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Contents
Status report 3
Major project management 4
Lean construction 14
Heinzelmann and Diavik 16
Construction sites in Germany 18
Bauma 2016 20
Equipment in customer operations 22
Remediation of the Kesslergrube
landfill site 23
Construction sites in Europe 24
Bauer and Schlumberger 28
Mine rescue in China 29
Construction sites around the world 30

2 International visitors at Bauer's Bauma booth


Status report
T
he situation in the world markets, the political situation will also influence the willingness to invest in the Middle East
in many regions and numerous hot spots continue to and other already affected countries.
have an impact on our company. These circumstances It is satisfying that we were able to achieve some great suc-
have also required us to make adjustments and implement cess in these difficult times. Thanks to the large-scale project
restructuring measures. for Roche Pharma AG, our environmental division has suc-
As a result, 2015 was another difficult year. Total Group rev- cessfully launched the largest single project in the compa-
enues were EUR 1.656 million, up 6.2 percent from the pre- ny's history. Despite a shortage of orders in Malaysia and
vious year. Earnings after tax stood at EUR 29.0 million and, Hong Kong, capacity utilization is good in the Construction
like revenues, ultimately exceeded the goals we set in the segment, primarily due to a high order backlog.
annual report. Nevertheless, many positive and negative cir- In the Equipment segment, we unveiled new products at
cumstances have had such a significant impact on us that we Bauma 2016 in Munich that show considerable progress in
cannot be satisfied with this year's results. the areas of noise emission, energy efficiency and productiv-
In 2015, the Center Hill Dam project and our subsidiary in ity. We have managed to keep our sales relatively stable de-
the USA continued to be a source of problems and caused a spite the fact that global sales in construction machinery have
EUR 7.3 million loss in the Construction segment, where rev-
enues increased by 2.4 percent to EUR 742.9 million. In the Geographical breakdown of total Group revenues
Resources segment, our water and exploration drilling com- in EUR million
panies suffered greatly from the decline in oil prices and the Africa 77 (4 %)
downturn in commodity markets. In response, restructuring Germany 474 (29 %)
measures were implemented and were continued in 2016.
As a result, revenues in the Resources segment also fell by America 297 (18 %)
12.3 percent to EUR 221.6 million in 2015, accompanied by a
considerable loss.
On the other hand, we achieved great success in the Equip-
ment segment thanks to our new joint venture in deep drilling

Development of total Group revenues by segment Asia Pacific,


in EUR million (segments after deducting Other/Consolidation) EU excl. Germany Far East & Australia
162 (10 %) 348 (21 %)
Total 1.656
1,800 Middle East & Central Asia
1,600 Resources Europe (other) 71 (4 %) 227 (14 %)
218
1,400
1,200 Equipment declined by 28 percent (50 percent in China) in the past four
1,000 705 years. That is an achievement. Chinese machine manufactur-
800 ers, on the other hand, had to reduce capacity significantly.
600 Construction Nevertheless, there is still surplus capacity but we expect
international
400 551 things to normalize in the phase ahead.
200 Construction Given this general climate, 2016 was not an easy year. We
0 Germany 182 have continued to make adjustments in many areas and are
2000 01 02 03 04 05 06 07 08 09 10 11 12 13 14 2015
trying to adapt to the adversities of the environment.
There has been an important change on the BAUER AG Man-
technology with Schlumberger, a partnership that has also agement Board. On 1 October 2016, Peter Hingott, a highly
involved BAUER Deep Drilling GmbH and the Bauer Manufac- committed successor, replaced Heinz Kaltenecker, who left
turing plant in the USA. We also sold shares in a subsidiary. the company at the end of the year.
Together, these activities significantly increased earnings for I would like extend my thanks to Heinz Kaltenecker and wish
the Group. As a result, revenues in the Equipment segment him all the best for the future. I would also like to thank all
increased by 17.8 percent to EUR 753.1 million. employees for their dedication during this difficult time, and I
Once again, we had to acknowledge that the global climate would like to thank all of our customers, partners and friends
and markets as a whole are becoming more difficult in 2016. for their loyalty. I wish all of us a successful future and hope
All the political uncertainties and crises in the Ukraine, prob- that we continue our excellent teamwork.
lems with the Islamic Sate in the Middle East and North Af-
rica and the economic impact of weak markets in Russia,
China, South America and various countries in the Far East
remain virulent. Furthermore, we predict that low oil prices

3
The Schwarzkopf Tunnel: a large-scale
rail project north of Aschaffenburg

4
Large-scale
project management

C
onstruction projects don't just roll through his personal contacts. He
off the assembly line. Whereas also consults the Federal Transport In-
a new car is designed once and frastructure Plan, which lists projects
can then be sold a hundred thousand planned until 2030, one of which is for
times, in the construction industry, ev- a new section of highway with seven
ery project is a prototype. In every proj- tunnels. The question for Bauer Spe-
ect, all opportunities and risks are cen- zialtiefbau is whether the tunnels will
tered around one unique case, which be constructed by mining or excava-
must be planned and thought through tion. The "Schwarzkopf Tunnel Bypass"
in extreme detail and a long-term per- rail project was announced more than
spective. If everything is implemented a decade ago. Originally, the project
smoothly, the construction project will was not supposed to involved much
ultimately be profitable. specialist foundation engineering. "But
"Much has changed in large-scale proj- I knew the region," says Hans-Gerd
ect management over the last two Haugwitz, still proud of the project. In
decades," says Thomas Bauer, CEO of the end, Bauer was awarded a contract
BAUER AG. "We're extremely well or- for 43 million euros.
ganized now." The management team Haugwitz stays in touch with the proj-
for a large-scale project operates like ect team the whole time a large-scale
a company of its own. "In the field we project is being executed in Germany.
can work just like we do at the corpo- Collaborating with the project manager,
rate office." That includes an IT system, he represents specialist foundation en-
Internet and video conferencing for gineering for the client and assists with
all processes from calculation to cost negotiations, sometimes on the techni-
accounting. Business One is used for cal side, sometimes on the legal side.
bookkeeping and inventory accounting. Agreement between construction
When it comes to preparation – the fo- companies and clients makes work
cus of this article – all the departments easier for everyone, but, according to
involved have to cooperate with as Haugwitz, harmony is not always a
few interdepartmental communication matter of course. "Things go well if ev-
problems as possible. eryone has the same level of construc-
tion expertise." Problems arise when
How do we find large-scale projects the client is hesitant to make decisions
in the German construction market? or doesn't make them at all. "That's al-
Hans-Gerd Haugwitz, head of the Proj- ways the worst."
ects department, has an eye on the A project is far from completed after
German market and focuses on "large- Bauer has finished the job and the
scale projects that involve a significant equipment has left the construction
amount of specialist foundation en- site. During the billing process, "we of-
gineering." He researches potential ten have to fend off costs that others
projects online or learns about them try to pass on to us." Change orders can

Interdisciplinary
team work

5
be especially costly for the companies the bidders who were initially in fourth very little lead time. Parts of the proj-
executing the project. Some projects place were chosen, partly thanks to ect were also planned by Bauer's De-
are long-term and it takes years before several supporting offers and propos- sign Department (BK). Project manager
the final invoice can be submitted. als for additional savings. The client's Klaus Wecker traveled to Innsbruck for
Haugwitz cites Bauer's team continuity call for bids includes drawings, a bill weekly coordination meetings. Next,
as a positive factor: "It's a great advan- of quantities, geological surveys and the client has to review the plan.
tage for the client. The people they've preliminary remarks. Deutsche Bahn The call for bids for the Schwarzkopf
worked on the project with are still ac- has a decentralized planning manage- Tunnel was in mid-February 2013, the
cessible." Whereas on the client side, ment team and also works with exter- contract was awarded in June and the
the company is often negotiating with nal consultants. The bidders estimate construction office and workshops
different people all the time. costs based on the drawings and the were formed in September 2013. By
schedule of services and have three to October, the project was ready to be-
The Schwarzkopf Tunnel Bypass as six months to submit offers. gin. A highly experienced team was
an example of a large-scale project The offers are then publicly reviewed at appointed to support the project man-
When the company bids on a major a submission meeting. Bidders are rep- ager, including construction managers
project, the future project manager is resented by one or two engineers who
selected in advance. For the Schwarz- take notes. Alternatively, there may be
kopf Tunnel Bypass project, that was a non-public negotiation process with
Klaus Wecker, who had already man- each individual bidder. Bidders may
aged major projects for the client, be invited to negotiations up to three
Deutsche Bahn. Wecker was involved or four times. Bidders can make alter-
in the project from the outset as part native proposals so that they always
of a bidding consortium made up of have another chance at the contract.
Bauer, Kunz, Baresel, Schälerbau and They can make improvements, give dis-
Leonhard Weiss. He was involved in counts or submit the offer again. But
planning, all negotiations and the con- sometimes all the work is in vain – an-
tract award process. The Schwarzkopf other bidder gets the contract.
Tunnel project exemplifies the process- If the submission deadline is 4 pm, the
es involved in a large-scale project in envelopes are opened at 8 am the next
Germany. day and the offers are read. Each bid-
Seven companies were bidding on the ding consortium has an employee on
Schwarzkopf Tunnel project and had to the spot. The bidding consortium then Project manager Project Klaus Wecker,
go through a prequalification and quo- discusses the negotiations and ex- right, surrounded by shelves full of con-
tation process as a bidding consortium. changes information internally. struction file folders

