ROCKHIT 2023 – Finalising a high-throughput, low-emission breaker attachment for use in construction

In order for the UK construction sector to reach net-zero, equipment must become markedly more efficient and emissions reduced. At the same time, new infrastructure needed to incorporate renewable energy and low carbon transport will lead to an increase in construction activity. We, at Webster Technologies, have developed a breaker, used in construction, demolition and quarrying to shatter concrete and rock.

Whilst competitors use hydraulics to actuate a chisel or hammer at relatively high speed (1200 blows per minute) and low energy per blow; we have designed and built prototypes that use elastic ropes to generate up to 20-times higher blow energy. The breaker operates at a lower speed (60-90 blows per min) and attaches easily to any excavator's hydraulic system.

Benchmarking has shown a potential threefold increase in productivity (amount of material broken) alongside a halving in fuel consumption for the base vehicle. Smaller base vehicles can be used, further reducing fuel costs, hire costs and logistics costs of delivering vehicles to sites. Noise and vibration nuisance to operators and site neighbours are reduced.

Wear on the bases vehicle is reduced, allowing new modes of operation, e.g. on a boom up to 27m long. However, operational life of current prototypes is only ~160 hours before major overhaul, vs. industry accepted standards of 500 hours.

We have conducted FEA to identify subcomponents prone to failure and revise designs accordingly. In this project, we will design and build three new prototype breaker attachments and repeat benchmarking to achieve a 500 hour unit life. Balfour Beatty Vinci JV-HS2 as main contractor delivering HS2 will trial outputs and are a likely first Tier 1 customer, followed by further UK large plant hire companies.