42

Contents
Status report 5
Bauer in Africa 6
Building in Germany 20
The work of SPESA 24
Schachtbau projects 25
In-house exhibition 26
Equipment in
customer use 28
BG PremiumLine 29
International projects 30
Schrobenhausener Tage 39
Bauer Resources 40
Safety rst 42
Deep drilling 43

Executing 14,000 sqm of diaphragm wall down to a

depth of 40 m for the Warisan Merdeka underground
station in Kuala Lumpur
 In-house
news
veryone has their own ideas about

E Africa, whether based on visits

there or merely on media imagery.
Our main feature in this issue portrays
the work of BAUER Group companies
in Africa over the last four decades, re-
vealing in particular how we cope with
the great diversity of tasks and challen-
ges on the continent.
We also report once again on our pro-
jects from all over the world, with images
showing the various construction pha-
ses. It is usually the case that our rea-
ders do not then find out what happens
on the many sites we feature once they
are actually built. This time we present
a number of examples of completed
projects, primarily from within Germany,
some of which are prestigious architec-
tural works, such as the Reichstag in
Berlin or the "Exzenterhaus" in Bochum,
while some are civil engineering instal-
lations, including a canal lock.
The Bauer Maschinen In-House Exhibi-
tion in the Spring of 2012 was once again
a major event in the company's year.
And Bauer Spezialtiefbau hosted its
"Schrobenhausener Tage" conference.
Concluding the conference, Professor
Thomas Bauer presented a lecture on
the subject of diversity, and how it is in-
tegrated into the new corporate gover-
nance rules. Rather than presenting a
short summary of Professor Bauer's
address, we decided to interview him
on the topic, and took the opportunity
also to ask him about a range of other
business-related issues which are cur-
rently the subject of widespread public
debate.
Other features include an insight into life
at Bauer companies. The Old Welding
Shop building at the company's head-
quarters location in Schrobenhausen
has over the last 10 years become a po-
pular conference centre for many regio-
nal organizations. We look at the kind of
events it hosts, complete with a gallery
of images.
4 Status report