and foremen, safety specialists, job


planners, commercial managers and
administrative assistants. A team of
more than 15 people. There were sev-
eral delays in the course of the project,
first in planning, then in execution,
partly because the rock in the Spessart
mountains was much harder than ex-
pected. But in the end everything was
completed on time.
Large projects require dedicated work-
shop facilities for the project equip-
ment. Drilling tools are welded on site,
major repairs are sent back to MT in
Schrobenhausen. A welding facility
with a crane is available in nearby Gold-
bach. The large container complex on
the construction site houses not only
As big as an office building –
office and desks, it also has several
stacked containers at the Schwarzkopf Tunnel
rooms of shelves with hundreds of job
site folders. The folders contain over
Price is not the only criteria for award- After the contract has been awarded, 10,000 individual plans in addition to
ing a contract. References from past the winner has to focus on detailed general documentation.
projects are also considered. Bidders planning of all areas, including spe- Construction supervision containers for
have to show how they envisage the cialist foundation engineering, civil thirty people are set up next door to the
construction process, and all factors engineering, tunnel construction and construction offices of the consortium.
are reflected in a point system. In the foundation engineering. The ILF office Deutsche Bahn outsourced site super-
case of the Schwarzkopf Tunnel proj- in Innsbruck was in charge of planning vision to external engineering firms
ect and Bauer's bidding consortium, the Schwarzkopf Tunnel project with such as Grontmej, Schuessler-Plan and

6
Gebauer in Munich. This site supervi- by Dr. Klaus Idda, Head of the Design vices in many different ways. For ex-
sion, according to Klaus Wecker, en- Department at Bauer, for a structural ample, they developed a software solu-
tails more than simply reviewing doc- engineering review. Do the design and tion for project phase management as
uments. All completed work is techni- the proposed methods fit together? well as the PAS project filing system,
cally monitored and inspected in detail. Are the dimensions correct? Often, the which ensures optimum management
The assessments of supervisors are Design Department has suggestions of large numbers of documents. This
also relevant for claims, that is, any for changing certain details or making system contains drawings and docu-
services provided beyond the contract. them more cost-effective. "We're ser- ments from more than 10,000 projects.

The large-scale Peribonka project in Canada

Claims are carefully examined by the vice providers," says Klaus Idda, and The documents in the archive, which
construction supervisors. The applica- we're always open to the question "Do was created twenty years ago, are very
tion is then sent to the client's legal you have an idea ...?" important. They provide clear records
department and sometimes to an ap- Execution plans are developed in the of past project management activities
praiser as well. Next, the client and the Design Department, and in rare cases and show who worked on specific jobs.
contractor negotiate the terms. During planning also takes place during the These documents can also be used to
the Schwarzkopf Tunnel project, Bauer bidding stage. The Design Department dismiss legal allegations if complaints
had about 95 claims, which were in- works primarily for the domestic mar- of improper work are raised many years
dividually negotiated and for the most ket. The "International Projects and later, and can ultimately prove that
part accepted. Services" department is responsible work was performed properly based on
for international contracts and some the information available at the time.
The Bauer Spezialtiefbau subsidiaries have their own structural The Design Department is also respon-
planning office engineers. The cost-effectiveness of sible for safe shipping of documents
During large-scale projects, proposed methods is considered during planning, and drawings.
plannings are submitted to a team led although the engineers who develop
and submit the offer are responsible for Large-scale projects in remote places
the actual pricing. Alternative plans are – a learning experience for managers
often not approved at first, that's when Work can be difficult in remote places,
knowing the regulations is important. far-away countries, lonely forests and
Usually there's a clause that allows for mountainous regions. Thomas Bauer re-
the change of plans. members his 2005 visit to the Peribon-
In the case of the Schwarzkopf Tunnel, ka construction site in Canada, where
the Design Department was extensive- sealing walls were being built for a new
ly involved. The client agreed to chang- hydro-electric power station: "We had a
es in the Nantenbach area that had lot to learn." Petra Peter, who worked
been proposed by Schrobenhausen: in the controlling and commercial de-
The originally planned bored pile wall partment at the time, witnessed many
Hans-Gerd Haugwitz and Klaus Idda, in was replaced by a nail wall. Over the details first-hand. She summarized the
charge of large-scale projects and the past few years, the Design Department problems that became apparent at the
planning office has been working on improving its ser- outset and during the project.

7
"We had a 40-million-euro contract in from SAP has now been introduced at
a country that we have never been all major construction sites. Petra Peter
to before and we needed to operate says: "We learned a lot and in the end
through a branch or subsidiary," she we had a very positive outcome."
says. And we had no bank, no tax con-
sultant. First we established a subsidi- The PSA department –
ary, then we had to apply for licenses, Martin Heinrich's team
install an accounting system, form a Construction projects in far-away coun-
controlling team, open bank accounts, tries are very different from projects in
hire a tax consultant, etc. Most impor- Germany. In remote places, engineers
tantly, we had to recruit personnel in don't have the usual administrative
the local job market. Canada was un- support with everything from tax laws
charted territory. to the VOB (German Construction Con-
The machinery and the rig operators tract procedures). The PSA department
came from all over, from the USA, from (International Projects and Services),
Germany and from the Arab world. headed by Martin Heinrich, specializes
Import and customs issues for equip- in the different international laws and
ment had to be resolved. Is equipment regulations. The department focuses
from Bauer companies considered on large-scale specialist foundation
purchased or rented? That was an im- engineering projects around the world,
portant consideration for issues such and provides acquisition and execution
as withholding tax. Also, the regula- teams in countries where Bauer Spe-
tions of the local trade unions had to zialtiefbau does not have a subsidiary.
Sources of information for large-scale
projects include the Internet and Bau-
er's worldwide network. The team is
also contacted by external custom-
ers, project managers or consultants
in need of a professional partner for
a specific task. "Many of our major When it comes to submitting the offer,
project are in the field of dam con- the best approach is to be reserved and
struction," says Martin Heinrich. Most offer only "as much as necessary, and
recently, the Bagatelle Dam projects in as little as possible." Plans are often
Mauritius and the large dams in Bhutan made public, so it's best not to reveal
were executed by Bauer Spezialtiefbau everything to competitors. At the same
branch operations. time, it's also good to keep the initial
International Projects Services – Martin
Heinrich, Dagmar Lange, Martin Pielmeier, Bauer is registered in the central pur- costs to a minimum. Still, this prelim-
left to right chasing systems of many of the world's inary technical proposal can fill up a
major construction companies – the whole binder. The plan is not detailed
be respected during the personnel re- well-known global players. "We need to any further or improved until the con-
cruitment process. After all, there were know about a planned project as soon tract is awarded.
people from twenty different countries as possible," says Martin Heinrich. That Contract management for large-scale
from all over the BAUER Group on the way, if the project looks promising, we projects starts as early as the bidding
construction site. Tax issues and social can often assist by advising on con- phase. For international construction
insurance had to be considered with struction methods or other issues. projects, the country-specific frame-
respect to their home countries. And of Bauer is approached for many large- work must be considered first. FIDIC
course language also plays a role. In bi- scale and mega projects. Nevertheless, standard contracts are a good starting
lingual Canada – French was technically the overall feasibility of a project must point. But the client can make other
the official language of the construction still be assessed on a case-by-case ba- stipulations – "That's when we have to
site in Quebec – a lot of English, and of sis. Even the preparatory work during negotiate." The language of the agree-
course German were spoken. the acquisition phase involves a certain ments is also important. Not every cus-
The teams worked weekends too. Rare risk. After all the hard work, planning tomer accepts English contracts.
days off were spent on team-building, and costing, the company still might With the help of international consul-
in the spirit of "let's all do something not be awarded the contract in the final tants, the legal aspects of the agree-
together." Over time, Petra Peter be- decision phase. ments are adjusted to different coun-
came the go-to person for everyday Many clients only issue a functional tries, many of which have their own
matters in her office and at the camp, call for proposals, meaning the bidder regulations that do not always corre-
and she gained experience in conflict must show detailed plans for project spond to the legal understanding com-
prevention. When an employee had to execution. In Martin Heinrich's experi- mon in Germany. Tim Kneipp assists
fly home, she organized their transpor- ence, most customers act fairly if parts with drafting of contracts in Australia.
tation to the airport. of the project or the entire project are He has been Bauer Spezialtiefbau's
A lot of experience for subsequent completed at a lower cost than original- contracts consultant for many years
projects was gained from the Peribon- ly agreed. In that case, the client and and assists many international subsid-
ka project. The Business One system the contractor share the financial gain. iaries from the home office.

