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The customer magazine of
ThyssenKrupp GfT Bautechnik
02|10
Bautechnik
Page 04 GERMANY
NEW THYSSENKRUPP
QUARTER NOW OPEN FOR
BUSINESS
IMPRESSIVE GROUP HEADQUARTERS
FOR A NEW AGE
ThyssenKrupp GfT Bautechnik GmbH
ThyssenKrupp Allee 1, 45143 Essen, Germany
www.tkgftbautechnik.com
PAGE 18 WORLDWIDE
Down Under
THE LONG-ESTABLISHED BANUT 655
IN AUSTRALIA
PAGE 30 IN BRIEF
BAUMA 2010: GOOD OUTLOOK
FOR CONSTRUCTION PLANT SECTOR

02 Editorial CONTENTS 03
DEAR
READERS,
WELCOME TO THE LATEST EDITION OF “DIE BAUTECHNIK”.
THIS ISSUE CONTAINS REPORTS ON PROJECTS THAT COULD NOT BE MORE DIFFERENT. WE BEGIN RIGHT ON
OUR OWN DOORSTEP WITH OUR LEAD STORY “NEW THYSSENKRUPP QUARTER NOW OPEN FOR BUSINESS”,
A DESIGN THAT PROUDLY HERALDS THE START OF A NEW AGE IN TERMS OF ARCHITECTURAL AND ENTREPRE-
NEURIAL SPIRIT. AND THE ARTICLE “DOWN UNDER” TAKES US TO THE OTHER SIDE OF THE GLOBE, WHERE
POWERFUL IMAGES SHOW HOW WE HUMANS DEVELOP NEW LAND.
Within a few months, the long-serving Banut 655
covered some 11 000 km in Australia in order to open
up previously undeveloped regions.
Contrasting with this, our building site “on historical
ground” at Berlin’s Charité Hospital can already look
back on a chequered history. During the 300 years of
its existence, this hospital has witnessed demolition,
destruction and rebuilding on many occasions.
Two contrasting modes of transport, which complement
each other, however, are waterways and railways.
ThyssenKrupp GfT Bautechnik offers individual concepts
for both of these “worlds”. How significance is being
restored to the Oder–Spree Canal is the subject of our
article entitled “New investors for old industrial sites”.
The article “Sophisticated system solutions for
Deutsche Bahn” provides an insight into optimisation
measures that are not only interesting for railway
traffic.
bauma 2010 provided a stark contrast to the mood of
recent years. The economic downturn has bottomed
out and, like Phoenix rising from the ashes, the construction
plant sector is in business again. And by the
way, our new trade fair stand was the highlight on the
open-air site!
These and many more features of our work are described
on the following pages. We hope you enjoy reading
this interest-packed edition of “die bautechnik”.
Should you have any questions or comments or require
further information, please do not hesitate to contact
us at any time.
CONTENTS
GERMANY 04
deutschland
WORLDWIDE
IN BRIEF
Weltweit
PLANT NEWS
Kurz Notiert
10
04 12
09 14
12
16
13
18
14
22
16
25
19
22 29
23 30
32
24
33
26
34
28
35
00
35 36
NEW THYSSENKRUPP QUARTER NOW OPEN FOR BUSINESS
Impressive group headquarters for a new age
ON HISTORICAL GROUND
Berlin’s Charité Hospital: space for research and teaching
DUISPORT – CONTINUING THE EXPANSION PROGRAMME
The world’s largest inland port prepares for growing demand
NEW INVESTORS FOR OLD INDUSTRIAL SITES
Refurbishment of Kersdorf Lock to meet new demands
MORE TRAINS ACROSS THE RHINE
Additional bridge over the Rhine in Basel
DOWN UNDER: THE BANUT 655
11 000 km across Australia in five months
NEW CONTAINER TERMINAL FOR ODESSA
Efficiency achieves record figures on the Black Sea
SOPHISTICATED SYSTEM SOLUTIONS FOR DEUTSCHE BAHN
Permanent way improvements through stabilisation
ONLINE USED PLANT LOT
Finding the right machine quickly and simply
VERY PROMISING OUTLOOK AT BAUMA
ThyssenKrupp’s new trade fair stand gives visitors that “technology fever”
NEW LOOK FOR THYSSENKRUPP
Revamping the corporate design
SERVING RENEWABLE ENERGY
MÜLLER clamping unit
DELMAG RHV 40 ROTARY DRILLING RIG
For the really big piles
LEADER-GUIDED MRZV-VV VIBRATOR WITH COMBINATION CLAMPING UNIT
Compelling market launch
MÜLLER SOUND-INSULATED VIBRATION TECHNOLOGY IN USE
Less noise for people and the environment
preview
38
BUILDING SITE AT BERLIN’S “RED TOWN HALL”
Work continues on Berlin’s U5 underground line
Godehard Drees
Christian Walter
Rolf F. Oberhaus
Impressum
CREDITS
PUBLISHED BY ThyssenKrupp GfT Bautechnik GmbH, ThyssenKrupp Allee 1, 45143 Essen, www.tkgftbautechnik.com
CONTRIBUTORS TO THIS ISSUE Mathias Himmel, Dipl.-Ing. Frank Tapken, Bettina Briese, Dipl.-Ing. Vladislav Kasakovski, Andrea
Schnadt, Eva Amend, Dipl.-Ing. Michael E. Bezzo, Doris Becker-Spohr
EDITOR Nicole Becker, Marketing Manager, nicole.becker@thyssenkrupp.com
ThyssenKrupp GfT Bautechnik
CONCEPT & DESIGN Freudenhaus Werbeagentur GmbH & Co. KG, www.freudenhaus.tv
PLEASE SEND YOUR FEEDBACK TO nicole.becker@thyssenkrupp.com
“DIE BAUTECHNIK” is issued in German and English. Reprinting is only permitted with the publisher’s consent.
This also applies to inclusion in electronic databases and copying onto CD-ROM.

04 GERMANY LEAD STORY
GERMANY 05
NEW THYSSENKRUPP
QUARTER NOW OPEN
FOR BUSINESS
The workplace for more than 2000 ThyssenKrupp employees. Architecture for
a new age. An exceptional event for the company. Three years of construction
work came to fruition when the new group headquarters for ThyssenKrupp AG
was officially inaugurated.
The new corporate headquarters of ThyssenKrupp AG – the
ThyssenKrupp Quarter – was inaugurated on 17 June 2010.
Present at the ceremony were former Prime Minister of North
Rhine-Westphalia, Dr. Jürgen Rüttgers, Essen’s mayor, Reinhold
Pass, the Chairman of the Board of Trustees of the Alfried
Krupp von Bohlen und Halbach Foundation, Prof. Dr. h.c.
mult. Berthold Beitz, and the Chairman of the Supervisory
Board of ThyssenKrupp AG, Dr. Gerhard Cromme, and numerous
public figures. The consolidation of its administrative
offices at the traditional locations of Essen and Duisburg
marks the start of a new epoch for the Group. The Quarter in
Essen – combining administrative offices previously spread
over
various sites – will become the heart of the whole Group.
Dr. Ekkehard Schulz, Executive Board Chairman of Thyssen-
Krupp AG, says: “The Quarter stands for the dawning of a
new era. It stands for internationality and modernity, for
openness and cooperation, for innovation and sustainability.
The ThyssenKrupp Quarter is thus the architectural embodiment
of our corporate culture.”
The decision to build the new headquarters in Essen, and
thus consolidate administration in Essen and Duisburg, was
made in 2006. The ambitious aim behind the new headquarters
was set out in the guidelines for the architectural competition:
“The ThyssenKrupp Quarter is to become a symbol for
the forward-looking, sustainable development of the Group.”
Realisation of the winning bid by JSWD Architekten and Chaix
& Morel et associés, who form the consortium “Architekten
ThyssenKrupp Quartier”, began with the symbolic groundbreaking
on 12 June 2007. The laying of the foundation
stone took place on 5 September 2008, and the topping-out
ceremony was held on 17 July 2009.
The modern architecture, split over several buildings, stands
for dialogue and the sharing of knowledge among the more
than 2000 employees who will have their new workplace
here. The aim of creating an architectural appearance that
was as transparent and homogenous as possible was met
in full. More than 300 firms have worked on the project, and
in the final stages more than 1600 specialists in the various
trades were at work on the site every day. The ThyssenKrupp
Academy and two further administrative buildings will follow
in a second development phase. Their construction is
currently on hold. However, construction of the child daycare
centre will begin immediately. This centre underlines
ThyssenKrupp’s efforts to allow employees to combine
family and career. The company also attaches importance
to fostering the all-round development of pre-school children
and awakening their curiosity for science and technology.
One of the highlights of the ThyssenKrupp Quarter is the
cube-shaped centrepiece Q1. Its height of 50 m and its
distinctive, expressive shape make it a real eye-catcher for
visitors. Some 500 employees moved into their offices in
July 2010. Building Q2, the Forum, houses several conference
rooms seating up to 1000 people, a staff restaurant,
guest restaurant and a “Room of Tranquility”. The Q2 Forum
is a place for meetings and project work – a true hub of communication.
The ThyssenKrupp Quarter is complemented by
buildings Q5 and Q7. They form an architectural ensemble
with Q1 and the Q2 Forum, offering space for another 220
and 300 employees respectively.
The modern, transparent architecture of the headquarters with its great
expanses of glass on all sides allows a fascinating insight into the
internal workings and at the same time symbolises the transparent
structure of the group.