In Doha, the capital of Qatar, Bauer executed the

piling and grouting works for two new buildings at
the Education City campus
 Status report
2
011 was a year of great change. It brought more disturbances
than any in recent times. They included the political upheaval
in many Arab countries as well as the earthquake, tsunami and
subsequent nuclear accident in Japan. These events impacted on the
business of the BAUER Group, though some positive prospects were
opened up in the aftermath of the Fukushima disaster as the German
government's energy policy was shifted away from the nuclear option.
We began 2011 in a spirit of high optimism; markets were recovering
after the crisis, and new products were opening up opportunities
to attract customers with new offers. Yet the year had barely begun
when political unrest was ignited in Egypt. The protests in Cairo's
Tahrir square greatly impacted on our business, as we were at the
time working on three construction sites in the immediate area. Soon
afterwards, our projects in Libya were also brought to a standstill. The
concerns of other governments in the region that the protests might
spread led to many further construction projects and machinery sales
being halted.
Following the nuclear disaster in Japan, the governments in many
countries reviewed their plans for new power station development.
This, too, had a negative effect on our specialist foundation enginee-
ring business. And then, to make matters worse, concerns about a
renewed nancial crisis were also re-ignited. This naturally resulted in
customers being more cautious in their investment decision-making,
and consequently new machinery orders were depressed.
In addition to these global issues, we also had problems with three
large-scale projects in Hong Kong, Panama and Jordan which for
Development of total Group revenues by segment
in EUR million (segments after deducting Other/Consolidations)
Total 1,372
1,500
Resources
1,250 209
1,000
Equipment
601
750
500 Construction,
international
405
250
Construction,
0 Germany 157
2000 01 02 03 04 05 06 07 08 09 10 2011
different reasons impacted negatively on the Group's balance sheet
and earnings in 2011. While the BAUER Group's 2011 full-year total
consolidated revenues of EUR 1,372 million were 5.2 percent up on
the previous year, our after-tax prot declined from EUR 39.8 million
in 2010 to EUR 34.1 million. This meant we did not achieve our budget
target. Our performance was nevertheless good, bearing in mind the
problems on our markets.
Our Construction segment was the most heavily hit of our business
units in 2011. Its total consolidated revenues of EUR 582.1 million
were 5.4 percent down against the previous year. Segment earnings
virtually halved, to EUR 4.9 million. Despite this, the segment's trend
in orders in hand developed very positively in the course of the year.
Adding to the large-scale Center Hill Dam project in the USA, worth
almost USD 106 million, and the remediation of the Sylvenstein Dam
in Bavaria, a number of new contracts were also acquired in other re-
gions, especially in the Far East, which further boosted orders in hand.
The Equipment segment saw healthy growth. Its total consolidated
revenues rose by 13.6 percent to EUR 661 million. The gures are set
against a weak previous year, yet even so the segment's revenues
and earnings were well up on its 2009 performance too. As in those
previous years, the trend in demand shifted further towards large con-
struction machinery. As there are lots of major projects worldwide for
which our customers need highly specialized machinery, this market is
relatively stable. We recorded our rst sale of a TBA 300 deep drilling
rig, to a customer in Venezuela, in June 2011. The rig was delivered
in the autumn, and the customer started work with it in early 2012.
The TBA has successfully proved its worth in practical operations. We
achieved a further success in July off the north coast of Scotland. On
a project led by Bauer's Construction segment, and employing a com-
pletely newly developed rig from Bauer Maschinen, a mono-pile for a
tidal turbine was successfully installed under extremely hostile tidal
conditions. We hope that this will open up some interesting project
opportunities for us in the offshore sector in future.
The Resources segment maintained its positive growth trend in 2011.
Its total consolidated revenues rose by 19.0 percent against the pre-
vious year to EUR 211.5 million. The segment's Materials division suc-
Geographical breakdown of total Group revenues
in EUR million
Africa 67 (5 %)
Germany 370 (27 %) America 191 (14 %)
Asia-Pacic,
Far East & Australia
292 (21 %)
EU excl. Germany
154 (11 %)
Middle East & Central Asia
Europe (other) 127 (9 %) 171 (13 %)
ceeded in expanding its business further. New plants were establish-
ed in Togo and Chile. The Exploration and Mining Services division
likewise made positive progress. The large-scale Disi-Amman project
in Jordan did not go to plan, however, and is having a negative impact
on earnings. This major contract involves drilling a well eld to supply
the capital city Amman with drinking water over the coming decades.
The performance of the Environment division was very healthy. The
biological water purication plant in Oman, which is scheduled to dou-
ble its capacity in 2012, is operating to the customer's complete satis-
faction. The innovative idea underlying the plant has received a number
of prestigious awards.
Although we again saw a positive overall trend at the start of the year,
2012 turned out to be difcult. There were a number of positive as-
pects, too, however. The Construction segment acquired some inte-
resting new projects in the course of the year, including the contract to
execute the foundation works for the Kingdom Tower in Jeddah, Saudi
Arabia, which at over a kilometre in height will become the world's
tallest building. The Resources segment continues to enjoy healthy
growth, though the disturbances to the large-scale project in Jordan
will have a negative effect on our earnings. By contrast, our Equipment
segment failed by some distance to live up to initial expectations. The
re-igniting of major uncertainty on international nancial markets allied
to severe disturbances on markets in some regions will mean that our
sales will be down against the previous year, and as a result earnings
will decline considerably. Overall, we expect the BAUER Group to ge-
nerate full-year total consolidated revenues of EUR 1.45 billion and to
return a prot after tax of EUR 25 to 30 million.
I would like to thank all the Group's employees for their effort, enthu-
siasm, creativity and great work over the past year. I would also like to
thank our customers and partners for their continued trust in us, and for
their constructive cooperation. We will be making every effort to main-
tain our progress with the utmost vigour and commitment in future.
 here are some great books and lms
T with stirring titles "The Green Hills
of Africa"; "The Snows of Kiliman-
jaro"; "The Sheltering Sky; "Serengeti