8
ment support team at the construction
site needs a fully equipped workshop.
On the technical side, Construction
and Planning handles replacement part
lists, construction procedures, exe-
cution planning and construction site
accessories. Wear and spare parts are
also purchased. All the while, the proj-
ect manager continues to receive as-
sistance with a range of contractually
relevant technical details.
Although organizing all the technology
is essential, recruiting the best team
for the project is even more important.
Martin Heinrich and Martin Pielmeier
usually tackle this task together. Their
job is to create a core team with key
positions filled by Bauer specialists.
Besides the project manager, other
essential team members include con-
struction managers, rig operators and
foremen. The team has to be a good
match both professionally and socially.
Large-scale projects require more hu-
man resources than the departments
can provide. As a result, team mem-
bers are recruited from across the
Bagatelle Dam project in Mauritius
global Bauer network. If a project orga-
nizational chart shows that 100 to 120
Once an agreement is finally reached faces right down to the lowest levels of people are needed, then the question
with the customer, the Job Prepara- the organization are displayed. is: Which positions can we fill? What
tion team gets to work. And as soon qualifications do we have to look for?
as construction kicks off, the reporting The Job Planning team then Professional freelancers and local re-
system starts and delivers a weekly ties everything together cruits, among others, are also used
report on all processes. Technical docu- Martin Pielmeier is responsible for work because Bauer Spezialtiefbau employ-
mentation and the cost/progress report preparation and planning in the PSA de- ees are considered very expensive for
provide key information. Construction partment. The goal is to find the right remote construction sites.
procedures and quality are recorded technical solutions for the execution of In some cases, the client's own per-
in detail, mainly in the interest of the the project as early as the costing and sonnel requirements must also be
company performing the work. As a acquisition phases. As a rule, construc- taken into account. For many projects,
rule, the client, the construction super- tion begins about three months after the client requires the résumés of all
visor and the contractor are in constant the contract is awarded. All the prereq- employees along with proof of qualifi-
communication. uisites for a smooth construction pro- cations. For example, for certain posi-
Today, digital media provides even cess have to be met during this time. tions, the customer may want only a
greater transparency for the customer: Once the contract is signed, the de- single specialist with ten years of prov-
The customer can visualize and validate partments involved hold a project kick- en experience in a specific field.
the construction schedule on a screen off meeting. For this purpose, a list of The camp and trailer offices in remote
even during the bidding phase. In the equipment for the planned procedures regions are often provided by the cus-
digital BIC system, a flow chart shows is created in coordination with the MT tomer or the main contractor, but often
the entire construction process. Inter- department. The next step is to deter- these facilities require improvements.
mine where specific equipment will Supplies and provisions also have to be
be sourced for the construction site. organized. In addition, the equipment
For large projects, Bauer Spezialtiefbau support team needs a fully equipped
usually does not have all the resources workshop.
at its disposal. Machinery from our own None of these are simple tasks. That's
inventory has first priority, followed by because life consists of more than just
machinery from the rental pool of BAUER work, even on a construction site. Liv-
Maschinen GmbH. The fleet is supple- ing far from civilization in a deserted
mented with rental equipment from environment with nothing but pile walls
external suppliers. Transport to the con- and trenches for weeks on end can also
struction site is then the responsibility have an impact on a person's psyche.
Heads of Logistics and Equipment De- of the logistics department. Any import The project manager needs to be sensi-
partment – Rudolf Henning and Thomas and export issues must be considered tive and know how to be a compassion-
Pavlu, right and resolved. In addition, the equip- ate listener or come up with good ideas

9
for recreational activities. The team in is developed with MT's guidance. If Logistics also handles a wide range of
Peribonka explored the beautiful scen- a special version is required, such as other tasks in addition to the technical
ery of the surrounding region several a low headroom device for CSM, MT side of shipping. The department uses
times. In Bhutan, a group outing to the turns to the Development and Design its own customs software solution for
nearest city didn't turn out to be that and Construction (EK) department customs processing. Employees regu-
exciting, but stopping to eat at a small at BAUER Maschinen GmbH. A task larly attend professional development
restaurant was a nice change from the force is formed for the development courses to stay up-to-date on customs
daily cuisine on the construction site. of a new machine version. The equip- and foreign trade policies. Logistics
Once the construction site is ready, the ment selected by MT then goes to the also does compliance checks. The de-
project manager assumes responsibil- shipping department, i.e., Logistics, in partment keeps international sanctions
ity for all tasks, but sometimes PSA the site mobilization phase. MT is re- lists and checks every contact address.
provides support during the transitional sponsible for ensuring that nothing is To determine what a shipment will
phase. This means that in the first few missing, not a single screw, spare part cost, Logistics issues calls for bids via
weeks, one or two project managers or wearing part. Once the equipment its own digital platform, where a doz-
from PSA also work on the construc- reaches the construction site, it is set en Bauer-approved freight forwarders
tion site. But after that, everything on up by MT installers. The department's are registered. When a shipment is
the construction site is the responsibil- roughly 100 employees include 20 pro- announced, the forwarding companies
ity of the officially designated project cess engineers and technicians as well apply and bid on the order. "We then
manager. Martin Pielmeier: "We don't as 70 workshop employees. As far as select an offer, and not necessarily the
completely disappear, though. We as- possible, every custom-made machine, cheapest." Sometimes the third- or
sist until the project can proceed with- even very unusual designs such as the
out our help." And as always, the goal trench cutter for the Center Hill Dam,
is to avoid interdepartmental coordina- is built on the basis of existing equip-
tion problems. ment, says Thomas Pavlu. For every
project, however unique, machinery is
always designed from the outset so
that it can be dismantled after comple-
tion of the project and used again in
its standard configuration as soon as
possible. "The goal is simple: We nev-
er develop one-off equipment in such
cases. You always have to use capital
sensibly."

Logistics – how equipment


gets around the world
Everyone has seen those low bed
trucks carrying large construction
equipment on Germany's highways,
Not always a stack of containers: A rented
but heavy-duty rotary drilling rigs and
house serves as construction office for
the A72 project south of Leipzig (see back trench cutters are actually shipped
page of this issue) for Peter Asam (left) around the world on cargo ships. The
and Ralf Meyer. Logistics department, headed by Ru-
dolf Henning, is responsible for organiz-
Equipment for projects ing shipments to all construction sites
all over the world and every destination in the world. The
The Equipment Department (MT) is in- BAUER Spezialtiefbau GmbH Logistics
volved as early as the acquisition phase department is also responsible for the
of a large-scale project. Their job is to other business segments within the
determine which machines are required group of companies.
for the project and to ensure that equip- The team of eighty employees with
Reed-bed treatment plant in Oman
ment costs are included in the cost es- forwarding specialists, industrial sales-
timate. "Our first task is selecting the people and business administrators is a
equipment," says Thomas Pavlu, Head service provider that takes care of the fourth-place bidder gets the contract
of MT. Bauer Spezialtiefbau's strategy diverse needs of the group. Logistics if a clearer picture emerges after fur-
is to be effective with as few types has its own fleet of twenty vehicles. ther information is obtained from the
of equipment as possible. "Whenever Shipments from Schrobenhausen are bidder. This additional information is
possible, we use equipment from our transported by truck or low loader to and essential for comparing prices. Once
own inventory," says Thomas Pavlu. But from the constructions sites. Forward- Bauer selects a bidder, competing bids
with so many different projects, many ers are frequently hired, but "often we are automatically rejected.
of which have extreme requirements, also do the driving ourselves." Logistics The forwarding company typically se-
sometimes the standard features of costs are usually not that high in large- lects the appropriate ship and shipping
the equipment are not adequate. In scale projects, says Rudolf Henning, but line for an intercontinental shipment.
this case, new machine technology deadlines are extremely important. Shipping times and the ship's sched-

10
ning: "Everything has to run smoothly; had to present their company in detail
costs can reach 20,000 to 50,000 USD and submit references. All candidates
a day." Shipping by air (even complete had to provide the customer – in this
drill rigs have been shipped this way in case Oman's Ministry of Environment
the past) is only an option in extreme- – with a detailed explanation of their
ly rare cases, if requested and paid for technical solution. During this phase,
by the customer. Spare parts are also BAUER Umwelt GmbH discussed the
shipped by ocean freight. project schedule, drew up costing and
Logistics provides the relevant docu- financing plans and defined technical
ments for all shipments. Some coun- objectives. At the same time, a re-
tries require companies to be regis- cruitment campaign was launched. The
tered in order to import goods. Also, company began looking for local part-
Roman Breuer headed up the reed-bed
the entire contents of shipping contain- ners and subcontractors and planned
treatment plant project in Oman right ers almost always have to be listed in a joint venture. Staff was selected in-
from the start minute detail. ternally, especially for the long-term
phase. People were also hired from
uled stops en route are considered. Millions of plants – a large-scale outside the company.
Machinery from Germany is shipped project of a different kind Financing played a major role. "It was a
via North Sea or Mediterranean ports. Nimr Oman, the giant reed-bed treat- high-risk project," says Roman Breuer,
Shipping large equipment from the Arab ment plant for the oil industry, is a explaining BAUER Umwelt GmbH's ini-
tiative. Bauer had never pursued a proj-
ect of that scale before; there was no
precedent for it anywhere in the world.
The bidding process confirmed that as
well: Only four of the original twenty
candidates remained in the final stages
before the contract was awarded. Since
Bauer had to pre-finance the project, a
financial model had to be developed
together with banks. Ultimately, DEG
bank in Cologne (German Investment
Corporation), a subsidiary of KfW, was
chosen for the innovative project. The
bank had to submit a business plan, a
risk plan and a cost estimate.
Over two days in August and Septem-
ber 2008, several rounds of talks were
held at BAUER Umwelt GmbH to dis-
cuss the risks. Every last detail was
discussed: the contract, technology,
financing, equipment requirements,
storms, pests, the threat of locusts, etc.
There were only six months between
the signing of the contract and the start
of construction. The bid was submitted
on 27 September 2008, the contract
award was confirmed by fax on 28 No-
vember and BAUER Umwelt GmbH
officially accepted the project on 3 De-
cember. In January 2009, Bauer Nimr
Oman was formed because Bauer
had not yet established a subsidiary in
Oman. BAUER AG acquired a stake of
region to the United States is extreme- good example of how a mega large- 70 percent, two other partners held 25
ly costly. In such cases, Bauer Logistics scale project is planned in advance. Dr. and 5 percent. The ratio shifted with
finds a cargo ship independently. Things Roman Breuer was head of the project the sale of Bauer shares in 2015, and
get expensive when a ship has to make right from the acquisition phase. "It was Bauer now holds a 49 percent share,
an extra stop at a port outside of regu- a fundamentally different undertaking with 30 and 21 percent shares held by
lar routes, as was the case with recent than a traditional Bauer project in many two other stakeholders in Oman. That
shipments to Mauritius and Venezuela. ways." In this long-term project, Bauer shift, says Roman Breuer, gave Bauer
The construction department is respon- completed the construction work over better access to further potential proj-
sible for planning these shipments be- several years and will operate the plant ects in Oman.
cause loading times and waiting times for twenty years. The call for bids had Technical facilities for the project, which
at the port are expensive. Rudolf Hen- several phases. To prequalify, bidders included oil-water separators, a pipe-