06 GERMANY LEAD STORY
GERMANY 07
The external facilities are just as impressive as the architecture of the
buildings. Some 700 trees, numerous landscaped areas and a pond
200 m long by 30 m wide substantially improve the microclimate of
the whole site. They are integral ingredients in the concept of a modern
working environment.
Demands for the sustainable use of raw material resources were met
in the design and construction of the buildings and the grounds. The
heat/cold in the ground will be used for geothermal heating and cooling,
while heat will be recovered from the waste air from the offices.
A newly developed sunshade system consisting of some 400 000
centrally controlled slats will ensure pleasant indoor temperatures.
The rainwater falling on the roofs of the ThyssenKrupp Quarter will
be drained into the lake in the neighbouring Krupp Park. From there
it will be fed into the River Emscher, where it will help to improve
water quality.
THYSSENKRUPP QUARTER
SETS NEW STANDARDS
Sustainable treatment of environment and natural resources
“The ThyssenKrupp Quarter is to become a symbol for the forwardlooking,
sustainable development of the Group.” This ambitious aim,
set out by ThyssenKrupp in the guidelines for the architectural competition,
has now been successfully realised after a construction period
of around three years. This is reflected in an efficient energy supply
concept, the predominant use of materials available or produced
locally, and an energy-efficient heating and cooling system for the
buildings, to name just a few examples.
This project set the direction for an urban development programme with
significance beyond the region. Sustainable development must meet
ecological, economical and social objectives – ecological in the sense
of protecting health and the environment, economical with regard to the
sparing use of resources, and social in terms of fair, integrative and
pleasant living conditions.
The geothermal system not only heats and cools the buildings, it
can also be used to store surplus heat or cold in the ground.
Responsibility for the environment
Before construction work started, the entire site of the Quarter was
examined for possible legacies from almost 200 years of industrial
history such as obstructions or contamination. With the assistance of
experts, minor contamination was professionally disposed of off-site.
The landscaping of the site is exemplary. More than 700 trees will be
planted – involving 15 species from five continents. Throughout the
Quarter, rainwater on the roofs of the buildings will be collected and
fed to the lake in Krupp Park via a drainage system separate from the
effluent drains. For this innovative rainwater separation system in the
ThyssenKrupp Quarter, the Emschergenossenschaft water management
association has presented ThyssenKrupp with its “Watermark”
award. The “Watermark” from Emschergenossenschaft symbolises
an intact natural water cycle and is awarded to projects making sustainable
use of rainwater.
Eco-friendly construction materials
In the construction of the ThyssenKrupp Quarter, only indigenous,
fast-growing wood species were used whose production conditions
are known. In the interiors too, e.g. wooden flooring, only eco-certified
wood was used. The materials for the external areas were selected
consciously on the basis of sustainability. In the majority of cases,
materials produced locally or nationally from renewable sources were
used.
Lighting power consumption optimised
To limit power requirements, the ThyssenKrupp Quarter will use a
fully automated system with daylight-dependent brightness control
and presence detection. That means light will only be provided where
and to the extent to which it is really required. Lifts are fitted with LED
lights, which in comparison with conventional fluorescent tubes use
up to 90% less energy. And on the escalators as well, low-level LED
strips and LED underglow lighting ensure the necessary level of
brightness.
Award for sustainable building
The ThyssenKrupp Quarter sets new standards for minimised consumption
of energy and resources, the increased use of renewable
resources, minimal ecological impact and the creation of modern
working environments. At the EXPO REAL 2009 international real
estate show, the German Sustainable Building Council (DGNB) awarded
the new building a Pre-certificate in Gold for the newly created
German Certification for Sustainable Buildings.
Technology:
ThyssenKrupp products
in new headquarters
The most conspicuous proof of the group’s materials technology competence
is found in the sunshades on building Q1: 400 000 stainless
steel slats control the amount of incoming light. Stainless steel grade
4404 has been used, a highly corrosion-resistant alloy containing chromium,
nickel and molybdenum and supplied by ThyssenKrupp Nirosta.
Shaped by ThyssenKrupp Umformtechnik, these slats are key elements
in a sunshading system that so far is unique. But the real highlight is
that the system aligns itself automatically according to the altitude of
the sun, in doing so excludes direct sunlight and at the same time redirects
the incident light into the interior so that the offices are properly
illuminated. To do this, the slats, each about 7 cm long, are fixed to
vertical central shafts. These shafts can rotate and therefore align the
stainless steel slats according to the altitude of the sun. Data concerning
the respective seasonal trajectory of the sun are stored in the
system’s control and additional information about the current weather
situation is gathered by the system from a weather station on the roof
of Q1. On cloudy days all the slats are rotated such that the sunshade
remains open.
More than 10 000 m² of steel flats with an innovative special coating
were produced for the headquarters by ThyssenKrupp Steel Europe.
The coating, sold under the trade name of PLADUR ZM Premium, has
a high-quality appearance due to its multi-coat paint finish in a shade
known as “pearl metallic gold Q1”.
Thanks to this special pigment, the coloured tinge of the surfaces
changes with the light or viewing angle. The coating was applied using
the so-called coil coating method in which paint is applied to a flat ribbon
of sheet steel in a continuous process in special plants. The principal
technical innovation is that the surface of the sheet steel is protected
by a zinc-magnesium alloy before the paint is applied. This alloy
provides a level of corrosion resistance that is almost double that of
conventional hot-dip galvanising.
The fully automatic system for controlling the brightness in the
individual rooms closes the slats in the windows of the buildings
when the sunlight is too intense.
Dr. Ekkehard Schulz gives us an insight into the background: “The
decision to relocate the Group’s head offices to Duisburg and Essen
was and still is a sign of our firm commitment to Germany, North
Rhine-Westphalia, and the Ruhr. For even as a globally active technology
group, we remain a company of the Ruhr. This tradition is
important to us, it shapes who we are and what we do – throughout
the world.”
Office buildings as power plants
The ThyssenKrupp Quarter will use the heat and cold stored in the
ground for geothermal heating and cooling. To do this, ground couplings
were installed at depths of up to 100 m in the roughly 1000 m²
“geothermal field”. ThyssenKrupp GfT Bautechnik supplied the plant
necessary for drilling the boreholes – a HBR 205 GT drilling rig. A total
of 30 boreholes 100 m deep will in the future extract heat from deep in
the ground for efficient space heating and hot-water supplies.
Technology: ThyssenKrupp products in new headquarters
Almost 50% of the materials used in the construction of the new
headquarters were supplied by ThyssenKrupp itself. In addition, there
are 20 high-tech lifts, three escalators and further passenger conveyors
that were produced within the ThyssenKrupp Group.