Shall Not Die!"; "Out of Africa" which
tell of the magic and mystery of Africa.
But how do those images match up to
reality?
Is it in fact a very different place? The
history of Africa from the twentieth cen-
tury up to the present is certainly not
a tale of magic. It tells of the legacy of
colonialism, and the bloody aftermath of
liberation wars. Our news reports have
in recent times been lled with images
of civil war in Angola and Sudan; of ge-
nocide in Rwanda; of mass starvation in
the Sahel zone; and of refugees in small
boats trying to cross the Mediterranean
in order to reach Italy.
The name "Africa" is often regarded as
a single, unied entity, yet those with
a deeper knowledge are well aware of
A continent
building for its
its multitude of cultures, often creating
extreme diversity within surprisingly
close geographical bounds. The clearest
distinction from a European viewpoint is
the divide between the Arab nations in
the north of the continent and the sub-
Saharan countries of central and sou-
thern Africa. The conquering empires of
the ancient world took an interest in all
of them. While North Africa became part
of the trans-Mediterranean culture, and
Egypt became acknowledged as a pre-
cursor of European civilization, it is less
well-known that the Romans also con-
ducted expeditions further to the south.
Africa
future
It is against that historical backdrop and
working with the latest economic de-
velopment data that companies from
Europe and elsewhere around the globe
engage on business ventures across Afri-
ca. "The future belongs to Africa!" is a slo-
gan which economists have adopted to
express what they see as the continent's
great potential. Africa's massive raw
material wealth is without doubt key to
its economic prosperity. To ensure the
essential development, the continually
growing African population needs better
infrastructure and education.
So what is Africa? It is difcult to portray
a unied picture. The size of the conti-
nent alone is something which many
people fail to adequately grasp. In fact,
overlaying maps of the same scale on
a map of Africa reveals that the United
States of America, all of India and Cen-
tral Europe would t together within its
land mass. The continent comprises 54
nation-states, the most recent addition
being South Sudan.
The BAUER Group operates in a num-
ber of countries throughout Africa. All
three of the Group's business seg-
ments Construction, Equipment and
Resources work on projects as well
as running their own facilities. The glo-
bal reach of the BAUER Group across
every continent allows comparisons
to be drawn: Whereas in South East
8 Bauer in Africa
Asia a likewise diverse group of coun-
tries have established structures enab-
ling their economies to work together
on a calculable basis, many countries
in Africa lack a reliable framework for
economic development. BAUER AG
Chairman Thomas Bauer comments on
the political history of recent decades
in Africa: "Highly developed cultures
were suddenly swallowed up by social-
ist systems over periods of many years;
then new dictatorships emerged which
"I have fallen
in love with Africa"
auer employees who have spent
B any length of time in Africa in
whichever country often talk of
the continent's fascination and their love
for it. Walter Sigl had his rst encounter
with Africa as far back as 1969, when
as a student he volunteered to help
handicapped children during the Bia-
fra-Nigeria civil war: "That was when I
fell in love with Africa." His afnity grew
further in the course of his work as an
engineer in a series of African countries
between 1972 and 1984. He spent time
in Algeria, Togo, Namibia, Benin, Mali,
Tanzania, Cameroon and Guinea.
Dionys Widmann worked over many
years for Bauer Maschinen, and he re-
mains under the continent's spell to this
day. Having spent 20 years in Africa, he
has grown to know the innumerable
micro-cultures, as well as the problems
which arise from tribal rivalries. As he
comments: "Africa is wonderful. Once
you've been bitten by the bug, you ne-
ver escape it. Africa can be warm and
brutally suppressed any positive pro-
gress which might have been made."
This resulted in periods of dramatically
uctuating economic boom-and-bust for
many countries; previously prosperous
countries descended into chaos; some
recovered, but there was a lack of stabi-
lity. And the process of political change
is still not complete in some countries
of North Africa: "As a result, this huge
continent for the time being remains a
relatively small market."
generous, but it can be so brutal too!" Pro-
fessor Reiner Homrighausen, who joined
the BAUER Group when it acquired GWE,
experienced a number of different African
countries during his time as a student,
and as he asserts: "I have fallen in love
with Africa." It was back in the mid-1970s
that he got to know a number of regions
in the course of his work on behalf of the
German Federal Institute of Geosciences
and Natural Resources (BGR) in Hanover.
Professor Homrighausen's affections are
clear for any visitor to see: his ofce in
Peine is decorated with African sculptu-
res and pictures.
Stefan Ernst, Head of International
Sales with GWE pumpenboese, has
been a a regular visitor to Africa for three
decades. He makes a plea on behalf of
one country which is going through dif-
cult times, and which consequently
many Europeans are avoiding Nigeria:
"Nigeria is suffering under its negative
image; it is seen as one of the most cor-
rupt countries on Earth. Yes, things are
difcult in the capital Lagos, but if you
drive out around the region, you nd so
many needy and grateful people It's
vital that this country is not written-off!"
Lars Roesler, Managing Director of
Bauer Technologies South Africa (BTSA),
has opted to make the continent's most
southerly country his home for the long
term with the full agreement of his
wife Peggy, of course. He loves South
Africa, but he is also well aware of what
he acknowledges as "the enormous di-
vergence between South Africa and the
rest of the continent" in terms of stand-
ard of living. He loves the exuberant joy
for life he encounters in many people,
such as in Ghana.
Hermann Schrattenthaler is respon-
sible for machinery sales in Africa,
having previously worked there for a
long time in the construction industry.
He is fascinated by the great diversity
across the African continent, quoting
Ernest Hemingway's comment: "Africa
you either hate it or you love it."
But not everyone takes to Africa with
such abandon. One female member of
staff commented after two-and-a-half
years in Angola: "It's been an interesting
time, but now I've had enough." And
among the young engineers, Uli Schpf
comments on how uneasy he feels
when driving in an armoured vehicle on
the way to a construction site, past peo-
ple who are obviously living in the most
desperate poverty. As he says, things
like that make him feel good to get back
to Europe again.
 Bauer in Africa 9
Well drilling and specialist
foundation engineering
auer Spezialtiefbau has been car-