11
line network, pressure transducers, Schmaus. Very often, there was an em- sented our solution at forums and
measuring instruments and a weath- ployee on site who could help. The risk they've been a big hit." The IT team ex-
er station, came from Germany and and vulnerabilities of these makeshift changes ideas with other construction
Holland. Almost everything else came solutions presented a challenge: How companies at these informal sessions,
from the region. The sealing membrane can we optimize processes? There's a which are held with 50 to 60 compa-
came from a manufacturer in the Mid- big difference between a construction nies three times a year.
dle East, and even the equipment was that has a laptop with an Internet con- Connectivity is a key issue when set-
sourced locally. A key issue was the nection and one that has access to a ting up IT systems, as illustrated by the
procurement of plants. A nursery in the Bauer IT file server. problems during the Diavik project in
area was commissioned to grow the The IT department developed a solution the Arctic Circle in Canada. Tobias Ge-
first plants. Later, plants were cultivat- with easy-to-move components and bauer installed the system on site and
ed in a dedicated facility on the large called it "data center to go." The only IT connected it to the client’s radio link.
site. A data connection to Schroben- equipment needed at the construction Now, all information from the construc-
hausen was immediately established site would be two cables, a power sup- tion site is accessible in Schrobenhau-
for Nimr. The IT system was linked to ply and internet access. The team de- sen, an important security factor.
the home IT office, and Business One veloped a cabinet on wheels, similar to Unique forms of smart digital technol-
accounting was connected to central IT the flight cases used to transport stage ogy, still in their infancy, are being de-
in Schrobenhausen right from the be- equipment. It contains computers, veloped for construction sites, says Jo-
ginning. servers, a battery for power outages, a hann Schmaus. An electronic construc-
The Nimr concept is patented and ap- firewall and a WAN (wide area network) tion documentation solution is taking
proved as a European patent in the accelerator. The carpentry department shape; large-format printed blueprints
United States and the Middle East. used Tobias Gebauer’s blueprints to will soon be a thing of the past. In the
Specialists all over the world are inter- build an enclosure, a rack system that future, it will be possible to project
ested in the unique project. Many visi- fits in the back of a station wagon. large-format drawings onto screens at
tors from the oil and gas industry have This rack solution containing IT com- meetings. A visual drawings compari-
visited the site from as far away as Ma- ponents is used on large construction son will reveal all project discrepancies:
laysia and Mexico. What was planned? How was it built?
In the construction industry of the fu-
IT system ensures autonomy ture, plans could be passed on to sub-
of construction site contractors and successor companies,
Today, many documents are still printed saving time and money.
out on paper, and the trailer complexes
on large-scale construction sites have Construction administrators –
storage spaces full of project folders. working from anywhere in
But in the digital age, Johann Schmaus, the world
head of IT in the BAUER Group, and his If you were to peek into the computer
colleagues Marco Fröhlich and Tobias of a commercial manager, you would
Gebauer, can provide any construction find every imaginable subject related to
every technical and organizational as-
pect of a project. It's all there: human
resources, equipment, logistics, cus-
toms, insurance, purchasing, banking,
issues of national currency, compensa-
tion, taxes. In large construction proj-
ects, which usually last several years,
This IT case for construction sites fits into the administrator position is usually a
any station wagon full-time job. But what about adminis-
tratorswho get sent to a new country
sites. A smaller version was also de- for the first time? They don't have much
veloped: the LTE case (LTE is a high- time for training and learning about
speed connection). The components their destination.
are housed in what looks like a pilot’s Dagmar Lange from the PSA depart-
briefcase. The "to-go versions" caught ment is using her 38 years of interna-
on quickly. As of summer 2016, 22 of tional business experience to devise a
Tobias Gebauer, Marco Fröhlich and
these small units are now in use. "It's standard package for launching com-
Johann Schmaus, left to right, bring IT to important for the engineers to have mercial operations at major construc-
construction sites confidence in our system," says Jo- tion sites. She brings extensive experi-
hann Schmaus. Marco Fröhlich adds: ence to the table. She spent more than
site with the necessary administrative "Our solution has been a success in the ten years in Africa, and has worked in
tools to ensure its independence far field. Now we’re even involved in the several countries in Asia, Europe and
from headquarters. bidding stage of major projects." North and South America. She even
"In the past, every construction office "There's nothing like it", Johann has experience with large-scale proj-
simply rigged up its own administrative Schmaus says, referring to the flight ects that have lasted for over three and
system and IT technology," says Johann case/briefcase solution. "We've pre- four years.

12
Dagmar Lange is now developing what tries. Locally recruited personnel re- levied independently of the project in-
she calls a "commercial manual " for ceive contracts that must be approved come, such as customs duties, value
large-scale projects in countries in by the human resources department added tax based on the EU model,
which Bauer does not have a subsidi- in Schrobenhausen. Employees who sales and use tax, stamp duties and all
ary. To make sure "a project gets going come from Schrobenhausen receive a types of retention taxes, which are of-
on time," the administrativeteam has to separate employment contract for the ten a type of income tax that function
be fully empowered as soon as a con- project. She deals with foreign assign- like a withholding tax. If the tax costs
tract is awarded. ment regulations and contracts, visas are underestimated in advance, any op-

Dam sealing in Bhutan

Working far from home, they can't just and flights, accommodation and food, erating income is quickly offset by the
"go and procure something on the fly." as well as how employees will receive tax burden.
When a project is launched in a for- their salary while posted abroad. In contrast with other international
eign country, their first priorities are enterprise such as IT corporations, a
to establish contact and register with Considering taxes – construction company cannot easily
authorities and learn about the local in every country in the world shift profits to tax havens through legal
tax system. The project includes oth- Applicable taxes – a significant cost and quite often aggressive tax planning
er aspects such as the form of enter- factor – must also be taken into ac- strategies. This is simply because con-
prise and the conditions for working in count as early as the bidding phase struction projects are executed in a set
a consortium, liquidity planning, and a location in a specific country. There-
review of the customer's creditworthi- fore, careful tax planning with a focus
ness. The commercial manual also con- on the origin and use of necessary
tains forms in different languages. resources is all the more important
Many detailed questions have to be during planning and execution of a con-
answered: How is the construction site struction project. The primary objective
being financed? Is there adequate in- must be to avoid double taxation of in-
surance? If there is enough cash for on- come taxes and understand the other
going expenses...? The accounting and types of taxes.
payment system has to work properly. In international projects, double tax-
In most cases, Bauer is a subcontrac- ation would always result if both the
tor, which requires a good relationship Matthias Mayer: Every country in the home country of the contractor and
with the finance department of the world wants to collect taxes. ... the home country of the project were
main contractor. to tax profits, either partially or in full.
All human resources issues need to of a project, when all costs have to In such cases, all the hard work that
be resolved before construction be- be estimated as precisely as possible, went into the project would be in vain.
gins. Petra Fohrmann's office at the according to BAUER AG tax specialist Familiarity with the tax regulations of
headquarters in Schrobenhausen is Matthias Mayer. Income taxes on profit both countries is essential. With good
responsible for handling contractual are what normally come to mind when planning during the preparation stage,
and taxation matters for all personnel we think of taxes. However, in other unpleasant surprises can be avoided
on construction sites in remote coun- countries, some taxes and duties are down the road.

