Fabio Bruno deploys ultra high reach excavator for large-scale project in Brazil

Fábio Bruno Construções’ new CAT 395 UHR at work on the Maceio/Alagoas Project in Brazil. (PHOTO: Fábio Bruno Construções)

Fábio Bruno Construções, one of Brazil’s leading demolition contractors, has introduced a 150-tonne 2023 Caterpillar 395 Ultra High Reach (UHR) excavator to its fleet.

Delivered just weeks ago, the new machine has already been deployed on a major demolition project in Maceió, Alagoas, where it is being used to dismantle numerous tall structures as part of a two-year project contract.

Features of the CAT 395 UHR: Safety and Mobility

Featuring a 49.6-metre-long (163 ft) telescopic boom, the 151-tonne machine is equipped with advanced safety systems, including a tilting cab with demolition protection, dust suppression, and a stability monitor.

Manufactured by Kocurek and sold by Power Trac, the CAT 395 UHR features a modular design that allows for easy assembly, disassembly, and transport using only three trucks without requiring a crane.

(PHOTO: Fábio Bruno Construções)

Specialist Training for High Reach Demolition in Brazil

To ensure safe and efficient operation, Fábio Bruno Construções enlisted a specialist mechanic from the UK to train its team. Three operators, three mechanics, and one engineer underwent two weeks of intensive training, covering the machine’s operation, assembly, disassembly, and maintenance.

“Since we already had a high reach excavator with a reach of 20 metres, the adaptation was not that difficult. The operators were able to adapt quickly to the new machine,” said Managing Director Fábio Bruno Pinto.

Maceió/Alagoas Project: Demolishing Over 800,000 Square Metres

Undertaken by Consórcio Fábio Bruno e Solum—a joint venture between Fábio Bruno Construções and Solum Demolidora—the Maceió/Alagoas Project encompasses the demolition of 706,000 sq m of structures up to four storeys high and 103,000 sq m of buildings with five or more storeys.

Work on the project began on 1 August 2024 and is scheduled to last 24 months, with up to 218 employees on-site during peak operations.

According to Pinto, the project comprises the “complete and integral demolition services of buildings” located in the State of Alagoas, of which Maceio is the capital city.

(PHOTO: Fábio Bruno Construções)

Addressing Equipment Transport Challenges in Maceió

The contractor’s new 150-tonne CAT 395 UHR excavator is working alongside a fleet that includes 22, 35, and 44-tonne excavators, as well as a smaller 20-metre UHR machine. However, transporting equipment posed a major logistical challenge due to the city’s lack of local rental demolition machinery.

“All the equipment had to travel nearly 2,000 km to reach the demolition site,” Pinto explained, adding that “a large mechanical team is on site for corrective and preventive maintenance.”

The CAT 395 UHR is tasked with deconstructing 21 structures over five storeys tall, including the tallest, which measures 54 metres.

Overcoming Demolition Hazards: Electrical Cables and Traffic

Pinto highlighted that demolition work on the Maceió/Alagoas Project is complicated by the presence of electrical cables near the structures.

Additionally, “some streets located within the demolition area are still being used by vehicles,” said Pinto.

“As a result, in several locations we have to carry out extremely controlled demolition, and sometimes we even work on weekends so that we can stop traffic in some more critical situations, to avoid any accidents.”

(PHOTO: Fábio Bruno Construções)

Alternatives to Explosive Demolition for High-Rise Structures

While explosive demolition is often considered the safest and most cost-effective method, Pinto explained that it is not suitable for all high-rise structures. Even when it is viable, many clients remain hesitant about carrying out implosions.

“For many services where implosion is not feasible, we now have the option of demolishing them in a very safe manner, with fewer people involved and with an excellent deadline when using UHR,” said Pinto.

“The most important thing now is to spread the word, especially in South America where this is the only UHR of its kind, to raise awareness of its capabilities.”

Risk Management and Waste Reduction on the Maceió Project

Safety is a top priority for Fábio Bruno Construções, and the Maceió/Alagoas Project has been implemented with the goal of achieving zero accidents. Workers receive training before starting their roles, and regular safety campaigns are conducted to maintain awareness.

“An Environmental Emergency Plan was also prepared with the aim of identifying and evaluating possible emergency scenarios,” said Pinto. This plan includes procedures for mitigating risks and corrective actions for emergencies.