08 GERMANY LEAD STORY
GERMANY 09
A change in level of more than 10 m had to
be overcome for the new multi-storey car
park. ThyssenKrupp GfT Bautechnik supplied
the sheet piling for this.
ThyssenKrupp Steel Europe supplied more than 17 000 m² of
HOESCH Additive Floor ® for the six-storey car park with spaces
for more than 800 vehicles. This lightweight floor is a composite
system of profiled steel sheets and concrete. It is about 40% lighter
than solid concrete slabs with a comparable load-carrying capacity.
HOESCH Additive Floor ® has therefore been extremely successful
in the marketplace.
ThyssenKrupp GfT Bautechnik was also involved in this project,
supplying a retaining wall of anchored LARSSEN steel sheet pile
sections to secure a max. 10.30 m change in level. Staff in our
own engineering offices provided structural calculations, driving
plans and detailed constructional documentation to complement
the design services of consulting engineers API. Steel walings,
made from two 400 m channels with waling bolts and waling bolt
plates, were installed from a scaffold mounted on the main sheet
pile wall. The exposed parts of the waling bolts and waling bolt
plates were given an anti-corrosion coating prior to installation.
This waling provides a connection for the round steel tie rods and
also aligns the wall to make sure that in the final condition both the
engineering and the architecture are flawless. The capping on the
top of the sheet pile wall in the form of a coated steel beam also
helps to create a harmonious overall appearance.
Facts & figures
Size of ThyssenKrupp headquarters site
17 ha
Site facts
more than 300 contractors involved
more than 1600 workers on the site
450 000 m³ of earth moved
excavations up to 12 m deep
50 000 m³ of foundations uncovered
approx. 3000 m of site fencing
17 cranes (13 of which simultaneously)
several hundred site vehicles every day
Materials, buildings
400 000 sunshading slats made from
ThyssenKrupp stainless steel
320 000 m of wiring (excluding IT)
approx. 9000 m of water pipes
23 000 t of steel
90 000 m³ of concrete
approx. 16 000 m² of glazing
approx. 30 000 m² of carpeting
approx. 10 000 m² of parquet flooring
Materials, external works
75 000 m² of landscaped areas
235 x 30 m pond, water 0.15 m deep
“Allee der Welten” alongside pond:
68 trees from 5 continents
(15 different species)
Technologies that spare resources are vital concepts
in the design of the lifts and escalators supplied by
ThyssenKrupp Elevator. For example, the six lift installations
in Q1 are fitted with regenerative drives: excess
energy generated when braking the lift cars is converted
into electrical energy and fed back into the electric
circuits. Two of the six lifts in Q1 are TWINs, which
means there are two cars, one above the other, travelling
independently of each other in one shaft. With this
system, lift users reach their destinations much
faster and the lift shafts require one-third less space. •
The new multi-storey car park for the
headquarters has six levels. There is room
for more than 800 vehicles on the lightweight
steel-concrete composite floors.

10 GERMANY
GERMANY 11
ON
HISTORICAL
GROUND
The Charité in Berlin is one of the largest university hospitals in Europe.
Originally founded by King Friedrich I as a “plague-house”, these days the
campus with its associated clinics, centres and institutes employs about 14 500
staff. The Charité celebrated its 300th anniversary in 2010. On a site rich in
tradition, between the historical children’s clinic and the Max Planck Institute
for Infection Biology, a building is being erected to house the preclinical
departments for research and teaching.
Facts & figures
Client
BSV Spezialtiefbau GmbH, Hennickendorf
Scope of supply
268 t LARSSEN 602, 8.00–12.00 m long
10–15 t LARSSEN 602, 5.00–6.00 m long
22 corner piles, 8.00–12.00 m long
Plant
TM 10/12.5 leader mounted on an SR 20
TM 11/14 leader mounted on an SR 25 (“Heidi”)
Contact
Mathias Himmel, Berlin Branch
Tel: +49 (0)3375 9217-24
E-mail: mathias.himmel@thyssenkrupp.com
The site is located between the well-used buildings
of the Charité University Hospital and the elevated
tracks of the capital’s light rail system. Work in the
hospital is continuing as normal during the construction
work. The ceremony of turning the first
sod was carried out by Berlin’s mayor, Klaus
Wowereit.
BATEG Ingenieurbau GmbH was appointed as the
contractor and our customer BSV Spezialtiefbau
GmbH from Hennickendorf won the contract for
supporting the excavations and installing the bored
piles.
Our storage depots in Mittenwalde and Seelze
provided 268 t of LARSSEN 602 piles in lengths
from 8.00 to 12.00 m. Another 10 to 15 t of L 602
in lengths from 5.00 to 6.00 m have yet to be
delivered for the inner areas. In addition to forming
the corners and changes of direction, we supplied
22 corner piles in lengths from 8.00 to
12.00 m, both for welding and as junction piles
which permit the most diverse angular solutions
without welding. All sheet pile interlocks are
sealed by the customer with SIRO 88 or WADIT.
ThyssenKrupp GfT Bautechnik GmbH provided the
bitumen boiler and sealing compound required as
part of its all-in-one solution. It is estimated that
the excavation must remain open for four months,
although a part of the sheet pile wall will be integrated
into the final structure which means that
approx. 103 t of L 602 piles will remain buried in
the ground.
Installation is being carried out with the customer’s
TM 10/12.5 leader mounted on an SR 20
and also a TM 11/14 leader mounted on an SR 25
(“Heidi”) hired from our Magdeburg Branch. Predrilling
with a continuous auger to loosen the
ground was unavoidable because of the difficult
subsoil conditions. Old foundations and piles were
encountered during the pre-drilling work which
were overcome using the customer’s own rotary
drilling units and the installation of cased replacement
Ø 620/580 mm boreholes along the driving
axis. It was therefore possible to install the sheet
pile wall to support the sides of the excavation.
Walings and stiffeners made from beam sections
will be installed to stabilise the excavation after
completing the driving work. We receive the
detailed specification based on measurements
taken on site, which is only possible once the
excavation work has started. We subsequently
supply an optimally priced solution based on the
use of minimal resources. •
Despite difficult subsoil conditions, the piles were installed
without serious problems using the TM 10/12.5 mounted
on an SR 20 and the hired “Heidi” TM 11/14 leader
mounted on an SR 2

12 GERMANY
GERMANY 13
Facts & figures
Client
Duisburger Hafen AG
Contractor
Kniepper Entsorgungs- und Baustoffe GmbH,
Dinslaken
Steel hydraulic engineering
Hülskens Wasserbau GmbH & Co. KG, Wesel
Grouted anchors
Stump Spezialtiefbau, Langenfeld Branch
Detailed engineering design
Ing. Büro MMS, Wuppertal
Prof. Dr. Ing. J. Steinhoff
ThyssenKrupp Gft Bautechnik
Checking engineers
Ing. Büro MVG, Mönchengladbach
Prof. Dr. Ing. W. von Grabe
Contact
Dipl.-Ing. Frank Tapken,
Essen Branch
Tel: +49 (0)208 435864-0
E-mail: frank.tapken@thyssenkrupp.com
DUISPORT – CONTINUING
THE EXPANSION PROGRAMME
Sheet pile wall materials
• approx. 820 t LARSSEN 606n
19/12.5;L 607n; L 603 in grades
S 355 / S 430 GP, up to 16.50 m long
• 6 pcs. LV 606n in lengths up to
22.0 m, each with 8 side bollards
(300 kN)
Anchor materials
• 16 pcs. ASF 4 inch grouted anchors
up to 26.00 m long
• 69 ASF 3¾ inch “dead man” anchors
up to 22.00 m long
ASF equipment
• 260 m of twin-channel 400 walings,
anchor plates, bolts, pile bypasses,
10 ladders, 88 recessed/side bollards
(300 kN), 260 m of edge protectors,
anchor plate walings
Driving plant
MÜLLER MS-32 HFV vibrator with
MÜLLER MS-A 660V diesel-hydraulic
power unitMS-A 660V
DUISBURG, THE WORLD’S LARGEST INLAND PORT,
HAS BECOME A BRAND: DUISPORT. SITUATED AT
THE CONFLUENCE OF THE RHINE AND THE RUHR, IN
THE HEART OF EUROPE’S GREATEST ECONOMIC
ZONE WITH MORE THAN 30 MILLION CONSUMERS,
DUISBURG IS THE MOST IMPORTANT TRADING AND
TRANSPORT HUB IN THE RHINE-RUHR REGION –
AND BEYOND AS WELL. TRUE TO THE MOTTO
“STAGNATION = REGRESSION”, THE PORT AND
QUAY FACILITIES ARE BEING CONTINUALLY
MODERNISED AND EXPANDED.
The new south quay in the parallel basin is the first step in expansion
work intended to provide modern facilities between the parallel basin
and the outer basin. Further building phases in Duisburg port are
planned for the future in order to meet the growing demand for
logistics locations in the port.
This phase involves constructing a new quay approx. 260 m long in
the form of a partially sloped bank construction with a single row of
anchors tying back the sheet pile wall, mooring dolphins incorporated
into the wall structure and an approx. 7.5 m high embankment
behind. The anchorage consists of 22 m long horizontal ties, a “dead
man” design, plus 26 m long grouted anchors with a load-carrying
capacity of up to 1366 kN.
U-section piles were specified as preferred in the tender because it has
been shown that the geometry of U-section piles best meets the needs
of driving. This is because they deform only minimally during driving
and so their system width remains constant. Furthermore, it is easier
to introduce recessed bollards, ladders and anchor plates at a later
date because such built-in items can be fabricated as standard items
and therefore costly on-site measurements for these items are
unnecessary.
A functional specification formed the basis of the tender issued by
Duisburger Hafen AG. Structural calculations, driving plans and
detailed drawings were prepared for the entire project jointly by
engineering consultants MMS and our engineering department.
The technical work was checked by Prof. Dr.-Ing. W. von Grabe
from engineering consultants MVG in Wegberg.
After awarding the contract, work on site began in January 2010.
Vibratory driving was used for the new quay wall – in the shape of
a MÜLLER MS-32 HF V vibrator. The fabrication of accurate driving
guides enabled the LARSSEN wall, consisting of L 606n 19/12.5
and L 607n double bearing piles, to be built so accurately that the
theoretical wall length of 260 m could be maintained.
ThyssenKrupp GfT Bautechnik is a leading player in port and
specialist civil engineering. Our integrated product range comprising
sheet pile sections, pile driving plant, anchors and engineering
services has therefore enabled us to accomplish a complex and
challenging engineering project successfully in close cooperation
with the customer.
Horizontal ties and grouted anchors
form the anchorage for the new
260 m long quay wall.