13
Zero-error principle
Lean construction – a new
approach to large-scale projects
M
ajor construction projects are tion" is now well established in the con- Continuous flow of materials
fascinating. They even have struction industry. The different under- and information
a special allure for laypeople standings of lean are as varied as the This principle originally comes from as-
and often become tourist attractions. different approaches to industrial man- sembly line production. In a construc-
From the outside, it's immediately ap- ufacturing. One of the most common tion context, this means ensuring a
parent that a high degree of planning definitions is: "to add value without continuous flow of work as well as a
and coordination is required to run the waste," in other words, "to optimally continuous flow of all information, from
various concurrent projects on a con- coordinate all activities necessary for the design stage to each individual pro-
struction site. From an inside perspec- value creation and avoid superfluous cess step in the construction project.
tive, scheduling is an essential element activities." Highly complex production
of project management. However, a tasks can be conceptualized by envis- Synchronizing planning
schedule is only a snapshot of planned aging workflows as processes. and production processes
processes that are based on a num- This principle significantly improves
ber of assumptions. During large-scale overall construction output. A construc-
projects, these assumptions (or basic tion site with a clearly defined produc-
conditions) are constantly changing in tion cycle can be much more efficiently
the course of the project. There may organized. The workflows (the cycle)
be delays in the supply chain, changes are defined in terms of the production
to plans or, a very common occurrence task, e.g., pile drilling and all upstream
for specialist foundation engineering and downstream processes such as
projects, changing soil and rock condi- concrete, reinforcement, etc., are exe-
tions. Therefore, a key task of project cuted in the same cycle.
management is to respond quickly to
changing conditions and continually ad- This is consistently applied
just the schedule accordingly. to the whole construction task,
However, the more interconnected the everything else is readjusted later
individual construction activities are, Practical experience shows that a
the more complex it becomes to re- Dr. Konrad Nübel strictly deterministic management of
adjust the schedule. If you adjust one construction sites is not feasible, al-
cog, you move numerous other cogs in For example, in the construction indus- though some customers would pre-
the machine. This means that methods try, the construction of a bored pile can fer it. Instead, all processes must be
and decision-making criteria must be be broken down into individual inter- aligned with the practical requirements
employed and continually developed connected steps. High drilling rig per- on site. It is not very useful to define
so that schedules can be adjusted formance is a key factor in the overall schedules that are not feasible from a
without bringing the whole structure effectiveness of construction, but other production standpoint. From the per-
out of balance. criteria also play a role. On-time deliv- spective of the production task, sched-
Lean production or lean management is ery of the reinforcement cage and con- uling and material supply planning is
one methodology that has shown to be crete are just as important to the over- done in reverse from the perspective
extremely effective for controlling and all process as on-time production of the of the time line.
optimizing complex production tasks drilling template or the approval of the
in other industries. Generally speaking, construction permit. As always, sched- Zero mistakes
lean production is a holistic approach uling is important. The project manager Rigorous quality control of products
to controlling and improving produc- must not only ensure the effectiveness and process steps during production.
tion processes. Bauer already has a of the drilling rig, he or she must also The longer it takes to address an error,
lot of experience with this method in coordinate all the necessary pile con- the more expensive it will be to correct.
machine production. Now the project struction activities from a scheduling These principles provide a mental
management team at BAUER Spezial- and quality control standpoint. framework for better controlling and
tiefbau GmbH is applying this concept In the context of lean construction, improving processes on construction
to the construction process. They are these activities are coordinated based sites. Another aspect of lean produc-
using lean construction principles to re- on the following principles, which are tion is the aforementioned elimination
define workflows. originally lean production principles, of waste. The goal is to reduce any part
Lean production has its origins in the but can be easily applied to the con- of the activity that does not clearly add
auto industry. The term "lean construc- struction industry. value to the product. The seven wastes

14
The Diavik A21 project in Canada requires extremely detailed planning because of its extremely remote location and extreme weather
conditions. Lean construction principles were implemented and lean tools were used in this project.

of lean manufacturing can also be ap- The flow principle requires that the reinforcements can then be scheduled
plied to the construction industry: flow of production, for example during precisely according to that cycle. Deliv-
If consistently applied, these principles pile construction, must be maintained ery of wearing parts is also important.
are highly effective on the construction continuously, including all material de- However, excess inventory on the con-
site. This can be easily illustrated using liveries. This can best be ensured if the struction site is expensive. Ideally, the
the example of scheduling, which in- construction site is in a regular produc- order should not be initiated until there
cludes construction scheduling. tion cycle. Delivery of concrete and is an actual need for the item, and the
delivery time must also be taken into
Seven types of Construction operations Production planning account. This is called the "pull princi-
waste ple". Quality inspections are performed
directly during production at Bauer (ze-
Excess capacity E.g., construction rigs Aimless planning ro-error principle) using tools such as
the B project system. The seven types
Transport Unnecessary movement Unnecessary planning of waste can be used to develop mea-
of material interfaces sures for continually improving pro-
duction processes on the construction
Inventories Material and equipment Superfluous requests
site. Bauer increasingly supports data
management by using production data
Movement Unnecessary process Searching for information that is collected by various machine
steps sensors and systematically evaluated.
Lean construction will help Bauer ap-
Waiting Idle times Unsynchronized planning proach tasks in large-scale projects in an
organized way, use equipment and man-
Incorrect technology Inefficient construction Incorrect depth of planning power highly effectively, respond flexibly
procedures to requirements and provide added value
for the customer by meeting deadlines
Corrective work Due to errors in Due to errors in planning
and delivering high-quality products.
production
Dr. Konrad Nübel

15
Harald Heinzelmann
Team player for XXL projects
B
ig things often start out small. At Bauer, he is associated with a presti- equipment and personnel. Once again,
Harald Heinzelmann recalls: "I gious project of recent years: the foun- the project involves building a seal for
was at a Christmas party and dation for the future tallest building in an excavation pit in a lake in the Arc-
Peter Teschemacher asked if I could the world, the Kingdom Tower in Jed- tic Circle to enable open-pit mining of
imagine managing a big project abroad dah, Saudi Arabia. During the bidding
at some point." Heinzelmann casually process, the Arab Bauer subsidiary ur-
answered "Why not?" and three months gently needed a highly qualified project
later he was on his way to the Merowe manager, and Heinzelmann promised to
dam construction site on the Upper find one. He became increasingly famil-
Nile. That was in 2007. iar with the project, and when the ideal
In fact, Heinzelmann already had years manager failed to materialize, he decid-
of experience with large-scale projects. ed to manage the Kingdom Tower proj-
After German reunification, he was ect himself. The contract worth 26 mil-
project manager for the redesign of the lion euros was signed in October 2012.
central train station in Leipzig, the tun- The project kicked off with a team of
nels connecting the government build- 130 people, primarily from the Arab
ings along the Spree River in Berlin, and region. A team from Schrobenhau-
the excavation pit for the Marie-Elisa- sen provided support. "I had never
beth-Lueders-Haus. He was in charge worked in the Arab world before", says
of five projects for Terminal II at Munich Heinzelmann, but he quickly man-
Airport, managed the Denkendorf rail aged to build a good relationship with
tunnel trench project north of Ingolstadt the client, Bin Laden, and the Bauer
and the feeder line project for the Bren- subsidiary in Saudi Arabia. As project
ner Base Tunnel in Fritzens in Tirol. manager, he developed a good, even
friendly relationship with all parties
involved - "they respect me, they ac-
tually adore me," he says. They were
impressed by his technical expertise
and ability to inspire employees of all
levels in their work. To ensure maxi-
mum efficiency, he suggested an un-
orthodox 5-fold friction kelly for pile
drilling, which were up to 110 m deep.
It was designed and constructed at
Bauer Maschinen in a few months and
Harald Heinzelmann, born in 1961, proved extremely effective.
comes from Meinheim in Middle Fran- The foundation for the Kingdom Tower diamonds at a depth of approximately
conia, studied civil engineering at the was not only a profitable untertaking 200 meters.
Technical University of Munich, joined for Bauer, it also garnered the highest And once again, an experienced project
Bauer on 1 February 1989 and quickly praise in the Arab world, as evidenced manager was needed for this extreme-
worked his way up to construction man- by the client's own words: "We thank
ager and chief construction manager for God for giving us Bauer!" While perfect
southern Bavaria. He is now a member preparation and management are es-
of the management board of BAUER sential, "It's very important for me to
Spezialtiefbau GmbH, is responsible for complete a project and finalize it with
large-scale projects and is in charge of no loose ends," says Heinzelmann.
project manager training. With that in mind, he conducted final
"I'm a team player, I'm not a fan of negotiations in summer 2016, securing
conflict on the construction site" says further healthy profits for Bauer.
Heinzelmann, summing up his attitude. Since the spring of 2016, Harald
He is well known for his leadership tal- Heinzelmann has been managing spe-
ent: "You can't have motivated people cialist foundation engineering in the
and be successful unless you work as a Diavik A 21 project in northwest Can-
team!" He is recognized as a facilitator ada. The project has been well known
in his management role, and maintains at Bauer since 2000. It is the third proj-
good relationships with clients and con- ect of its kind after projects by BAUER
struction superintendents. Maschinen GmbH, which supplied

