The Rise of Hydrodemolition in Extending Concrete Lifespans
In an interview with Keith Armishaw, Business Development Manager for Aquajet’s North American subsidiary, we explored the evolution of Hydrodemolition and its role in extending the life of concrete structures.
Back in the early 1980s, Sweden’s National Road Administration (SNRA) faced a problem that was literally cracking its bridges from within. Traditional concrete repair using jackhammers was leaving microfractures in the remaining structure. Core samples revealed that these seemingly tiny cracks had a big impact: repairs didn’t last as long, and the structural lifespan was reduced.
According to the European Water Jetting Institute, this sparked a research initiative that would redefine the industry. The goal was to find a science-based, non-destructive method for removing damaged concrete without harming the sound material beneath. The answer was Hydrodemolition – the use of high-pressure water jets to strip away deteriorated concrete while leaving the solid sections intact.
By mechanically controlling the water jet, contractors found they could achieve faster, more precise results. The method eliminated the risk of impact damage, preserved structural integrity, and offered a cleaner, safer working environment. Over time, Hydrodemolition grew from a niche idea into a global industry, now more than 35 years in the making.
Turning Up the Pressure
Modern Hydrodemolition systems are far more sophisticated than their early counterparts. A typical setup includes a robot, a high-pressure pump, and a fully automated water treatment system. Early pumps delivered around 14,000 psi, which was considered adequate at the time. Today, that’s the low end. The latest models push up to 40,000 psi, offering remarkable versatility.
Pressure range matters. For selective removal – stripping only damaged concrete – operators might choose 15,000 to 20,000 psi. For aggressive surface preparation, 30,000 to 40,000 psi can be used. This flexibility allows engineers and asset owners to tailor the process to the project’s exact needs.
Keith Armishaw explained: “Today’s enclosed pump systems not only deliver consistent performance but also improve safety and comfort on site. You can stand beside a fully enclosed high-pressure pump at full capacity and still have a normal conversation.”
These enclosed designs protect operators from noise and potential hazards such as hose bursts. They also contribute to reliability, with long-running units capable of continuous operation in tough conditions.
Smarter Machines for Tougher Jobs
When Hydrodemolition robots first appeared, they were designed mainly for flat surfaces. Operators used manual hydraulic valves to guide the water jet, and any technical fault required a mechanically skilled crew member to diagnose and repair.
Today’s machines are a different breed entirely. Advanced models come with programmable logic controllers, sensor arrays, and user-friendly operator interfaces. They can cut complex shapes – circles, triangles, rhomboids – and even change depths in a single pass. High-pressure lances now feature improved nozzles and flow dynamics, boosting productivity and surface quality.
One significant development has been the adoption of the figure-eight lance motion, combining oscillating and rotating movements. This technique delivers a constant speed over the surface, producing a rough yet uniform finish ideal for bonding new concrete. It avoids creating unwanted holes and increases repair durability compared to manual impact tools.
Versatility Beyond Bridges
While Hydrodemolition was initially deployed for bridge deck repairs, it’s now used in a wide variety of applications:
- Overhead work
- Vertical walls
- Below-grade projects
- Tunnels and dams
- Underwater structures
- Building interiors
This adaptability has made it a preferred choice for engineers tasked with extending the life of critical infrastructure.
Water Management and Environmental Stewardship
Hydrodemolition’s reliance on water makes waste management a priority. In the early days, contractors often improvised filtration systems, sometimes outsourcing wastewater treatment – an expensive and labour-intensive process.
Today, compact, fully automated water treatment units have transformed the process. These systems neutralise pH levels, remove suspended solids, and allow contractors to either discharge treated water safely or recycle it back into the equipment. The environmental benefits are twofold: reduced water usage and compliance with local regulations.
Armishaw noted: “Automated water treatment has been a game changer. It streamlines compliance, lowers operational costs, and shows clients that environmental care is built into the process.”
Why Hydrodemolition is the Gold Standard in Concrete Repair
Over more than three decades, Hydrodemolition has consistently delivered on its promise: impact-free, precise, and durable repairs. Organisations such as the International Concrete Repair Institute have contributed to the growing body of knowledge in the field, while manufacturers like Aquajet continue to refine equipment for greater productivity, safety, and environmental responsibility.
Aquajet, acquired by Brokk AB in 2016, leads the market in Hydrodemolition technology. With headquarters and manufacturing in Holsbybrunn, Sweden, and sales spanning the globe, the company is well-positioned to keep driving innovation.
The ultimate goal? For Hydrodemolition to become the default choice for concrete removal and surface preparation – specified by engineers, requested by asset owners, and executed by contractors whenever long-term performance is the priority.
Building a Future of Longer-Lasting Repairs
The journey from jackhammer microcracks to water-powered precision is a testament to the construction industry’s ability to innovate. Hydrodemolition has already proven it can extend the life of concrete structures, reduce environmental impact, and improve worker safety. With ongoing advances in automation, equipment design, and water management, it’s poised to remain at the forefront of sustainable infrastructure maintenance.
As Armishaw summed it up: “When you take impact out of the equation, you give structures a fighting chance to last for decades longer.” That’s not just good engineering – it’s good stewardship of the built environment.