14 GERMANY
Germany 15
NEW INVESTORS
FOR OLD
INDUSTRIAL SITES
In the light of new settlement successes
brought about by major investments that
are creating hundreds of new jobs, the upgrading
of the Spree–Oder Waterway is becoming
more and more important. “We have
been fighting for these improvements for a
long time. It is therefore very pleasing for the
whole region that refurbishment and expansion
work at Kersdorf Lock has now begun.”
Those are the words of Brandenburg’s
Minister of Transport Jörg Vogelsänger
(SPD), who together with the district administrator
and the mayor in the presence of
members of the federal state parliament,
representatives from the Federal Water &
Shipping Administration, the contractor and
the public gave the signal to start work on
expanding this important and environmentally
friendly form of transport on 26 April
2010. And as appropriate to this project this
was not carried out with an official turning of
the first sod with a spade, but with the first
driving operation. After the VIPs had pressed
the button to start the work, the specialist
crew from Bickhardt Bau AG vibrated the first
sheet pile section, weighing about 3.5 t, into
its vertical position in the ground.
The north chamber of the lock, built in 1904, is
currently being extended from 57 to 115 m with
sheet piling. Some 1900 t of sheet piles, 500 t of
reinforcing steel, 1400 m³ of underwater concrete
and 3000 bonded anchors will be required in the
course of this project. “This lock will be lengthened
to suit the needs of modern shipping,” explains
Thomas Menzel, President of the East Division of
the Federal Water & Shipping Administration. In the
course of this major refurbishment, the crumbling
walls to the lock chambers must also be demolished
and replaced with concrete ones. The lock
gates and their mechanisms will be replaced, and
the control and communications systems brought
up to today’s standards. The upstream basin will be
upgraded to suit the longer lock and will be given a
waiting and coupling point for commercial shipping
plus a separate waiting area for pleasure craft.
All shipping will pass through the south chamber
while the work is in progress - probably a period of
about two years. Once completed, it will be possible
for modern cargo vessels to pass through the lock
without having to be decoupled first and recoupled
afterwards. That will save time and will turn the
Oder–Spree Canal into an attractive mode of transport
for industry once again. Kersdorf Lock is the
westernmost lock for the summit canal of the
Spree–Oder Waterway.
The start of expansion work at Kersdorf
Lock: the first vibratory driving operation
for the first sheet pile section, weighing
about 3.5 t.
Facts & figures
Client/developer
Waterways Building Department, Berlin
Contractor consortium
Bickhardt Bau AG, Kirchheim
Schäfer Bauten GmbH, Ibbenbüren
Materials
approx. 1900 t HOESCH steel sheet pile walls
and steel sheet piles/dolphins, walings, round
steel tie rods, bollards and equipment for steel
hydraulic engineering
Vibratory and driving plant
MÜLLER MS-20 HFV with MÜLLER MS-A 420 V
power pack
MS-32 HFV with MS-A 675 V power pack
MENCK SB 270 fast-action driving hammer
Contact
Dipl.-Ing. Michael E. Bezzo,
Frankfurt am Main Branch
Tel: +49 (0)6028 97911-10
E-mail: michael.e.bezzo@thyssenkrupp.com
Design
The older, south chamber consists of
gravity chamber walls on a continuous
base, the north chamber of gravity
chamber walls and a chamber base
spanning between these in the form of an
“inverted vault”, in each case made of
concrete. Both head bays are fitted with
gates above a sill. The south chamber
has a lift gate in the tail bay, the north
chamber a mitre gate.
Design und Funktion in idealer Verbindung:
die straßenseitige Außengestaltung
KERSDORF LOCK WAS BUILT IN 1891 AND ITS DIMENSIONS NO
LONGER CONFORM TO MODERN REQUIREMENTS. PROVIDING THE
LOCATIONS ALONG THE SPREE–ODER WATERWAY WITH A PERMANENT
CONNECTION TO THE TRANS-EUROPEAN WATERWAYS NETWORK
REQUIRES ALL THE LOCKS ON THE ODER–SPREE CANAL TO BE
REFURBISHED SO THAT IN FUTURE THEY CAN ALSO ACCOMMODATE
MODERN MOTORISED CARGO VESSELS UP TO 115 M LONG.
Originally, the lock was operated by
means of side ponds located between
the chambers, but this method of
operation was abandoned for economic
reasons many decades ago. Filling and
emptying are carried out by a siphon
system.

16 Worldwide
worldwide 17
MORE TRAINS
ACROSS THE RHINE
Facts & figures
Client
SBB (Swiss Federal Railways)
Drilling contractor
Rheinbrücke Consortium
Contractor
for the sheet piling works in the river: OHF Hafen &
Flussbau GmbH
Site management
CSD Ingenieur & Geologen AG, CH-4410, Liestal
Total cost of works
approx. CHF 20 million
Cost of works, hydraulic engineering
approx. CHF 3 million
Materials
for river piers: approx. 600 t LARSSEN 25 in grade S 355 as
single and double piles up to 15.85 m long
Plant
MÜLLER MS-32 HFV with MÜLLER MS-A 560 V power pack
MÜLLER MS-48 HFV with MÜLLER MS-A 1000 V power pack
low-pressure pump type HG 40/7 L
Used plant from ThyssenKrupp GfT Bautechnik
MENCK hammer type MHF 3-7
Project duration
approx. 3 years
construction of sheet pile wall:
4 months per cofferdam
Contact
Bettina Briese, Stuttgart Branch
Tel: +49 (0)7156 4307-22
E-mail: bettina.briese@thyssenkrupp.com
FOR SWISS FEDERAL RAILWAYS (SBB), THE BASEL REGION
IS ONE OF THE MOST IMPORTANT JUNCTIONS FOR
CONNECTIONS TO NORTHERN EUROPE. THE HEART OF THE
BASEL LINK IS A RAILWAY BRIDGE THAT CONNECTS
BADISCHER STATION ON THE EAST BANK OF THE RHINE
WITH BASEL ST. JAKOB STATION AND THE SBB NETWORK
ON THE OTHER SIDE. ALL NORTH–SOUTH FREIGHT AND
PASSENGER TRAFFIC PASSES OVER THIS BRIDGE.
A SECOND RAILWAY BRIDGE IS NOW BEING BUILT TO COPE
WITH THIS GROWING VOLUME OF TRAFFIC.
The new bridge is situated about 15 m upstream of the existing
bridge. Two of the four piers are built directly off the river bed itself.
As the piers of the existing bridge have been severely undermined by
the flow conditions of the last decades, the cofferdams for the new
piers in the river continue around the old piers as well. This guarantees
that the repair works for the damaged areas of the piers can also be
carried out within these sheet pile cofferdams. It is not only the very
low headroom that is a problem during the installation of the sheet
piles, but also the constantly changing flow velocities in the river plus
the difficult geology.
The geological survey revealed partly eroded and compact Cyrene
marl as well as the typical sediments of Rhine gravel. “According to
the client’s brief, we are to vibrate the piles into the subsoil but use
impact driving to drive them to their final depth of 10 m,” says OHF’s
site manager. But the difficult geology forced a change to the planned
method of installing the sheet piles. Low-pressure jetting combined
with high-frequency vibration was used and after a last-minute
changeover the sheet pile sections were able to be driven to the full
depth required by the structural analysis.
The low headroom also proved to be a problem. About one-third of the
sheet pile sections had to be spliced, five times in some cases, and
fitted with jetting pipes because of the limited space beneath the existing
bridge. Jetting essentially involves directing a fluid (usually water)
into the ground around the base of the section being driven at a controlled
pressure and/or constant flow rate. The jetting pipes are fixed
to the sheet pile walls and connected to the pumps via hoses. Jetting
accelerates the installation procedure because the jet of water loosens
the soil during driving and reduces the skin friction. In addition, it
reduces vibrations in the ground and hence damage to surrounding
buildings.
The OHF site manager sums up: “All in all, we were able to conclude
the construction of the problematic sheet pile cofferdams without any
further problems.” •
Heavy plant preparing cofferdams for the
construction of a second railway bridge in
Basel about 15 m from the existing bridge.
The LARSSEN pile sections were able to be installed
with the MENCK hydraulic hammer type MHF 3-7
despite the low headroom.