B rying out specialist foundation en-

gineering projects in Africa since
the mid-1970s. The motivation came
from a severe decline in the German
construction industry, which led the
company head Dr. Karlheinz Bauer to
send out engineers abroad looking for
work. Among the key early works were
well drilling projects in Libya, as Thomas
Bauer reports: "It was certainly surprising
at the time to see a company such as
ours suddenly sinking wells in Africa."
In fact, Bauer had begun working in West
Africa a few years before. When const-
ruction company Dyckerhoff & Widmann
was contracted to build a large bridge over
the Benue river in Cameroon in 1967/68,
it engaged Bauer as a subcontractor to in-
stall the foundations for the bridge pillars.
The ambitious Schrobenhausen compa-
ny already had a good reputation in the
eld, and its own innovation, the Bauer Bauer anchors for the phosphate conveyor belt in Spanish Sahara, 1973
anchor, was also very much in demand:
In El Ajun in the Spanish Sahara in 1973,
a 140 kilometre long phosphate conveyor
belt was installed all the way to the coast.
BAUER Group subsidiary Egesa Bauer in-
stalled anchors to secure the supports.
One of the engineers who went out ac-
quiring those early contracts in North
Africa was Wolfgang Brunner. He ap-
proached the challenge with great de-
termination, taking pains to familiarize
himself with an initially alien culture: "I
had to obtain various approvals for our
project in Libya. But it appeared nobo-
dy could understand my English, until I
realised: the ofcials didn't like dealing
with foreigners. So I gave up for the time

Well drilling at Garabuli in the Libyan desert in 1975

Foundation works in Tripoli, 2009
being, and spent a few weeks intensively
learning Arabic. Then I went back "
The German engineer was immediately
greeted much more cordially. The rst ma-
jor project was the Garabuli well. It was
soon followed by a project to draw water
at the Joufra oasis. The next contract ac-
quired was to install the foundations for
the Souk el Khamis cement works sou-
th-west of Tripoli; another was the "Man
Made River" project, to divert water from
the heart of the desert to Tripoli.
Among the largest projects in Libya, car-
ried out in the late 1970s, was the foun-
dation work for the Homs power station.
This was followed by the foundations for
the Misurata steel plant a large-scale
project which imposed the highest de-
mands on engineers Dieter Stetter and
Josef Soier. But before it could begin
there was high drama: The plan was to
install 210,000 metres of bored piles
using several BG 7 rigs and four new
BG 11 models, but while being shipped
to the site the new rigs fell overboard dur-
ing a storm in the Bay of Biscay. When
it appeared that this would delay com-
pletion, the boss of the Korean general
contractor came to Schrobenhausen and
threatened to commit suicide! With a
great deal of skill and improvisation, the
required machinery was delivered to the
site and the job was completed on sched-
ule. Over the years, until the fall of Gad-
10 Bauer in Africa