16
ly complicated task. After exploratory this dam using replacement bores and living conditions are very stressful and
talks with Spezialtiefbau CEO Peter a Cutter Soil Mixing method. To ensure similar to living in barracks. The sleeping
Teschemacher, AG CEO Thomas Bauer the best possible seal, curtain grouting container feels almost like a cell block.
and regional manager Sebouh Balian, work is also being performed in the un- The rooms are small, sometimes there's
once again, the top choice was Harald derlying rock and the window between only a shared shower and toilet. Life is a
Heinzelmann, whose response was: the CSM wall and the bedrock horizon cycle of food-work-sleep, with very little
"I'll do it!" He recruited Egyptian Mo- is being closed using jet grouting. variety. "People go through low periods
hammad Hussieny as his deputy proj- A wide range of equipment is being de- sometimes," says Heinzelmann.
ect manager, who was mainly in charge ployed in the first phase of Bauer's proj- The work day begins at 6 am with a
of auxiliary operations at the Kingdom ect, including two BG 30s, one BG 40, briefing on safety and the tasks of the
Tower site. three Klemm KR 806s, an MC 96 crane coming day. Up to 70 team members
meet for the briefing, conducted by the
HSE Department and a management
representative, which focuses on cur-
rent tasks, potential hazards and clean-
liness in the workplace. At 6.30 am
they head to the construction site. The
trip takes about five minutes by bus.
Cars are provided for the management
team. Once at the site, each team re-
ceives another detailed briefing. They
eat their lunch in a trailer near the job
site. At 5:30 pm they head back by bus.
There is constant daylight during the
short Arctic summer. That means the
night shift is the second day shift.
The stages of the Diavik project de-
pend on the seasons. Without special
gear, working outdoors is only possible
from April to October. In February and
March, equipment and all heavy goods
are delivered and hauled away via a
360-kilometer ice road. Employees fly
to the Diavik mine, which has a small
airfield. Bauer's work will be completed
in two phases from March to October
2016 and 2017. In winter 2016/17, grout-
ing work to seal the bedrock horizon
will be done in heated tents. The nec-
essary water for the operations is re-
Scenic view – the Diavik project moved from the lake and runs through
a flow heater.
The weather plays a big role, and
The first task at Diavik is to compact as well as mixing systems and pumps. weather forecasts often turn out to
a previously poured dike using a deep Two more BG 30s and eight HPI pumps be unreliable. Weather conditions can
vibrator on an MC 96 crane. A 25- will be used in the second phase. change quickly. Fog from thawing ice
meter-deep cut-off wall is being built in The Bauer team consists of employ- often affects visibility. In the summer
ees from Germany and subsidiaries all of 2016, there was still snow on the
over the world. The client is constantly ground in late June, and winds can be
present at the site and heavily support- very strong, even on bright sunny days.
ed by consultants. Harald Heinzelmann "I couldn't have done these projects in
is responsible for more than 150 peo- Africa, Saudi Arabia and the Arctic Cir-
ple, including assistants provided by cle without the support of my family,"
the client as well as subcontractors for says Harald Heinzelmann, who actually
surveying and laboratory work. Bauer traveled a lot for work in Germany be-
is supplying about 100 employees, fore this. He receives that crucial sup-
one third of whom are from Germany. port from his wife Claudia, daughters
They work in a four-weeks-on and two- Denise and Melanie, born in 1990 and
weeks-off cycle. The rotation schedule 1993, and his son Michael, born in 1998.
of each team member must be careful-
ly planned.
Forget about luxury accommodation – Workers have to live and sleep at the
the camp in Diavik camp during this remote project far
from all civilization. The working and

17
DIBAG Industriebau AG Munich is
building a residential and commercial
building on Lützowplatz in Berlin. The
excavation pit was constructed with
4,500 m² of MIP wall up to 15 m deep
and 1,500-linear-meter anchors, in addi-
tion to 35,000 m³ of soil excavation and
dewatering. Right

A new residential and commercial build-


ing is being built at Findorffer Tor in Bre-
men. An RG 25 was deployed to con-
struct 5,500 m² of load-bearing MIP wall
that is 500 mm thick and 21.5 m deep.
Above

A hotel and an entertainment complex/shopping center is being built on the site


of the former Schultheiss brewery in Berlin. After ten buildings were demolished
and contaminated soil was removed, the 8 m deep excavation pit was created with
11,000 m² of soft gel blanket, 8,000 m² of MIP walls, 250 anchors, 200 m uplift piles
and 3,500 m³ of shoring. Above

18
Specialist founda-
tion engineering
all over Germany
Flachstahl AG is expanding its facilities in Salzgitter.
2,200-linear-meters bored piles up to 31 m deep and 750 mm
in diameter were constructed for new foundations without
interrupting production in the building. Below

The Rotkäppchen-Mumm sparkling wine cellar is building a


new glass storage warehouse in Freyburg in Saxony-Anhalt.
1,700 m² of anchored pile wall were constructed for the proj-
ect. A BG 24H was used for 880 mm piles and a Klemm KR
806 anchor rig for 2,000-linear-meter anchors. Left

19
Bauma 2016
Bauer machines:
New developments
point to the
future
B
auma experienced "more visitors "the trade fair of superlatives. Nowhere for diaphragm wall technology, includ-
than ever before." For the Munich else in the world attracts so many in- ing an actual guide wall on the ground,
Exhibition Corporation, too, Bauma ternational visitors, who come to learn was one of the central attractions at the
is in fact the highlight of its extensive about the latest trends in the industry." Bauer booth. As at previous trade fairs,
exhibition programme. In April 2016, Sales manager, Christian Gress, adds: large-diameter rotary drilling rigs, includ-
some 580,000 visitors from 200 coun- "That international presence was also ing multi-functional PremiumLine mod-
noticeable at our booth. We had lots of els equipped with various attachments,
good conversations with prospective formed the heart of Bauer Maschinen's
customers. We sold several machines extensive exhibition programme. Bauer
during Bauma week, and the atmo- also presented a new generation of
sphere at the booth was fantastic." This ValueLine drilling rigs – a mid-range
was at least in part due to the design of platform designed for bored piles with
our visitor centre. Lots of light from both diameters up to 2.5 meters and drilling
the east and the west gave the two-sto- depths up to 70 meters.
ry building with its lobby and meeting Once again, Bauer was the only ex-
rooms a welcoming atmosphere. Galler- hibitor able to present the full range of
machines and equipment for specialist
foundation engineering, which included
drilling rigs, diaphragm wall equipment
and duty-cycle cranes from the parent
company as well as new products from
Federal Minister for Transport, Alexander subsidiaries Klemm Bohrtechnik, Prak-
Dobrint, left, with Thomas Bauer la, Hausherr, ABS Trenchless and MAT.
RTG Rammtechnik showcased its newly
tries attended the trade fair with 3,400 developed soundproofed vibrator Silent-
exhibitors from 54 countries. Thomas Vibro. Reducing noise, saving energy, im-
Bauer, Chairman of the Management proving operational safety while boosting
Board of BAUER AG, was also "extreme- productivity at the same time – these
ly pleased" after the seven-day event. In were Bauer's innovation topics at Bau-
addition to good outcome for BAUER ma 2016. Our drilling rig safety concept
Maschinen GmbH, the trade fair was The simulator is a great way to discover also received recognition. Two out of five
also a source of some interesting ob- the various functions of the machines EuroTest awards went to Bauer. Klemm
servations about the general climate: won the award for its modular system
The market is clearing out. Most nota- ies on both sides offered an expansive for drill rod manipulation. With these
bly, Chinese manufacturers had a much view over the open-air exhibition area. awards, the German Professional Asso-
smaller presence this year after show- "Bauer was pretty much the only com- ciation of the Construction Industry rec-
casing their specialist foundation engi- pany presenting innovations in specialist ognizes outstanding achievements in the
neering equipment with large exhibits foundation engineering," said Thomas field of occupational and machine safety.
three years ago. Bauer. "For example, we were the only The many visitors to the Bauer exhi-
For Dieter Stetter, Managing Director exhibitor in this field to showcase trench bition compound also included some
of BAUER Maschinen GmbH, Bauma is cutters." Our model construction site guests of honour. Federal Minister for

20
Construction, Alexander Dobrindt, took
the time during his tour of the trade fair
to take a closer look at some of Bauer's
innovations, especially control technolo-
gy systems. Ilse Aigner, Bavaria’s Depu-
ty Prime Minister and Minister for Eco-
nomic Affairs, even sat down in the cab
of a drillig rig.
Many civil and mechanical engineering
students also visited our booth. "We had
over 600 students, two or three groups
every day" said Wolfgang Harttig, who
familiarized in particular the civil engi-
neering students with our specialist
foundation engineering machines and
equipment. He was assisted by Patrick
Wenzel and Karl Krollmann, both of
whom gave guided tours for students.

Dieter Stetter introduces Ilse Aigner, Bava-


ria's Minister for Economic Affairs, to a BG

Bauma is just 70 kilometers away from


Bauer's head office in Schrobenhau-
sen. This home advantage gives Bauer
Maschinen the opportunity to host Bau-
ma attendees in a special way. Custom-
ers and representatives from around the
world are booked into hotel rooms in the
vicinity of Schrobenhausen, and buses
shuttle guests to Bauma in the morning
and back in the evening. Then guests
and hosts meet in the Old Welding
Shop. A special highlight of the week is
the Bavarian Evening of culinary delights
and live music, which gives a thousand
guests from all over the world a lively
taste of Bavarian lifestyle.

21
Germany Berlin-based Wendt Grund- China The Shanghai Foundation En-
bau GmbH used a BG 26 V to install gineering Group used a BC 40 cutter
1,200 mm diameter bored piles to a mounted on an MC 96 duty-cycle crane
depth of 14 m for the foundations of a to construct a 1,200 mm thick dia-
bridge over the A24 motorway in Glinde phragm wall to a depth of 118 m – a re-
near Hamburg. cord depth in China – for the Dzong Park
Shaft Project in Shanghai.