18 worldwide
worldwide 19
DOWN UNDER:
THE BANUT 655
AUSTRAL CONSTRUCTION HAS BOUGHT A BANUT 655, THE FIRST
IN AUSTRALIA, FROM THYSSENKRUPP STEELCOM. BETWEEN
OCTOBER 2009 AND FEBRUARY 2010, THIS MACHINE, WHICH CAN
LOOK BACK ON A LONG HISTORY, COVERED ALMOST 11 000 KM
ON THE AUSTRALIAN CONTINENT. SO THE BANUT 655 WITH ITS
HYDRAULIC FREE-FALL HAMMER IS WORKING “DOWN UNDER” IN
THE TRUEST SENSE OF THE WORD.
Banut 655 technical data
• Travel on leader: 15 000 mm
• Max. pile length: 20 000 mm
Leader mast displacement
• Above ground: +5500 mm
• Below ground: -1000 mm
Leader mast inclination
• Forwards/backwards: max. 18/45°
• Sideways: max. 18°
• Pile weight: max. 8500 (optional: 12 000 kg)
Weights and lengths depend on reach and
leader mast inclination
• Torque absorption: 18 000 daNm
Line pull
• Pile winch: max. 85 kN (optional: 120 kN)
• Hammer winch: max. 120 kN
Rope speed
• Pile winch: 50 m/min
• Hammer winch: 50 m/min
• Weight of driving plant without attachment:
67 t
The precursor of Austral Construction was founded back in 1979 and
concentrated primarily on smaller jobs in the construction and specialist
civil engineering sectors as a subcontractor. The firm has been trading
under the name of Austral Construction Pty. Ltd. since 1996. The company’s
experience and growth has enabled it to shake off the subcontractor
image and it is now operating throughout Australia as a specialist for
mining and marine projects.
Following commissioning of the Banut 655 in October 2009 in Dandenong,
the headquarters of Austral Construction, its first deployment was
at Cape Preston, some 4500 km away in Western Australia. This project
involves building a 30 km long road between a mine and the port. The
road is part of the AU$ 5.2 billion “Sino Iron” project of Citic Pacific
Mining. Once it is finished, the new mine and its infrastructure will be
one of the largest and most modern iron ore facilities in the world.
The road runs through mudflats and has to cross a tidal inlet. Austral
Construction presented the client with a bridge proposal as an alternative
to the planned tunnel crossing. Environmental protection requirements
and the tight timetable led to the scheme proposed by Austral Construction
being adopted.
The new road between mine and port crosses mudflats,
desert and a tidal inlet in the course of its 30 km length.

20 worldwide
BRIDGE INSTEAD
OF TUNNEL
This project is aimed at developing the gas field in
the Greater Gorgon Area approx. 130 km off the
Australian coast. Gorgon is one of the largest gas
projects worldwide and the largest in the history of
Australia. Besides exploiting the gas field, the project
also includes the building of a gas liquefaction
plant on Barrow Island and the necessary infrastructure
such as pipelines. The Gorgon project
requires the port and a further area covering
approx. 4.5 ha as a quarantine area for materials
and equipment destined for the Barrow Island
project. Barrow Island is a class A natural park and
this status means that extremely stringent environmental
protection stipulations apply. By securing a
service base and using the port facilities of AMC,
Chevron is able to transport considerable quantities
of materials and equipment by sea and hence
reduce the amount of road transport.
worldwide 21
The timetable was very tight because the road is
the only route for transporting heavy materials and
equipment between the port and the mine. The
bridge is 120 m long and 28 m wide and was built
in less than five months. A total of 159 piles (610 x
16 mm, grade G350) were installed, most of them
with a driving frame. However, a mobile machine on
caterpillar tracks was necessary for the piles at the
northern abutment.
The Banut 655 together with the SuperRAM 8000XL
hydraulic free-fall hammer installed a total of 32
tubular steel piles with a diameter of 610 mm in
just over four days. The 20 m long piles can carry
a load of more than 6200 kN.
The Banut 655 was used here to install sheet pile
walls. Austral carried out the driving work with a
vibrator and used the SuperRAM 8000XL free-fall
hammer fitted with a special helmet for driving to
the final depth. In total, approx. 1200 t of sheet pile
sections were installed in two months. In addition,
six piles with diameters of 762 and 914 mm and
lengths between 18 and 20.5 m were installed as
anchor bollards. Dense sand strata on top of
so-called Tamala limestone make up the geology
of this site, typical for the coastline around Perth.
The driving works were completed a month earlier
than planned, which means that the entire project
is now ahead of schedule.
The Banut 655 completed its tour of Australia in
Melbourne, where it was involved in the Victorian
desalination plant. •
The geology of this site consists of an approx. 4 m
deep loam stratum on top of limestone. Beneath
that there are strata of dacite and andesite (both
types of volcanic rock). It was in the andesite stratum,
with a strength of up to 100 MPa, that driving
came to stop.
Once its work on this site was completed, the Banut
655 travelled a further 1500 km to the Australian
Marine Complex (AMC) in Perth in order to install
sheet pile walls and steel piles for a new dockside
facility. This is a roll-on/roll-off installation for
Chevron’s AU$42 billion “Gorgon LNG” project.
In order to keep up with the tight timetable,
159 piles were installed in the first five months.
Fitted with a hydraulic free-fall hammer, the Banut 655
was able to complete the driving works one month
earlier than planned.

22 worldwide
WORLDWIDE 23
After increasing the size of the container
terminal by 19.3 ha, the port will in future be
able to function as a transhipment port for
larger container ships.
NEW CONTAINER TERMINAL
FOR ODESSA
Odessa, a city with one million inhabitants, is the most important Ukrainian
port on the Black Sea. The Black Sea has become more significant for global
container traffic in recent years and has seen a rapid rise in the number
of containers handled. Every year, new record handling figures are achieved
at the Odessa Container Terminal (OTC ).
Despite the confines of the site, the terminal operates with an efficiency equal to
that of modern facilities. Over the next three years the Ukrainian Ministry of
Transport is planning to set up a new container terminal with an initial capacity of
0.6 million TEU. The project at the strategically important port of Odessa is crucial
for this region. This is the most important port in the Ukraine for ocean-going
vessels and the reason why this area was settled in the first place.
According to the ministry, the new terminal, covering an area of approx. 19.3 ha,
will be integrated with the existing terminal as soon as it is finished.
At the moment, the ground level is being lowered and the excavation work for
the quay is being carried out. The next phase will see the construction of the
650 m long quay with a water depth of 14.5 m so that the terminal will in future
have optimum conditions for handling container ships with a capacity of
6000–9000 TEU. “That will solve the problem of congestion in the basin of the
container terminal,” according to a ministry spokesman. Able to handle the
largest container ships entering the Black Sea, the terminal capacity will be
increased to an annual capacity of 850 000 TEU. Afterwards, the terminal will be
expanded further to match demand. In the end, the terminal will be able to handle
more than 1.2 million TEU annually.

