Case Study

Large Cast Iron Valve Removal

The Problem

As part of a reservoir refurbishment a 45 year of large cast iron valve needed to be removed from a confined space at the bottom of a manhole ring.

Even though the bolts and nuts had been burnt off the flanges, the valve was stuck solidly in place due to corrosion. The operatives on site could not free the valve using the excavator, this was due to plastic pipe not far from the valve and it was feared aggressively trying to remove the valve would split the pipe. A petrol cut off saw could not be used in the confined space because of the danger from kickback and exhaust fumes.

Larger Cast Iron Valve Removal In Reservoir Improvement
Larger Cast Iron Valve Removal In Reservoir Improvement

The Solution

EC Hopkins suggested the Powergrit hydraulic pipe cutting saw as a safe method with the ability to plung cut in a confined space and enough depth of cut to go all way through the valve from one side.

Without the PowerGrit Saw the concrete ring would have to be dismantled and the area excavated until the site was no longer classed as a confined space, then a cut off saw could be used. It is estimated this would have taken a gang and extra 5 days to complete.

Once the flange bolts had been removed, the hydraulic ICS 890F4 PowerGrit Saw was used freehand to plunge cut through the valve creating a 6mm wide slot. This freed the valve up and it was easily lifted free of the excavation. The 2 valves that needed replacing in excavations were 40 meters apart, the first cut took 10 minutes and the second 20 minutes as it was necessary to cut the valve at a wider point. The saw would usually be mounted on the Pipe Clamp (4-12” pipe capacity), due to the shape of the valve the clamp could not be used but it is perfectly safe to use the saw freehand.

To find out more about ICS Diamond Chainsaws please call us on 0121 506 6095 or CLICK HERE to go to the ICS Diamond Chainsaw Section.


Featured Product

ICS 890F4 Hydraulic Diamond Chainsaw

ICS 890F4 diamond chainsaw is the largest saw in the range with the ability to cut upto 63cm deep in concrete, including reinforced concrete, natural stone and thick masonry walls.
The ICS 890F4 diamond chainsaw is the ideal choice for professional concrete cutters, specialist builders and the utility industry. The 890 saw has a quiet, smooth and service free hydraulic motor with a rugged body plus an easy to change drive sprocket, making it engineered to stand up to the toughest of jobs.

Available with different length guidebar and chains to give 25cm, 38cm, 50cm and even upto 63cm depth of cut using the superior Force4 diamond chains or the Crosslink diamond chains with one suitable for every application. Whether it is for modifying lift shafts, altering buildings or cutting concrete sewer culverts the ICS890 and the ICS diamond chains are the best solution for the construction and utility industry.



Give us a call on +44 121 506 6095 or drop us an email to
Alternatively you can request a callback below, fill out the form and we'll be in touch as soon as possible.