Norway Our customer Hallingdal from


Ål used two RM 20 pile drivers to con-
struct foundation piles with diameters
ranging from 400 to 800 mm to depths
of up to 60 m for the new Münch Muse-
Switzerland Grund- und Tiefbau AG um in Oslo. Sri Lanka San Piling (Pvt.) Ltd. de-
Solothurn used an RG 19 T pile driver to ployed four Bauer machines for the Ori-
construct a 12 meter deep double sheet ent City Project in Colombo: a BG 28,
pile wall as flood protection at a railway
construction site in Engelberg. Machines in BG 26, BG 24 and a BG 25. A total of
122 piles with diameters ranging from
600 to 1,800 mm were installed.

operation at
customers
Israel Our customer Shikun Binui de-
ployed a BC 35 cutter mounted on an
MC 96 duty-cycle crane and a BC 32 cut-
ter mounted on an MC 64 to construct
1.2 and 1.5 m thick diaphragm walls to
depths ranging from 38 to 54 m at four
Switzerland Our customer Implenia metro stations in Tel Aviv. The total wall China Our customer Guizhou Geology
Spezialtiefbau GmbH deployed a KR 806 area constructed was 56,000 m². 115 Brigade used an RB-T 100 pile driver
5 G anchor drill rig to secured a bored pile on the Anlong Geothermal Project. The
retaining wall in Munich by way of grout- first borehole to a depth of 2,500 m was
ed anchors with a diameter of 133 mm. completed in June 2016.
Noise emissions were significantly re-
duced thanks to a special sound-absorb-
ing package mounted on the drill rig.

22
„Sustainability in dialogue“
B Remediation of
AUER Resources GmbH was meter bore holes in the summer of 2016.
awarded the largest single con- The excavation pit will be divided into

the Kesslergrube
tract in the history of the BAUER three areas and covered by a spacious
Group in July 2015: the task of reme- housing to prevent emissions from es-
diating the Kesslergrube landfill site caping into the air during excavation.
in Grenzach-Wyhlen in the tri-border
region of Germany, France, and Swit-
landfill site Starting in the summer of 2017, all
material will be excavated under this
zerland. The project is worth over one covering, ensuring a high level of safe-
hundred million euros and is slated for Perimeter 1/3-NW and BAUER Umwelt ty for workers. The drilling work alone
completion in 2020. GmbH is responsible for overall opera- will involve significant efforts to en-
Fom the early 1950s to 1976, the Kes- tion of the construction site. Services sure occupational safety and emission
slergrube site, formerly a gravel pit, was include a wide range of tasks, including protection. All workers in the immedi-
used as a mixed landfill site for munic- raster sampling of the construction site, ate vicinity of the contaminated waste
ipal and construction waste as well as protection of property, maintenance of will be provided with a self-contained
industrial and chemical waste. thoroughfares, multi-stage noise pro- breathing apparatus. Using a covered
In the past, Roche also disposed of tection measures, health protection and bucket on the wheel loaders, the cut-
waste from its pharmaceutical and occupational safety measures for em- tings will be kept securely locked up un-
chemical production plants in the for- ployees and installation of airlock areas til they reach the loading hall equipped
mer gravel pit. The complete remedia- including a washer system for construc- with an extractor where they will be put
tion of the contaminated site is expect- tion staff and equipment. in special gas-tight and accident-proof
ed to take until 2020 and is required by A multistage treatment plant for ground- containers.
Roche's corporate guidelines, which water remediation was installed on a While the large-diameter boreholes are
call for the remediation to be finished purpose-built 130-meter-long pier. After being drilled, the contaminated soil will
within a generation. excavation, removal and thermal dispos- be transported in gas-tight and secure
Such a complex remediation project al of the soil, the excavated pit will be special containers by truck to Weil am
also requires intensive communication refilled. Finally, the site will be restored Rhein for transloading to rail cars. Once
with all interest groups and stakehold- for commercial and industrial use. the excavation in the airtight and sound-
ers. Roche is carrying out the remedi- BAUER Umwelt GmbH's primary task proofed housing starts in summer 2017,
ation with an integrated approach to is to excavate approximately 280,000 the material will be shipped by boat to a
communication that promotes what tons of soil. For this operation, an exca- port on the Rhine, where it will be taken
it calls "sustainability in dialogue." The vation pit consisting of a secant bored to the nearest rail terminal. One of Bau-
goal of all measures is to create cre- pile wall with piles up to 26.5 meters er's first tasks involved constructing the
ating openness and transparency in all deep will be constructed to provide a temporary pier from autumn 2015 to
phases of the remediation. Bauer is the sealed enclosure. BAUER Spezialtief- spring 2016. Sheet piles were installed
general contractor for the remediation of bau GmbH started drilling the large-dia- for the jetty on the Rhine.

23
Netherlands Three Klemm 585 rigs on a floating pontoon were used to construct
uplift piles for an underwater concrete base for Holland's deepest underground park-
ing garage in Leiden's historic town center. Right

England Construction of the excavation pit for the Principal Place Residential proj-
ect in central London took into account neighboring buildings and the city's under-
ground rail system. The pile walls and foundation were constructed using BG 30s
and BG 40s, some of which operated from scaffolding platforms. Below

Bauer Spezialtiefbau:
innovating all over
Europe

24
Austria A BG 36 was used to create slurry-supported bored piles up to 48 m deep
for the foundation of the new laboratory at the regional hospital in Salzburg. At the
same time, groundwater heat was transformed into 450 KW of cooling capacity via
9,000-linear-meter lines installed in the piles.

Turkey Problems with water leakage appeared in the 25-meter-deep excavation pit
for Üsküdar Station (construction work on the tunnel under the Bosphorus is taking
place below sea level). Bauer was contracted to install 1,250-linear-meter grouted
columns in a pile wall using a BG 15 HPI. Left

25
Hungary A BG 28 was deployed to construct 220 CFA piles
with diameters of 800 and 600 mm and approximately 1,570
displacement piles with diameters of 620 mm for the exten-
sion of the Audi factory in Györ. The project included nine pile
load tests. Below

Georgia After massive flood damage in June 2016, a 250-meter-long, 18-me-


ter-deep and 1,200-mm-thick pile wall was constructed to secure the banks of the
Vere River. The work was carried out with a BG 15 rotary drilling rig. Above

Slovakia Soil improvement was required for the construction of a new Jaguar au-
tomobile factory. Three BF 13s were used to build 75,000 Vibro stone columns from
October 2015 to March 2016. Right

26
Russia Foundation piles up to 64 m in depth were construct-
ed for the future Achmat Tower in Grozny. Several rigs used
the BV 2000 casing oscillator; deeper bore holes required poly-
mer-supported drilling. Left

Bulgaria 3,370-linear-meter foundation piles were drilled


into the bedrock for a bridge for the extension of the E 75
to Serbia. The work was carried out from April to June 2016.
Below

Romania Thirty-eight foundation and


stabilizing piles up to 17 m deep and
rock socketing were constructed un-
der challenging conditions for a bridge
on the Moroieni-Pucheni line using a
BG 9. Above

27
Bauer and Schlumberger
Partners in deep drilling technology

S
ometimes people find each other sical measurements for the oil industry. needs to be developed still further,"
in roundabout ways. Bauer and the Both companies, Schlumberger and summarizes Wolfgang Pünnel. Whilst
oil and gas company Schlumberg- Bauer, see great opportunities in the engineering design, i.e., the central
er have entered into a strategic partner- joint venture. Schlumberger’s man- development unit, will remain in Schro-
ship in deep drilling equipment, which agers were particularly impressed by benhausen, final assembly and sales
Bauer Maschinen has been developing the high degree of automation in Bau- will primarily be based in Conroe, Texas,
since 2007. In December 2015, BAUER er’s machines and equipment, which where Bauer has provided a 45-hect-
Maschinen GmbH finalized negotia- matched Schlumberger's vision for are site with assembly facilities and a
tions for a joint venture with Schlum- future drilling rigs. In partnership with paint shop for the joint venture. There is
berger, the world's leading supplier of Schlumberger, Bauer reorganized the also a 40,000 square meter drilling site
technology, integrated project manage- deep drilling technology division, which available for final assembly and testing
ment and information solutions for the will in future be operating under the down to a depth of up to 500 m.
oil and gas industry. name NeoRig. By joining forces with Bauer, Schlum-
Schlumberger acquired a 49 percent Wolfgang Pünnel, born in 1960, rep- berger has found a partner who "ticks
share in BAUER Deep Drilling GmbH resents Bauer as Managing Director of immediately” as Pünnel puts it, a part-
with its registered office in Schroben- NeoRig in the joint venture. As a young ner who takes the same path to devel-
hausen, Germany, and BAUER Manu- engineer, Pünnel joined Weatherford, op technology and business together
facturing LLC with its registered office an international supplier to the oil and and also to shoulder responsibility.
in Conroe, USA. In the joint venture, gas industry based in Houston. During World market leader Schlumberger has
large drilling rigs are being developed his time there, the company grew from teamed up with the world market leader
and built for Schlumberger and third par- 1,000 to 56,000 employees. Later, Pün- in drilling technology and now, with the
ties for drilling in the oil and gas sector. nel worked for the company in Asia and innovative Bauer mechanical engineer-
Two drilling rigs were delivered to Europe, was head of marketing and ing, wants to push ahead with every-
Schlumberger in 2016. Bauer and strategy in North Africa and finally left thing "in-house" from design as well as
Schlumberger first came into contact Weatherford to join Aker Solutions in production and ultimately the product to
when Bauer was manufacturing a deep Norway. In 2013, he joined Bauer to the actual operational deployment.
drilling rig for petroleum specialist speed up the development of the deep Pünnel sees good opportunities for
Saxxon, which during this phase was drilling division. establishing Bauer's expertise in the
acquired by Schlumberger. The compa- In future, NeoRig will produce the cen- oil industry. Two deep drilling rigs have
ny Schlumberger is originally from Al- tral unit of a drilling rig complete with been built for Schlumberger during a
sace and has a very impressive history spare parts and control components, difficult time for the market. After all,
as a family-owned enterprise. The com- the power tong, and the frequently during the current oil price crisis 60
pany was founded in 1926 by the broth- automated drill rod magazine. "What percent of drilling rigs have been shut
ers Conrad and Marcel Schlumberger Bauer has worked on in recent years down. An increasing number of new
and started out conducting geophy- is extremely valuable. That know-how rigs is expected in the coming years.