24 WORLDWIDE
IN BRIEF 25
EXPANSION WILL OVERCOME
CONGESTION IN THE PORT BASIN
Facts & figures
14 500 t PEINER double bearing piles “sol. 25”
Length of double bearing piles
max. L = 45.6 m, one piece, no splices
93% of total tonnage is 45.6 m long
steel grade S 430 GP
Bearing piles are welded together in the works
to form double bearing piles because owing to
their length, the bearing piles cannot be moved
across the normal cooling bank.
Contact
Dipl.-Ing. Vladislav Kasakovski, East Export
Tel: +49 (0)201 844562703
E-mail: vladislav.kasakovski@thyssenkrupp.com
Deutsche Bahn’s CEO, Dr. Rüdiger Grube, welcomes
delegates to the Management Academy.
Dipl.-Ing. Godehard Drees, CEO of ThyssenKrupp GFT
Bautechnik, presents the advantages of new system
solutions.
45.6 m long bearing piles weighing 38 t are rolled by
PEINER Träger GmbH in a single length!
The Ukrainian Ministry of Transport sought advice from ThyssenKrupp GfT Bautechnik.
This is why we are supplying 14 500 t of steel sheet pile walls for this
project. One critical reason why we were able to secure this contract in the light of
stiff competition was that PEINER Träger GmbH was the only plant in the position
of being able to roll the 45.6 m long bearing piles required in one piece. The next
challenges were the fabrication services required by the client, i.e. the production
of double bearing piles, including welding, plus the transport by rail to the nearest
port (Brake). A total of 362 double bearing piles are required for this project, 95%
of which are double bearing piles each 45.6 m long and weighing 38 t! The close
cooperation between all those involved and the early clarification of the transport
route have meant that the first 50 bearing piles have already been dispatched.
The total value of the project already confirmed at cabinet level in the Ukraine is
approx. EUR 0.5 billion. •
Photo: Deutsche Bahn AG/Ralf Kranert
SOPHISTICATED SYSTEM
SOLUTIONS FOR
DEUTSCHE BAHN
It was on 15 July 2010 that the Board of Deutsche Bahn AG
invited managers to the Management Academy in Potsdam
for a presentation of ThyssenKrupp AG’s product portfolio.
This TechShow was a chance for ThyssenKrupp GfT Bautechnik
to demonstrate its sophisticated system solutions for Deutsche
Bahn AG.

26 IN BRIEF
IN BRIEF 27
STABILISATION
MEASURES WITH
INJECTION PILES
Settlement in the wedge-shaped
transition zone can be kept in check
by means of injection piles.
TITAN injection pile
Applications for
Deutsche Bahn:
• Foundation elements for DB
overhead line masts
• Reinforcing elements for
retaining walls/piers
• Noise barriers
• Tunnel nailing
• Embankment stabilisation
• Slope stabilisation
The stabilisation with TITAN 30/11 injection piles
counteracts the differential deformations in the problem
zones at transitions.
In addition to talking about the use of injection piles on
Deutsche Bahn AG projects for improving the permanent way
and reducing settlement of railway embankments, Dipl.-Ing.
Godehard Drees also explained the advantages of bridge
abutments in the form of sheet pile walls with knife-edge
bearing.
TITAN 30/11 injection piles can be used to improve the
permanent way and reduce the settlement of railway
embankments. Underbridges represent a new application
for injection piles. The transitions between earthworks and
underbridge structures are always problem zones because
of the different stiffnesses and deformations. Bodies of soil
are always much more willing to deform than the relatively
rigid bridge or tunnel structures. That results in differential
settlement which leads to inconsistencies in the railway
track. Such undesirable settlement becomes more and more
critical for train operations as the running speeds increase.
More repairs and maintenance are necessary.
One way of substantially reducing this settlement at the soilstructure
interface without impairing rail traffic is to stabilise
the subsoil with injection piles. This method has been carried
out in Spain with great success and has proved itself as a
technique for improving the permanent way. Depending on the
size of the embankment, between 15 and 20 injection piles
are installed in the wedge-shaped transition zone in 2–4
layers, some 2–3 m apart. The injection piles can considerably
reduce the tamping processes necessary in the track.
Summary: Trains can travel faster and the costs of repairs and
maintenance are lower. An innovative, simple method for
improving the permanent way and allowing trains to run faster.
How TITAN injection piles work
Steel tendons in individual lengths of max. 3 m are screwed
together and drilled into the ground to the required depth
with the help of a flushing fluid, which stabilises the hole.
Pressure grouting begins once the design depth has been
reached. The drill rotates without drilling deeper and the
pressure grouting begins. During the pressure grouting, the
flushing fluid, which supports the sides of the hole, is replaced
by the stiff grout suspension (w/c ratio ~ 0.8 at 5–20 bar).
After it has cured, the body of injected grout together with the
soil reaches a final strength corresponding to concrete grade
B 25 at least.

28 IN BRIEF IN BRIEF 29
Clear advantages for sheet pile walls
Dependability
Large, modern, user-friendly leader-mounted
driving plant and a small, well-established
driving team ensure good reliability.
Environmental compatibility
Steel is environmentally compatible because
it contains no contaminants and can be safely
used in water and in any soil.
Speed
Up to 500 m² of sheet pile wall can be
installed in a day; or vice versa – sheet pile
walls can be quickly removed without leaving
anything behind.
Economy
Just a few operations, minimal space requirements,
no additional excavation supports
required. Savings of up to 30% are possible.
Reinforcement arrangement for vertical and
horizontal loads using the example of LARSSEN 606.
Sheet pile walls can be adapted to suit the geometry of the route. A concrete
capping beam is cast on top of the sheet pile wall at the abutment. Static and
dynamic vertical loads can therefore be easily transferred to the sheet pile
sections without the need for any welded fixtures.
Bridge abutments in the form of sheet pile walls with
knife-edge bearing – approved by the German Institute
of Building Technology (DIBt).
The knife-edge bearing allows static and dynamic vertical
loads to be transferred directly, i.e. without any intermediate
structure, from the reinforced concrete abutment to the sheet
pile wall.
When using sheet pile sections as loadbearing elements in
bridge abutments, it is important to consider the aspects of
transferring the vertical and horizontal forces into the sheet
pile wall and transferring the vertical loads to the subsoil.
Transferring the vertical and horizontal forces from the superstructure
to the sheet pile wall is achieved with the help of
HOESCH knife-edge bearings. Additional load-distributing
welded assemblies, e.g. cleats, brackets, welded bars, etc.,
are unnecessary with this approach. The use of sheet pile
walls for bridge abutments has many advantages. Besides a
saving in construction time of 6–8 weeks, and hence also
shorter interruptions to railway operations and shorter diversion
measures, the installation of the sheet pile wall can be
carried out without delay, at the same time as constructing
the formwork and placing the reinforcement.
This form of construction virtually rules out undermining of the
bridge abutment because the sheet pile wall is driven to a
sufficient depth (loadbearing stratum). •
Hochwasserschutzanlage und
Deicherhöhung höhung bei Gallin A NEW SERVICE THAT WE WISH TO OFFER TO
OUR CUSTOMERS VIA OUR NEW INTERNET PAGES
IS OUR RANGE OF USED PLANT AND PLANT FOR
HIRE.
ThyssenKrupp GfT Bautechnik together with its branches
and partners throughout the world has at its
disposal a broad range of new and used construction
plant suitable for our main lines of work, i.e. port and
specialist civil engineering, plus other plant such as
cranes, excavators, pontoons, etc. All this machinery
can now be called up online by clicking on “Used
equipment market”. Potential customers will find
general information on the individual items of plant
available from the following areas:
• Excavator-mounted vibrators and drilling rigs
• Crane-supported vibrators with power packs
• Leaders for pile-driving and drilling on
carrier machines
• Rotary drilling rigs
• Anchor drilling rigs and drilling carriages
• Excavators
• Cranes
• Horizontal drilling rigs
• Hydraulic hammers
• MENCK and diesel hammers
• Pontoons
• Pumps
• Tubular pile drivers and extractors
• Other plant, equipment and accessories
ONLINE USED
EQUIPMENT MARKET
www.tkgftbautechnik.de
www.tkgftbautechnik.com
We offer plant from well-known manufacturers, also
from our own supply depot: ThyssenKrupp GfT Tiefbautechnik
GmbH/MÜLLER and ABI, APE, Bauer, Casagrande,
CMV, DELMAG, Furukawa, Hütte, ICE, IPC,
Irmair, Junttan, Krupp, Liebherr, MENCK/Pileco,
MÜLLER, Puntel, RCP, Sennebogen, Soilmec, Techmo,
Trakto Technik, Tünkers, Wimag, Witte, Wicema and
many more. Most of our plant is available for no obligations
purchase, hire and also hire purchase. As our
range of used plant and plant for hire is constantly
changing, we are very happy to deal with individual
requests because not all plant is listed online. We shall
be happy to check the availability of plant and prepare
a quotation for you. We very much hope that this new
service is to your liking and will encourage you to visit
our “used equipment market” regularly.
We welcome your questions and suggestions.
Contact
Andrea Schnadt
Tel: +49 (0)172 1754916
Fax: +49 (0)8131 381410
E-mail: andrea.schnadt@thyssenkrupp.com

