matic Inc, in the U.S. makes several models of gasoline and diesel vacuum excavation units. They offer both trailer mounted and skid mounted models. Spoils tanks range in size from 150 gallon up to 2000 gallon tanks.

Vac-Tron Equipment, LLC

Vac-Tron Equipment, LLC in the U.S. makes more than 50 models of hydroexcavation and dry excavation gasoline and diesel vacuum excavators.

Cappellotto

Cappelotto makes various powered cleansing equipment including CAPGEO. Its arm is said to reach 7 meters and to swivel 250 degrees.
Cappelotto was founded in 1953 and is based at Gaiarine in the province of Treviso in Italy.

The Cappellotto products are also distributed to 40 countries in the world, with KOR Equipment Solutions being the distributor for Australia and New Zealand

Uses

Suction excavators are useful to remove earth from around existing buried services or tree roots with much less risk of damaging them than using a conventional excavator with a metal bucket.
This type of excavation is held to be a safe and efficient form of excavation. However it is totally unsuitable for archaeological excavation. Using a powerful vacuum and high pressure water, precise holes, trenches and tunnels can be cut to the required size and proportion. Because compressed air or water is used to loosen the earth, the risk of damaging underground utilities is less and contractors can safely find and expose them. Often excavation reveals unknown utilities, saving lives, money and time.
It is also referred to as "daylighting", as the underground utilities are exposed to daylight during the process.
This type of excavating is quickly becoming recognized as a best practice when working in areas with underground utility congestion and frozen ground. Hydro excavation lessens the risk of damaging utilities, which may often be inaccurately mapped and located and marked on the surface.
A suction excavator is useful in bulk excavation in confined areas, where its suction hose can reach in over or through barriers, e.g. digging a swimming pool in a courtyard.
It can be used on railways to suck old track ballast off the track when re-ballasting the track.
It can be used as a very heavy-duty vacuum cleaner to pick up miscellaneous debris, e, g, rubble, or big accumulations of fallen leaves or litter.
It can suck up liquids, e.g. water from a hollow. In case of opting for air vacuum excavation, the Positive Displacement Blower should be properly checked because it can move great volumes of air and a malfunctioning can cause a serious accident. When digging on rocky soils, it is better to opt for water instead.
The National Grid Gas Plc has ordered 10 suction excavators.
As at July 2009 in England the North West Gas Alliance has 3 German-made suction excavators.
Vacuum excavation hire providers Pier work with utility and civil engineering companies throughout the UK to provide safer no-dig excavation. Projects include relocating underground utility lines to accommodate wider road lanes and filter lanes, and street works to provide essential maintenance of street lighting.
Force One Ltd specialist image library shows various uses of the new excavation technology including bridge refurbishment, clearing culverts, clearance of holding tanks, extension hose excavation, substations. rail excavations, airports, filter beds, lighthouse, and many more applications. Vacuum/suction excavators can excavate up to 140m horizontally and up to 20m depth depending on the type of material being excavated.

Specific jobs

Suction excavator jobs in Italy described in RSP Gmbh's publicity include:
Vacuum excavation is excavating by high-powered vacuum suction machines. This process significantly reduces the risk of loss of property and injury to workers associated with contacting or cutting underground utilities, as often happens if backhoe, auger, hand digging, or other mechanical methods are used.
Portable vacuum excavation equipment such as suction excavators can quickly dig small deep precisely-controlled holes to uncover buried utilities. Soft excavation technology can dig around buried pipe or cable without the risk of damage inherent with backhoes, excavators, or other mechanical tools.
Typically, vacuum excavation loosens the soil with a blunt-nosed high pressure air lance or water source and immediately vacuums away loosened material. Air and water, when used appropriately, are far less likely than sharp-edged tools to damage underground structures.
Depending on the machine used and soil conditions, a 12-inch-square 5-foot-deep pothole can be completed in 20 minutes or less. Most models are capable of digging deeper, but utility potholes seldom need to be more than six feet deep.
Vacuum excavation is best used in conjunction with conventional underground locating services. Because of a preponderance of overlapping buried utility lines, locating devices often miss some of the buried utilities on a site or cannot completely or accurately mark a site.
According to New Mexico One Call 811: Aligning Change, Locating with Potholing, "One-call paint marks and flags are the first step in making the process of locating underground utilities safer, the use of vacuum excavation technology adds an additional margin of safety."
Potholing using vacuum excavation, has made it safer to find underground utilities.
When conventional locating is unworkable due to high densities of buried utilities, potholing can also be used to verify the route of each buried line within the excavation zone. In some cases, the contractor may choose to perform the entire excavation using vacuum excavation.
Today, according to "In the Pipeline" in an article on enewsbuilder.net, "As vacuum excavation technology and techniques for locating underground utilities has become both readily available and affordable, it's already considered by many municipalities as a Best Practice." Many governmental entities and municipalities no longer allow the use of backhoes to find underground utilities, citing the risk of damaging them. Many have ordered use of vacuum excavation only.
To prevent utility strikes, the use of underground locating services has become the norm, and in most places, is required by law. However, the practice of underground location, while very useful, has its limitations. Locators have been known to miss some of the buried utilities or be unable to completely or accurately mark a site because there are many overlapping buried utility lines.
For these reasons, vacuum excavation can be an effective way to find, with virtually 100% accuracy, all underground structures in an excavation zone. Vacuum excavation is also typically more cost effective than hand digging.
Through aggressive educational efforts about the safety of vacuum excavation, vacuum excavation is now being mandated in many states and municipalities, and efforts are underway to achieve universal acceptance of vacuum excavation as the preferred technology.