The Challenge
As part of upgrading works in Kedah, the client required the removal of 17 underwater pile caps, each measuring approximately 1.8m² and 12m tall. The works had to be carried out fully underwater, within a tight timeline, and without compromising surrounding ongoing works and commercial operations. Given the size and reinforcement of the pile caps, conventional demolition methods were not suitable.
Our Approach & Result
Diamond wire sawing was the required cutting method for this project. We worked closely with professional divers to set up and loop the wire accurately around each pile cap. The wire sawing method allowed for vibration-free, controlled cutting, even in submerged conditions. Each pile cap was sectioned into smaller, manageable pieces for safe removal. All 17 pile caps were successfully cut and segmented within 1 week, meeting the project timeline and safety requirements.
Underwater concrete cutting demands a high level of coordination, specialised equipment, and experience. For this project, Sonicon was engaged to cut and remove 17 large pile caps located entirely underwater in Kedah. Each pile cap measured 12 metres long, 3 metres wide, and 600mm thick, presenting both size and reinforcement challenges.
To execute the works safely and efficiently, we utilised diamond wire sawing, a method well-suited for heavy, reinforced concrete and extreme environments. Our team worked in close coordination with divers to position the wire accurately around each pile cap before cutting. This approach allowed us to achieve clean, precise cuts without vibration, minimising impact on surrounding structures and marine conditions.
Once cut, we divided the pile caps into smaller sections to facilitate removal. The entire scope of underwater cutting was completed within a week, demonstrating the effectiveness of wire sawing in marine applications.
This project builds on Sonicon’s proven track record in underwater concrete cutting, including our Melaka offshore project, which remains one of the largest underwater cutting works we have undertaken. With the right expertise and technology, even complex underwater demolition can be carried out safely, efficiently, and with full control.
