For 30 years, KARL HUGO has been manufacturing welded mechanical tools for the maintenance and upkeep of nuclear power plants in Belgium, France, and Germany. KARL HUGO's teams put all their expertise to work for large groups by manufacturing tools and solutions that allow them to operate within the reactors.

The material dismantling of a nuclear power plant is a major technical challenge. It is supported by technological innovations aimed at improving the efficiency and safety of operations. A Belgian company specializing in nuclear maintenance has been awarded the contract to dismantle one power plant in Germany. They called on the expertise of the KARL HUGO Engineering Department to develop a saw used during the deconstruction of the reactor. “We have developed a saw system,“ explains Gerd Reiter, Senior Project Manager.

The machine was custom-designed to be installed in the plant's maintenance room, where the reactor main vessel, weighing 154 tons and 9 meters high, will be cut. “The structure of the machine is made of steel and covered with a 500 to 1000 µm layer of special paint allowing it to work underwater.“ In addition to designing the mechanical parts of the system, KARL HUGO's design office engineers also finalized the manufacturing and installation plans for the hydraulic and electrical equipment.

All elements of the machine were machined at KARL HUGO. Once the assembly phase is complete, the testing phase can begin with a provisional 7-meter test structure. Additionally, a special container has been built to test part of system underwater. “Before shipping the material to the client, we will perform a dynamic test with 110% of the maximum load, or at least 96 tons.“ Then, a static test with 125% of the maximum load will be conducted for 15 minutes to check for any deformations. “The reactor dismantling phase is expected to begin at the end of December 2024, beginning of January 2025,“ concludes the Project Manager.