30 IN BRIEF
IN BRIEF 31
VERY PROMISING
OUTLOOK AT BAUMA
WITH ABOUT 415 000 VISITORS FROM 200 COUNTRIES,
BAUMA 2010 ONCE AGAIN WAS A RECORD-BREAKING
EVENT. ON THYSSENKRUPP GFT BAUTECHNIK’S
REDESIGNED TRADE FAIR STAND IT WAS THE UNIQUE
ROOFTOP TERRACE THAT PROVED TO BE A REAL
ATTRACTION ON THE OPEN-AIR SITE AND COULD
CERTAINLY BE BLAMED FOR GIVING VISITORS THAT
“TECHNOLOGY FEVER”!
Despite clouds of volcanic ash over Europe and the associated flight
cancellations, bauma 2010 was still able to consolidate its position
as the leading global platform for the construction sector. The fair
marked a turnaround for the international construction plant industry
and led to the hoped-for change of mood for the better – the
economic decline in Europe has bottomed out. Confidence is returning
to the market. The outlook could not be better.
Customers and staff alike responded positively to the redesigned
trade fair stand of ThyssenKrupp GfT Bautechnik plus its optimum
position. With the open-air site enjoying almost unbroken sunshine,
it was no wonder that the unique rooftop terrace on our trade fair
stand proved to be a great attraction. From here staff and visitors
could enjoy a superb view over all the exhibits, indeed over the
entire trade fair grounds. The best outlook at bauma! So it was no
surprise that this became a favourite meeting place for many
customers and business partners from the specialist civil engineering
sector who were on the lookout for the latest technological
developments in plant and equipment.
50 exhibits on 600 m 2 open-air site
The true attractions for many visitors and
customers were the new items of plant. One
highlight was the 683 TP telescopic crane/
leader combination, uniting two functions in
one machine: telescopic crane and leader.
An absolute world’s first. The new generation
of MÜLLER vibrators also attracted a great
number of customers and visitors.
The “high striker” game, successfully tested
in 2007, was a favourite among visitors and
business partners. We were also well looked
after by the catering team. More records
here: 1470 pairs of sausages and Bavarian
treats plus 1160 litres of beer were served.
“Brazilian Night”
To celebrate our newly founded branch in Rio
de Janeiro, our customer evening was held
under the motto of “Brazilian Night”, and
was a complete success. Some 300 invited
guests attended and thoroughly enjoyed the
finger food and cocktails accompanied by
exciting Brazilian rhythms and dancers.
The managers of ThyssenKrupp GfT Bautechnik,
Godehard Drees, Rolf F. Oberhaus
and Christian Walter, are very pleased with
the results of bauma 2010: “Our stand
turned out to be a popular meeting place for
the specialist civil engineering sector. We
were able to welcome a great number of
experts and decision-makers from home and
abroad. Interesting and important discussions
were held, contacts established for the future.
Our expectations were exceeded by far, despite
the cancellation of many flights, which
meant that many were unable to attend and
so the bauma got off to a slow start.”
Unfortunately, the restrictions on air traffic did
prevent many of those overseas visitors we
had been expecting from attending. Of couse,
exhibitors felt the absence of many customers
from Asia and America at the start, a fact that
did not go unnoticed by ThyssenKrupp GfT
Bautechnik either, but in the second half of
the week the situation improved considerably.
A bauma of superlatives
The 29th international trade fair took place in
Munich between 19 and 25 April 2010. Some
415 000 visitors, many experts and decisionmakers
despite the lack of visitors from overseas
due to the temporary flight restrictions in
Europe. A total area of 555 000 m² and 3150
exhibitors from 53 countries. Visitors from
about 200 countries – a record! The bauma
takes place every three years; the 30th bauma
international trade fair for construction machinery,
building material machines, mining
machines, construction vehicles and construction
equipment will take place in Munich on
15–21 April 2013. •
The 683 TP telescopic crane/leader
combination proved to be a great attraction
– and not only because of its impressive
height. It combines the functions of a leader
and a telescopic crane.
ThyssenKrupp was present at the bauma
again, this time with a new trade fair stand.

32 IN BRIEF
PLANT news 33
NEW LOOK
FOR
THYSSENKRUPP
Hochwasserschutzanlage und
Deicherhöhung höhung bei Gallin
SERVING RENEWABLE
ENERGY
ThyssenKrupp GfT Tiefbautechnik has a new development that
will enable vibratory driving of thin-wall tubes.
The group’s new corporate design for brochures and
catalogues is distinct and up to date.
The reorganisation of the group was accompanied by a
revision of our corporate design. It symbolises the consolidation,
which all employees and all ThyssenKrupp
companies are experiencing, in a uniform visual identity.
ThyssenKrupp’s new brand presence was launched
on 1 October 2009. The previous text/image branding
has been moulded into a concise and attractive form:
the new ThyssenKrupp group brand. ThyssenKrupp GfT
Bautechnik took the opportunity of bauma 2010 for a
redesign and presented its new brochures, which can
be downloaded from our Web pages:
http://www.tkgftbautechnik.com/download.html. •
A new method of exploiting solar energy is being tested by
BrightSource Energy at Rotem in Israel’s Negev desert.
A total of 1600 heliostats – computer-controlled mirrors –
track the sun and reflect its rays onto a water-filled boiler
at the top of a high tower. The ensuing steam drives a
turbine.
Following the successful conclusion of the tests, the company
will erect five giant solar arrays in the Mojave Desert
in California. The setup will be the world’s largest solar
power plant and will supply 900 MW of electricity.
The mirrors are mounted on tubes approx. 6 m long,
approx. 160 m in diameter and with wall thicknesses of
approx. 3.0–3.5 mm. The tubes are galvanised to protect
them against the weather. The galvanising may not be
damaged. Consequently, installing these tubes by impactdriving
is out of the question. The rounding at the top end
of each tube may not be damaged because this is where
the so-called rotor hub has to be mounted very accurately.
The ground at the test array in Israel, and also in California,
is relatively hard and stony. Nevertheless, in order to
be able to vibrate these tubes into the ground cost-effectively
taking into account the above requirements, a new
method was needed and so BrightSource Energy contacted
ThyssenKrupp GfT Tiefbautechnik GmbH in Alsfeld.
The ThyssenKrupp team developed and built a clamping
unit to suit this particular specification. The new design:
the clamping unit does not fit around the outside of the
tube, but instead is fitted internally and holds the tube
from inside. The tip of the clamping unit was modified.
In the meantime, the tests have been completed to the
full satisfaction of our customer, and the clamping unit
is now being used in the USA, too.
This new way of clamping thin-wall tubes can be used
right down to the smallest conceivable diameter of about
120 mm depending on wall thickness and tube length.
A patent has been applied for. •
Contact
Doris Becker-Spohr, Civil Engineering, Alsfeld
Tel: +49 (0)6631 781-132
E-mail: doris.spohr@thyssenkrupp.com
Photo by Courtesy of Bright Source Energy

