DIGGING DEEP

Customised Komatsu PC700LC with 3D Machine Guidance perfect solution for raw gravel extraction

Production at German construction company Kann GmbH Baustoffwerke has literally doubled since they invested in a specially equipped and customised Komatsu PC700LC-11E0 long reach excavator, fitted with Komatsu’s Smart Construction 3D Machine Guidance, which has been described as ‘the first step’ to help operators everywhere embrace digital technology on the work site.

The Komatsu excavator is being employed in extracting gravel from deep underwater deposits at a site in Mülheim-Kärlich which is owned by the company whose core business is the manufacture of high quality concrete products, including decorative paving and blocks.

Around 500,000 tonnes of raw gravel are extracted annually from the site, and the Komatsu PC700LC-11E0 long reach excavator alone is expected to produce half of that each year for the family business which was founded in 1927 and today operates with 18 locations throughout Germany, including three gravel quarries.

This Komatsu excavator is especially ideal for extracting gravel from deep under the surface of the water, not just because of its long reach boom, but the addition of the Smart Construction 3D Machine Guidance, supplied by BRR's subsidiary AP Deutschland. It uses technology such as sensors, GPS and computers to improve digging accuracy. It works by comparing where the bucket is in the real world to a 3D digital model, essentially giving operators a virtual guide to assist them in their work.

What makes the Smart Construction 3D Machine Guidance system different is its affordability with lower start-up costs, which means companies like Kann are able to experience the benefits of the technology without committing to a lot of expense. It has considerably boosted efficiency and productivity on the site.

One of the local government restrictions in the area meant that Kann couldn’t draw up material from the gravel pit from more than a depth of 12 metres. Using the easy to operate Komatsu 3D Guidance System with its Smart Construction technology, operators are able to capture the movements of the 4.28 m³ capacity bucket, its angle and depth, beneath the water’s surface.

This entry-level Smart Construction 3D Machine Guidance, increasingly popular with other operators across Europe since its release about a year ago, is also available with an integrated payload meter option that allows for on-the-go weighing of material. This eliminates the need to stop and weigh each bucket, preventing overloading and increasing productivity by allowing uninterrupted operations.

Combining payload with Smart Construction Fleet, operators can also receive daily payload reports automatically, allowing them to precisely track load counts and volume moved, gain insight into productivity and reduce idle time.

"KOMATSU SMART CONSTRUCTION 3D MACHINE GUIDANCE USES TECHNOLOGY SUCH AS SENSORS, GPS AND COMPUTERS TO IMPROVE DREDGING ACCURACY"

Also available is Smart Construction Remote which works not only on Komatsu systems, but also on machines equipped with the latest from well-established guidance brands and the upcoming ones. This helps operators to effortlessly track and reduce their environmental impact. It calculates saved driving hours, fuel use, and CO₂ emissions, delivering essential data for audits and compliance — making green construction management simpler than ever.

Smart Construction 3D Machine Guidance system

Problem solving

Kann turned to Komatsu sales partner BRR Baumaschinen Rhein-Ruhr to come up with a satisfactory solution that would take into account the special nature of the excavation area where gravel deposits deep below the water surface placed high demands on the machines they were using. They needed something that would handle both the excavation and loading of the raw gravel, as well as replace a 40 year old dragbox which used an O&K RH9 crushing bucket as an anchor.

While the basic Komatsu PC700Lc machine provided the necessary stability and lifting power with its lifting cylinders from the Komatsu factory in England, the steel construction of the boom and arm had to be extensively customised by a third-party supplier so that the required length could be achieved when digging to reach the deep gravel below the waterline. The excavator was also supplied with a hydraulic ditching bucket.

Due to the challenges created by underwater use, AP Deutschland also installed a special solution to protect the sensors and connections relating to the GPS and Smart Construction 3D Machine Guidance kit, enabling it to effectively operate in what is a difficult underwater environment.

“The decisive factor in our decision to purchase the Komatsu hydraulic excavator was that, despite its length, the boom does not rest on the chassis to achieve the required depth, does not dig up the ground itself and can also maintain a safe distance from the bank. In addition, BRR was a competent partner right from the start, understanding and realising our requirements,” says Technical Manager Frank Hergenroether.

“The bucket's movement options, too, save us a lot of time, as we don't have to constantly move the excavator and it can work from the same spot. This is currently only necessary about once per shift. Another advantage of the excavator is that it is still very mobile despite its size. This is not only a relevant aspect in this gravel pit, but also for the future, when the machine changes the extraction area, as the areas are becoming ever smaller and more urbanised.”

“THE INCREASE IN PRODUCTIVITY AND EFFICIENCY IS THANKS TO THE DETAILED ON-SITE INSTRUCTION AND TRAINING PROVIDED BY BRR AND KOMATSU ON DELIVERY”

The combination of the silent 327 kW / 439 HP engine and the cab’s superb sound isolation, the Komatsu excavator is as quiet to operate as the average family car, while its large TFT monitor presents a clearer, easier-to-use operator interface.

Among the many other notable features of the Komatsu is the auto idle shutdown which automatically turns off the engine after it idles for a set period of time. This feature can easily be programmed from 5 to 60 minutes, to reduce unnecessary fuel consumption and exhaust emissions, and to lower operating costs. An Eco-gauge and the Eco guidance tips on the cab monitor further encourage efficient operations.

Further advantages of the Komatsu PC700LC, which offers outstanding fuel consumption, were highlighted by the machine’s operator René Münch. “The lifting power speaks for itself. In addition, the comfort during operation is impressive thanks to the superior cab suspension. Overall, the machine is very clear, tidy and intuitive to operate.”

Excellent operative training

Operators at Kann have found both the Smart Construction 3D Machine Guidance system and the Komatsu PC700LC simple to use. “Within a very short time, all machine operators were trained to work safely on the excavator and were ready for action,” says operator René Münch. “The length of the arm and how quickly we were able to achieve the required performance was surprising. The target of being able to extract at least 1,000 tonnes of gravel per shift has already been exceeded.”

Plant Manager Andreas Müller adds that the increase in productivity and efficiency is thanks to the detailed on-site instruction and training provided by BRR and Komatsu on delivery, helping all their operators to be comfortable with the controls and safety features. “The increasing performance curve of the employees with the new PC700LC11E0 is clearly visible,” he says.

Thanks to the close co-operation and flexible approach demonstrated by Kann, BRR and Komatsu, all of whom adopted a positive ‘can do’ attitude to come up with a workable solution to a challenging problem, this customised Komatsu PC700LC-11E0 crawler excavator, with Smart Construction 3D Machine Guidance, has proved to be a game changer at Kann where it continues to impress and make a significant impact not only on its operators but also on the ongoing success and efficiency of the business.