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Case Study: Recommendation after observing operations to improve performance and satisfaction

Jobsite: Sun Life Stadium (Miami Gardens, FL) surface preparation work to remove thick, non-skid surface coatings in areas where walls will be erected.

Problem: The operator was moving equipment back and forth like a vacuum cleaner, not properly like a surface preparator.

Recommendation:

1. Use a HEPA dust collector

2. Dial in the cut depth in the cutter impact zone prior to commencing operations. Here's how:

  • After selecting the right cutter drum assembly for the first phase of the work, go through the "dial-in depth setting" process
  • Properly set the cutter depth with the carbide milling face of the Mill-it cutters facing the direction of the rotation (down-cut)
  • Operate at full RPM and lower the cam lever gently to the surface until the edges impact above the concrete surface so it only removes the coating membrane at depths from 1/16" to 1/8"
  • As soon as the cutters contact, the operator must simultaneously pull the machine backwards to up-cut in a straight line at a slow pace so the cutters are impacting at a consistent rate without the equipment bouncing
  • Perform a short run to test to determine if the materials are being consistently removed. Always remember that because of the inconsistencies of the coating thickness and the undulations and characteristics of the surface, the operator will have to accomplish additional removal passes and reset the cut depth with another dial-in pre-operation set-up. Also, a secondary cutter drum may be required to remove the thinner or left materials since the original cutter drum assembly may be best suited for removing the bulk materials and this will also require a "dial-in" prior to operating. Once the profile is achieved, the operator should take photos and compare the profile with a profile pad to determine if he is achieving the right consistent profile pattern required by spec, and get this approved before starting operation
  • Once the dial-in depth is established, the operator must maintain a consistent backward slow walk and then raise the cam lever prior to stopping the backward movement when completing the run for the second run when removing wider materials in a new location or adjacent to the prior run

Operator notes: 

  • The removed materials will collect under the carriage (the operator should feel additional resistance due to the build-up) and immediately must clear the built-up materials by raising the cam lever to allow the materials to evacuate
  • It is extremely important to pre-set the cut depth and not continue to raise or lower the micro-depth controls during operation, but pre-set during the dial-in process at the start of the job
  • Due to the inconsistencies of the surface, the operator will hit blind steel or curled concrete joints causing the cutters to break. It is always important to have a secondary cutter drum assembly with a wear parts kit on the jobsite to anticipate short service life due to environmental conditions
  • Operator must consistently listen, feel and observe how the machine is operating, since vibration causes parts to loosen and wear prematurely.  Always service the equipment, tension belts, replace air filter in a clean room, and tighten any loose hardware. Of course, if anything breaks or wears, replace it immediately with OEM SMITH parts
  • For engine problems, call the engine manufacturer directly for warranty and service needs
  • For machine and cutter drum problems or needs, contact your Authorized SMITH Representative directly
  • SMITH offers drive-on attachments to your existing equipment, or self-propelled models that can keep the equipment operating at a consistent pace if the operator is unable to do so on his own

Many times the work you are doing is not properly specified, and to do the work correctly requires additional time, equipment, cutter tools and manpower. SMITH can assist you with providing justifications on why they should pay you more to assure the work is done properly, so surface profiles are left consistent to assure the new coatings, overlays, repair materials and fixtures bond permanently.

By following these simple common-sense guidelines, you will achieve faster and safer removal, with more consistent profile removal finishes that will satisfy your customer, and your bottom line.

We appreciate your comments and look forward to helping make the hard work of removal faster and easier for you.

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Also listed in
folder Removal Equipment -> SPS10 Surface Preparator
folder Cutter Drum Assemblies
folder Cutters -> Mill-It - Carbide Edge Milling Cutters
folder Free Help and Guidance -> Best Practices
folder Free Help and Guidance -> Equipment User Tips
folder Parts -> Wear Parts Kit

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