Core-ECT carried out precision concrete cutting at the Nestlé factory in Burton-on-Trent, removing sections of a 500mm-thick reinforced concrete slab in preparation for the installation of new heavy equipment. The work required a combination of track sawing and stitch drilling to remove the existing concrete without overcutting or damaging the structural steel beneath.
Precision Concrete Cutting for New Equipment Installation
Core-ECT was appointed to assist with preparation works at the Nestlé factory in Burton-on-Trent, where an existing reinforced concrete slab needed to be removed before a new higher-strength concrete base could be installed for heavy equipment.
At approximately 500mm thick, the reinforced concrete slab presented a substantial cutting challenge. More importantly, the work had to be completed without damaging the surrounding slab or the structural steelwork beneath, all of which was being retained and reused.
This required careful planning and highly controlled cutting rather than conventional demolition.
Track Sawing & Stitch Drilling
Our specialist operatives used a combination of track sawing and stitch drilling to create accurate, controlled cuts through the heavily reinforced concrete.
Track sawing provided the precision required to define the edges of the sections being removed, while stitch drilling enabled difficult areas to be cut without extending beyond the required opening.
The two techniques allowed the concrete sections to be released cleanly while avoiding overcutting into the remaining slab.
H2: Protecting the Existing Structural Steelwork
A critical part of the project was preserving the structural steel beneath the concrete.
The steel beams were being reused, so accidental contact or damage during the concrete removal process had to be avoided.
By carefully controlling the depth and position of each cut, the Core-ECT team successfully removed the required concrete sections while leaving the underlying structural steelwork intact.
Working in Challenging Site Conditions
The project was made considerably more demanding by temperatures on site regularly exceeding 40°C.
Despite the difficult working environment, our specialist operatives completed the concrete cutting safely and accurately, delivering the required opening ready for the next phase of works.
After eight hours a day surrounded by the smell of instant coffee, however, the team may have had enough Nescafé for a while.
The Result
The existing 500mm reinforced concrete slab was successfully cut and removed with:
* No overcutting into the retained concrete slab
* No damage to the underlying structural steelwork
* Clean, accurately controlled cuts
* Existing steel beams retained for reuse
* The area prepared for the new higher-strength concrete installation
The project demonstrates how combining track sawing and stitch drilling can provide a precise solution where conventional concrete removal methods could risk damage to surrounding or retained structures.