28
Mining accident in China
Trapped miners rescued
with Bauer equipment
A
t the end of January 2016, four min-
ers were rescued through a verti-
cal emergency shaft after a mining
accident in the Shandong Province of
Eastern China. The accident occurred
on December 25, 2015, when a gypsum
mine collapsed, trapping 29 miners.
Eleven were rescued immediately, one
was confirmed dead, thirteen were re-
ported missing. Four miners found shel-
ter in a tunnel and sent signs of life to
the surface. Two boreholes were drilled
in the first few days to send food and
clothing down to the miners.
After that they just had to hold out.
First, the necessary rescue equipment
had to be transported to the mine over
a distance of about 500 kilometers. The
most important piece of equipment
was a PRAKLA RB-T 90 deep drilling
rig designed and constructed by BAUER
Maschinen GmbH specifically for de-
ployment in such mine accidents in Chi-
na. A total of six of these rigs were sup- is brittle material. At first, the hole could the disaster. He noticed the difficulties
plied at the time. The rig is designed for not be stabilized and, in the end, casing in communication between German
rapid mobilization. It can be deployed had to be used to support the borehole. and Chinese managers, and said that it
at short notice without the need for a About a hundred people were involved took some time before "agreement was
low bed truck. The four-axle rig requires in the rescue, including mining special- reached with the commander of the Chi-
only a traction vehicle. The systems are ists, police and firefighters, and about nese team and everyone started work-
essentially kept in standby mode, and twenty Bauer employees. Drilling fore- ing in concert."
when the mobilization request was men Peter Eicher, Rudi Wolf and Luka The weather, often extremely cold,
received, the drilling rig was ready for Seslak, representing the combined spe- was hard on everyone. It was a once-
immediate use after a whole year on cialist know-how of Bauer Maschinen, in-a-lifetime stressful situation, espe-
standby. Prakla and Foralith, traveled from Ger- cially for drilling foremen Peter Eicher
Two additional Bauer machines were many to the site of the mine accident. and Rudi Wolf. After all, peoples' lives
used for drilling the rescue shaft, a BG Andreas Hafner, Richard Wang and Jack were at stake. It was so stressful that
26 and a BG 38, which drilled pilot holes Liu from the Chinese Bauer team aug- workers kept words to a bare mini-
before the RB-T 90 deep drilling rig mented the crew. mum between shifts (teams rotated
could drill down to a depth of over 200 The rescuers were under extreme between day and night shifts). At night
meters. The rescue mission was compli- pressure, says Andreas Hafner, who they slept at a hotel which was 25
cated by the difficult geology. Gypsum arrived at the mine four weeks after minutes away by car. There was also
a primitive camp at the site so they
could lie down for a rest.
For the Chinese, the rescue mission
gradually became a matter of prestige
due to being in permanent media spot-
light. A rescue capsule had been read-
ied for the final rescue operation, but it
was not used in the end. Television cam-
eras greeted the miners as they were
winched up in their rescue harnesses.
Sunday newspapers reported the res-
cue operation on their front pages.

29
Lebanon A 260-meter secant pile wall was constructed and anchored in multiple UAE In Dubai, four piles with a
layers for a residential and commercial building in Beirut with three underground diameter of 1,000 mm and 33.5 m
levels. Foundation piles up to 50 m deep were also constructed for this specialist depth and 19 piles with a diameter
foundation engineering project. Two drilling and three anchor rigs were used simul- of 1,500 mm and 54 m depth were
taneously. Below drilled for the construction of a
210-meter-high ferris wheel with a
Saudi Arabia The Four Seasons, a hotel and residential complex, is being built in 1,400-person capacity and 48 gon-
Jeddah. Bauer Spezialtiefbau built the pit and foundation with anchored pile walls, dolas. The BG 40 had to be hoisted
foundation piles, soil excavation and ground water control. Several drilling rigs and more than 60 meters in the air
an anchor rig were used. Bottom between the steel tube legs of the
structure.

Specialist foundation engineering


projects on all continents

30
Qatar Loads from local traffic, neighboring buildings and the ocean
shoreline had to be taken into account during construction of the
360,000-square-meter and up to 25-meter-deep excavation pit for the
Lauzail Plaza project in Doha. Bauer built the diaphragm walls. Above

UAE A new tower called the New Headquarters Building is being built
in Dubai. In the first half of 2016, several BG 28s and anchor drilling
rigs were used to build a secant pile wall, which was tied back with
anchors. Left

31
Ghana Two round shafts with a diameter of 9.5 m were constructed with secant
piles up to 20 m deep to create an access shaft for the tunnel boring machine for
the Independent Power Plant in Tema. Drills had to penetrate rock with strengths up
to 105 MPa. Below

Angola A 7,000-square-meter grab-excavated diaphragm wall with 7,400 linear


meters of ground anchors for a six-story parking garage was built for the Mutu Ya
Kevela project in Luanda. The project took more than a year to execute because of
the preparatory work required for drilling. Above

Indonesia After constructing 244 foundation piles (1,200 mm and 880 mm thick)
for the Semanngi Interchange Revitalization project, an extensive range of tests
was conducted, including eleven vertical load tests, two horizontal tests and integ-
rity testing on all piles. Above

32
Malaysia The Commercial Building in
Kuala Lumpur will be 118 stories high.
The foundation consists of 535 piles of
different diameters and 94 diaphragm
wall elements on two building sites.
Left

Philippines The Marcos Highway is


being built in the city of Rizal. Two BG

14s were used to construct 147 founda-


tion piles with a diameter of 1,000 mm
from May to June 2016.

Bhutan The Kingdom is building hydropower plants in the Hi-


malayas. Bauer provided underground sealing for dam walls
on several projects. Most recently, three BG 40s were used
to construct 190 bored piles that are 2 meters in diameter as
foundation piles for the dam body. Above

Thailand Two large rotary drill rigs and two grab units were
deployed to construct 335 bored piles of different diameters
as well as ten foundation elements and 5,620 m² of diaphragm
wall for the foundation and excavation pit of the Sinha Com-
plex in Bangkok. Left

33
Canada Additional access roads are being built for the main bridge over the St.
Lawrence River in Montreal. Bauer Spezialtiefbau drilled 324 piles, 23 m long, of
different diameters, for the foundation. The permanently cased piles had to be drilled
from pontoons. Right

USA Two piers will form the foundation of this bridge over a drinking water res-
ervoir in New Jersey. For this, two large bored piles were drilled in the Wanaque
Reservoir for each pier. A BG 40 was used to sink the casings up to 48 m into the
ground, which contained boulders in some places, with approximately 6 meters of
rock socketing. Below

Dominican Republic 22,000 linear meters of foundation project also required underground sealing to keep out sea wa-
piles of various diameters were drilled to depths of up 33 m ter. For this purpose, 40,000 square meters of diaphragm wall
for the large foundation of the Punta Catalina power plant. The were grab-excavated. Above

34
Imprint
Published by: BAUER AG
86522 Schrobenhausen, Germany
Phone: +49 8252 97-0, Fax: 97-1359
E-Mail: public.relations@bauer.de
November 2016 – BAUER REVIEW
Published once a year
Responsible for content and
editing: Prof. Thomas Bauer, Franz
J. Mayer, R. Wallner, V. Soier

Editorial design:
www.winfried-moser.de

Pre-press:
BAUER AG, Media Design

Photos: F. J. Mayer, T. Bauer, R.


Costa Rica Soil improvement for the Wallner, V. Kaspar, BAUER AG/
construction of a new container ter- K. Rysavy, P. Teschemacher, euro-
minal has been underway since April luftbild.de/Robert Grahn, Presse-
2016. The project requires 170,000 lin- foto Roche, P. Scharf, G. Stephen-
son, C. Abi Daher, A. Szulovszky,
ear meters of stone ballast columns,
O. Nairz, M. Stoykov, C. Radulescu,
380,000 m² of surface compaction and F. Jelenek, L. Vision, F. Lüder, A.
305,000 m³ of soil improvement using Döhring, S. Penzenstadler and
the DSM method. Above other employees of the BAUER
Group, Bauer archive

Panama Bauer Spezialtiefbau has been Rear cover: View of the A 72 con-
contracted to construct 560 bored piles struction site south of Leipzig
with a diameter of 2,250 mm for Line 2 Printing: Kastner AG, Wolnzach
of the Metro in Panama City. The project
is expected to take two years to com- www.bauer.de
plete. Left

35

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