Difcult sealing works on the

Merowe dam on the Nile
Above: Misurata project in Libya
da in 2011, the company regularly car-
ried out large-scale specialist foundation
engineering projects in Libya mainly in
Tripoli.
BAUER Maschinen GmbH Managing
Director Dieter Stetter also spent time as
a young construction engineer in North
Africa. In 1983 he was working in Oran,
in Algeria. The overzealous bureaucracy
proved a barrier when it came to get-
ting machines through customs, though
eventually assistance came from the
military authorities, since the machines
were intended for use in sinking piles in
a military port installation, working from
a pontoon. Dieter Stetter has good me-
mories of his weeks in Algeria however:
"Things were very liberal back then. The
culture was heavily French-inuenced,
especially with regard to the good food."
And he had time for some adventure too. Foundations of the Kafr-El-Zayat bridge over the Nile, 2003
Stetter recalls: "When the project was -
nished, Wolfgang Brunner and I headed
off home in my VW camper van nice
and slowly, so as to see something of
Bauer Egypt
the world, passing through Morocco, ac-
ross to Gibraltar, and up through Spain."
Throughout all these years, the
a success story
company's work in sub-Saharan Africa t was certainly a rocky road before it passing of a new law governing capital
was subject to many uncertainties. Pro-
jects were executed in numerous coun-
tries, often with the foundations provi-
I became a success story. Bauer Egypt
has acquired an outstanding repu-
tation based on sheer hard work, with
investment, that the young Egyptian en-
gineer Dr. Hamza came to Bauer with
the suggestion to form a partnership.
ded by a local subsidiary. But frequently, its performance repeatedly recognized The new law stipulated that the majority
any sense of continuity was hindered by across the Group. Its development is share in any such partnership had to be
political change or other negative factors. described concisely and tellingly by Tho- held by Egyptians, but the sweetener
Towards the end of the 1990s and mas Bauer: "from really, really bad to re-
through the year 2000 we handled a ally, really good!" Bauer Egypt has long
number of projects in Ethiopia and Eri- operated with an entirely Egyptian staff.
trea. During the same period we ac- It is headed by Mohamed Mostafa, who
quired large-scale contracts in Sudan, has been with the company from its very
many of them in the capital Khartoum. beginnings. It was in 1980, following the
One project on behalf of a Chinese ge-
neral contractor which was technically
highly challenging primarily due to the The head of the Egyptian operation:
difcult geology was the underground Mohamed Mostafa
sealing works on the Merowe dam on
the Nile north of Khartoum. came in the form of tax breaks over a
Among many other projects in Africa, in period of years. After a number of mee-
1976 Bauer built a mole in the Togolese tings, the joint venture was established.
capital Lom. In Malawi we provided the The early days were enormously dif-
foundations for the Mangochi bridge; cult. Bauer struggled with a scenario in
and in Mozambique we sank piles for a which foreign individuals held a majority
large harbour-side jetty installation. We in the business, meaning success relied
worked on projects in Chad, and in Ke- heavily on close collaboration. Cultural
nya we installed the foundations for the differences soon led to disputes; mee-
Mois bridge, 400 kilometres from the tings in the early years largely consisted
capital Nairobi. In Nigeria, Bauer sank of lots of in-ghting and little in the way
piles for the highway bypassing Benin. of cooperation. It was no way to make
We also installed foundation piles for money. A further hindrance was Egypt's
the large-scale oil processing plant on high rate of ination, and the excessive
the island of Songo Songo in Tanzania. levels of bureaucracy in the country also
Projects were undertaken in Djibouti resulted in the commercial manage-
too, and Bauer Spezialtiefbau also car- Bridge foundations beneath the minarets ment descending into total chaos. The
ried out some work in South Africa. of Damietta City, 2004 whole thing was a asco.
12 Bauer in Africa
In February 1981 Heinz Kaltenecker
became the rst German engineer to
join the business. He and his wife were
subsequently to spend three years li-
ving in Cairo. A two-room ofce suite
was acquired on the eleventh oor of a
high-rise tower, and the company began
acquiring and executing projects. They
employed a secretary and two local en-
gineers: Mohamed Mostafa and Hosam
Hamdi. German staff were responsible