34 PLANT news
PLANT news 35
LEADER-GUIDED MRZV-VV
VIBRATOR WITH
COMBINATION CLAMPING UNIT
The new, powerful MRZV-VV generation of variable vibrators is being
launched onto the market together with the new combination clamping
unit with sliding and rotating individual clamps.
DELMAG RHV 40 ROTARY
DRILLING RIG
The engines of the units comply with
European emission standard EU stage IIIB,
which comes into force in 2011.
THE RHV 40 ROTARY DRILLING RIG WAS DESIGNED FOR LARGE
PILE DIAMETERS: UP TO 2400 MM FOR THE STANDARD VERSION,
2700 MM FOR THE SPECIAL VERSION.
The RHV 40 has a torque capacity of 400 kNm and is characterised by high
stability and good torsional stiffness. The leader can be tipped forwards and
consists of two sections. For transport, the upper leader section plus kelly bar,
rotary table and counterweight are removed and transported on a second
low-loader. The complete setting-up procedure is carried out solely with the
on-board equipment, no additional plant is required.
The RHV 40 is mounted on ABI’s own T 122 D carrier. The machine can be
supplied with either a Scania or a CAT engine, which develop 405 and 403 kW
respectively. The engines meet European emission standard EU stage IIIB and
American standard US EPA tier 4 interim. However, the machine can also be
fitted with engines that comply with EU stage IIIA or EPA tier 3.
Besides traditional drilling with a kelly bar, this powerful rotary drilling rig is also
suitable for CFA drilling or lined holes using the DELMAG twin rotary head or the
VDW (“in front of the wall”) drilling system. •
With the VV vibrators it is not only the eccentric moment
that is adjustable, but also the oil flow and the hydraulic
motor. This means it is still possible to work very efficiently
even at a low r.p.m. with a high eccentric moment and
hence a high feed rate, for instance. The other variation
involves reducing the vibration load on the environment by
working at a very high r.p.m. Irrespective of whether
working very efficiently or very gently or somewhere in
between these two extremes to suit the particular building
site, the power provided by the carrier machine is used
almost to the full over the whole r.p.m. range.
This optimum use of the power available opens up new
opportunities. Comparable driving tasks can now be carried
out using machines with a lower driving power, or more
difficult tasks with the same driving power. This cuts
investment and running costs and at the same time lowers
the impact on the environment by sparing resources.
Deploying the new MRZV-VV vibrators with the combination
clamping unit enables very efficient working. Various double
Z- and U-sections and tubular piles can be driven using the
combination clamping unit. Setting-up is carried out manually
without the need for any assembly work. The double
clamping unit is currently offered in two sizes: a small
version for a centrifugal force of up to 800 kN, and a large
version for max. 1250 kN. The smaller combination
clamping unit can handle tube inside diameters between
460 and 760 mm; the larger version is for tubes with an
inside diameter of 660–1090 mm. •
The benefits of MRZV-VV vibrators
• Adjustable eccentric moment and
r.p.m.
• Constant centrifugal force over a
wide r.p.m. range
• Greater amplitude than conventional
leader-guided variable vibrators
• Lower running costs thanks to
optimised power output over a wide
r.p.m. range
• Low ground vibration thanks to
high speeds up to 2600 r.p.m.
• Max. centrifugal force even at a low
r.p.m.
• Same driving tasks with a lower
power output from the base
machine
The benefits of combination
clamping units
• Suitable for Z- and U-sections in the
form of double piles, also tubular
piles
• Faster section changes, manual
setting-up possible
• Less wear on the heads of the
sections
• Accurate positioning of piles

36 PLANT news
PLANT news 37
MÜLLER-SOUND-INSULATED
VIBRATION TECHNOLOGY
IN USE
ThyssenKrupp GfT Tiefbautechnik has developed the so-called acoustic
hood, initially for the models of the HFV series, in order to protect people
and the environment, especially in built-up or sensitive areas.
MS-A 570 (V) technical data
CAT C18 ATTAC diesel engine
• EU/EPA emission standard: stage II/tier 2
• Output: 571 kW
• 1800 r.p.m.
• Weight without fuel: 8500 kg
• Diesel tank capacity: max. 1050 l
• Hydraulic tank capacity: max. 440 l
Pump
• Vibrator drive pumps: 3 x 130 cm 3 /rev.
• Flow rate: max. 1050 l/min
• Operating pressure: max. 380 bar
• Clamp hydraulic pump: 10 cm 3 /rev.
• Flow rate: max. 27 l/min
• Operating pressure: max. 350 bar
The quiet yet powerful MÜLLER power packs are also gentle
on the ears, and a newly developed intermediate unit has
been added to this range. This new power pack, the MS-A
570 (V), is ideal for use with the MS-65 H3, MS-28 HF V and
MS-32 HF V vibrators, which in the meantime have also
undergone further development.
Special features
• Closes the gap between the MS-A 420 (V)
and the MS-A 700 (V), in terms of both
output and flow rate.
• Good handling during transport
thanks to compact housing.
• Can be used in conjunction with the
most diverse vibrators.
The sound level measurements carried out with a standard
vibrator from the HFV series, with and without acoustic hood,
under standard testing conditions show that the hood
reduces the sound level by a remarkable 10 dBA.
The acoustic hood not only reduces noise emissions, it also
places a further, beneficial vertical load on the spring yoke.
It protects the entire exciter block in such a way that the plant
can also be laid aside during breaks in the work without the
need for a special frame. The hood includes special openings
that allow maintenance and service work to be carried out
without having to remove the hood.
MS-35 H3 technical data
• Centrifugal force: 834 kN
• Eccentric moment: 32.5 kgm
• Frequency: 25.5 Hz
• Line pull: 400 kN
• Dynamic weight: 2660 kg
• Transport weight: 3600 kg
The MS-35 H3 compact
powerful vibrator with fixed
eccentric moment
A further unit with a higher eccentric moment has been
added to the range of powerful vibrators with fixed
eccentric moment and compact housing.
Special features
• Greater centrifugal force and eccentric moment but
still using the tried-and-tested compact design.
• Higher amplitude to improve the friction effect in
cohesive soils.
• Can be used with our powerful, reliable MS-A 260
power pack, which is well-proven in practice.
• Complements the series by providing a new intermediate
model between the units with 25 and 50 kgm eccentric
moment.
MS-10 HFV with
acoustic hood
MS-10 HFV without
acoustic hood
MS-28 HFV technical data
• Centrifugal force: 1473 kN
• Eccentric moment: 0–28 kgm
• Frequency: 36.5 Hz
• Line pull: 500 kN
• Dynamic weight: 3120 kg
• Transport weight: 5320 kg
The MS-28 HF V compact
variable high-frequency
vibrator
Following the successful introduction of the MS-20 HFV, a
new, powerful, compact vibrator has been added to the
range of variable high-frequency vibrators.
Special features
• Increased eccentric moment for improving the friction
effect in difficult soils.
• A modified spring yoke means that setting down the unit
does not subject the suspension ropes to severe stresses.
• Optimum exploitation of this vibrator’s performance is
ensured when used together with the MS-A 570 (V)
• Routing hoses outside the spring yoke simplifies
maintenance.

38 PREVIEW
PREVIEW 39
BUILDING SITE AT BERLIN’S
“RED TOWN HALL”
Contact
Mathias Himmel,
Berlin Branch
Tel.: 49 (0)3375 9271-24
E-Mail: mathias.himmel@thyssenkrupp.com
Klaus Wowereit presses the button to start the MÜLLER
MS-5 HF BV 3 vibrator.
One of Berlin’s most extensive infrastructure projects began in
April with the preparatory work for underground line U5.
The Mayor of Berlin, Klaus Wowereit, the
Senator for Urban Development, Ingeborg
Junge-Reyer, and the Chairman of BVG,
Andreas Sturmowski, pressed the button to
start the first driving operation for the preparatory
measures in the “U5 extension” project
between Alexanderplatz and Brandenburg
Gate. A MÜLLER MS-5 HFBV 3 vibrator, hired
from our Berlin Branch by contractor Tischer,
was used for this symbolic “turning of the
first sod”, marking the start of the archaeological
excavations ahead of the earthworks
required for building the new underground
station adjacent to Berlin’s famous “Red
Town Hall”. The preparatory works involve
laying services, archaeological exploration,
clearing the site and setting up site facilities.
The construction of the 2.2 km long line
connecting U55 and U5 at Alexanderplatz is
scheduled for completion in 2017. The line,
most of which will be constructed underground
with a TBM, runs from Alexanderplatz,
past the town hall, underneath the Marx
Engels Forum and the wide boulevard Unter
den Linden to the underground station at
Brandenburg Gate.
Mayor of Berlin Klaus Wowereit was among the many
guests attending the ceremony to start the extension
to the underground line.
Elaborate construction logistics
Most of the line will be built using tunnelling
methods. Owing to the high water table in
Berlin, the ground slab for the rebuilding of
Berlin Palace must be completed before the
TBM can pass beneath the structure. A total
of 235 000 m³ of soil will have to be excavated
and disposed of in order to make way for
the new underground stations. An environmentally
compatible concept was drawn up
for the routes to and from the site and the
construction logistics in conjunction with
those responsible from the Senate and district
authorities. The result is a separate
traffic route which minimises the traffic in the
sensitive area and provides for the spoil from
the tunnelling operations to be taken away by
ship. An appropriate mooring and loading
facility will be built on the River Spree.
The most extensive and most demanding
building measures will be those at the intersection
between Unter den Linden and
Friedrichstrasse. As the new U5 Underground
station will be positioned below the existing
U6 underground station, which will then be
suspended like a great trough within the new
station, the cut-and-cover method must be
used here.
Safety is a priority in Berlin, and not just because
of the events in Cologne. There will be
a comprehensive network of measuring
points and sensors, like that used during the
building measures for U55 at Brandenburg
Gate, which records critical ground or
groundwater movements in real-time in order
to enable a phased emergency management
plan to be put into operation if necessary.
In addition, the method of checking on-site
operations, backed up by an outside company
as well, plus the use of project control
and site supervision guarantees a full overview
of all con-struction measures.
You will be able to read more about this
major project in the next edition of
“die bautechnik”. •