Bauer technology was deployed to recover a tunnel bore machine trapped during work
on the Cairo underground
for the technical management on-site
and at the workshop, though they were
gradually replaced by locals. The work
on-site proved extremely difcult. The
Egyptian construction workers were un-
skilled and incompetent often to the
despair of their German foremen. They
had no afnity with modern machinery:
When the overload alarm sounded, they
simply cut through the wire; on the next
lift attempt the mast collapsed.
The fact that the business neverthe-
less became a success was down to
an approach which Thomas Bauer still
talks about in public today. For nan-
cial reasons, it was essential to replace
the German personnel, but this meant
the company had to recruit competent
construction staff for the long term. It
did so by a number of methods. A bo-
nus system was introduced to provide
nancial incentives to handle machinery
with care, and thorough instruction was
given in all the relevant techniques. The
approach paid off. As the workforce's
competence improved, they began
to enjoy what they were doing, and
soon developed a pride in being Bauer
employees. As far back as the 1990s,
the Egyptians had made a particular
name for themselves after fashioning
a virtually new rig from two end-of-life
BG 7 units.
The staff learnt to cope with obstacles.
It took 14 days just to get equipment
and containers through customs in Alex-
andria. And even keeping in contact with
Germany posed problems. Heinz Kal-
tenecker recalls: "Making international
telephone calls out of Egypt was almost
impossible. You had to contact the post
ofce to book a call, then wait for hours,
and nally often some time in the
middle of the night a voice came down
the line from Schrobenhausen. The ulti-
mate in telecommunications technology
was when we at least acquired a telex
machine."
The market was ripe for the taking.
Specialist foundation engineering servi-
ces were needed, but few techniques
were established locally. Bauer was the
only company to offer base grouted and
skin grouted piles. A structure gradually
emerged. Manfred Schpf set about ac-
quiring new business, and soon an ac-
counting department was established.
The still young construction department
had to do everything itself. It could not
rely on a pool of suppliers as was the
norm in Germany; ready-mix concrete
or reinforcement cages could not sim-
ply be ordered. Cages had to be woven;
an aggregates chute had to be specially
fabricated; and the truck's mixer drum
was used as a concrete mixer. There
was also a lot of work to do at the work-
shop, with as many as eight welders
being employed at any one time.
After three years, Bauer Egypt had a
staff of 230, including 17 engineers,
and a machinery eet comprising two
BG 7 rigs, a BG 11 and an anchor drilling
rig. Heinz Kaltenecker was succeeded
by Roland Kleina, who continued the
company's expansion. Thereafter a poli-
cy of handing over the business entirely
to local staff was pursued.
Over a period of 30 years, Bauer Egypt
has worked on numerous projects, es-
pecially excavation pits in the major
cities of Cairo and Alexandria, and has
installed foundations at many different
sites, primarily for bridges. In 2007/08
Bauer Egypt deployed trench cutters on
the construction of a new underground
railway line in Cairo. The works were
executed without fault, but the contract
partners had problems: There was a
collapse behind a tunnel bore machine,
and Bauer was commissioned to reco-
ver the rig. Specialists from across the
entire BAUER Group including from
Schachtbau and SPESA were deploy-
ed to construct a vertical shaft and then
approach the tunnel bore machine hori-
zontally with icing equipment to release
its tunnelling shield.
The success story in Egypt was brought
to a halt by political unrest. When the
centre of Cairo around Tahrir square
became the focus of anti-Mubarak pro-
tests in January 2011, Bauer was work-
ing on three major construction sites in
the area. The works were shut down for
months on end. All the company's staff
had to deal with the consequences. Mo-
hamed Mostafa reported at a number of
Group events on the challenges posed
by maintaining the business in a healthy
state despite all the problems.
Thomas Bauer believes prospects for
the future are bright: "We are one of few
companies which did not leave when
the so-called Arab Spring erupted. That
means we are ideally placed in Egypt
as elsewhere in the region to resume
and regain business when the turbu-
lence comes to an end."
 Bauer in Africa 13
Prospects in
Algeria and Angola
utside of Egypt, Bauer Spezi-

O altiefbau has major operations

in only two African countries:
Algeria and Angola. It is currently also
working on a project in Morocco. It has
no presence in some of the other areas
in Africa where it has previously carried
out work since the 1980s.
"Africa is a market with a future!" That is a
sentiment shared by BAUER Spezialtief-
bau Managing Director Peter Teschema-
cher: "We are of course observing events
everywhere, but we are being very cau-
tious in our approach to any projects of
interest especially in terms of pricing."
Some countries, such as Sudan at pre-
sent, are subject to international em-
bargoes. And there are some countries,
such as Congo or Nigeria, which Tesche-
macher regards as "not growth markets."
What makes the company's work gene-
rally more difcult is "the enormous bu- For the Teatro Avenida project in the Angolan capital Luanda, 230 foundation piles were
reaucracy in the countries in question." lowered to a depth of 41 m.
Regional director Arnulf Christa sees Af-
rica as being "doubtless more of an exci-
ting prospect than some other regions."
He manages the subsidiaries in Angola
and Algeria from his base in Schroben-

In Algeria, piles were installed for the quay

wall at the port of Behtouia under
extremely difcult conditions.

hausen, making several visits a year to

them. As he asserts: "It is not practicable
to manage Africa from within Africa, be-
cause travelling from country to country
is often very difcult." Peter Teschema-
cher regrets that it is not possible for the
Group to establish its usual networking
across such a vast geographical area.
He is, however, keen to ensure that
the subsidiaries concerned are staffed Bridge foundations at Chlef in Algeria on behalf of main contractor Consider
14 Bauer in Africa
Arnulf Christa and Peter Teschemacher,
directors of Bauer Spezialtiefbau
Piling for Morocco's
Tangier M2 project, a
container port on the
Mediterranean
with local personnel, including their ma-
nagements. Bauer Spezialtiefbau has a
regionally adapted Internet presence:
in French for Algeria; in Portuguese for
Angola. The Group is represented each
year at construction industry trade fairs
in the region: SITP in Algeria and FILDA
in Angola.
The Bauer subsidiary in Algeria is head-
ed by Michael Ortmeier. The business is
in the process of being built up. It has a
staff of some 25 people, including ve
engineers, and its machinery portfolio
comprises four drilling rigs. The const-
ruction manager is an Algerian, while the
workshop manager is from sub-Saharan
Africa. One of the company's outstan-
ding projects in recent years was the
bridge foundation works for the East-
West Highway.
In southern Africa, Angola is developing
rapidly. Just a few years ago it was con-
sidered highly dangerous to travel out-
side of the capital Luanda, mainly due to
the mineelds laid during the country's
civil war. The main language spoken lo-
cally is Portuguese a legacy of the co-
lonial era and local Bauer general ma-
nager Pedro Vale is himself Portuguese.
"We are well known in Angola," reports
Arnulf Christa, "We are contacted with
Foundation works for the extension of
the Baraki renery in Algeria
enquiries for almost every project that
arises." Bauer has a staff of 110 people in
Angola, including eight engineers, three
of whom are locals. Its machinery port-
folio comprises six drilling rigs. Recent
major projects included bridges over the
Catumbela and Dande rivers. In Luanda,
the company worked on the Teatro Ave-
nida, as well as installing hundreds of
ductile piles for the foundations of the
Nova Vida public housing project.
After 30 years of civil war, the situation
is still difcult especially when it co-
mes to recruitment. The long period of
internal strife has led to a skills shortage.
As a result, foreign staff primarily from
Portugal are often engaged to handle
the work at hand. Rising salaries are
becoming an increasing burden, as pay
levels struggle to keep pace with
Angola's enormously high cost of living.
Arnulf Christa highlights the fact that
Chinese rms are being encountered at
work throughout Africa. Although one
might complain that they receive govern-
ment support enabling them to quote
more cheaply, they are regularly found
to be valuable partners sometimes as
subcontractors, and sometimes as main
contractors providing BAUER Group
companies with work.
 Bauer - Machinery for Africa
umerous Bauer drilling rigs are lowering the cutter frame through the

N working on foundation enginee-

ring projects across Africa. How-
ever, machinery sales to Africa have
ship's hull so that it could then cut into
the sea bed. The cuttings were con-
veyed onto the ship where the material
always been focused on a different mar- was screened for diamonds. The Bauer
ket, with cutters, drilling rigs and grabs team was headed by Josef Maierhofer.
being targeted primarily at the mining Bauer drilling rigs have been used for
industry. Since as far back as the 1990s diamond exploration since the late
long before the BAUER Group's min-ing 1990s, primarily in South Africa. With
business was assigned to its new Re- Stefan Schwank handling all the nego-
sources segment Bauer Maschinen tiations, the company initially supplied
under the leadership of Erwin Sttzer three BG 36 rigs, and then in 2003 a
has been developing contacts with the BG 48 with a 36 metre mast height
major mine operators, and most espe-
cially with the global mining corporation
De Beers. Bauer equipment has regular-
ly been deployed for exploration drilling,
with company specialists seconded to
assist in operating the machinery.
One outstanding contract back in 1993
involved making a trench cutter which
was not intended to make a wall. What
the customer requested was a machine
to explore for diamond deposits off the
coast of South Africa, with the cutter
mounted on-board a ship. This involved
Machinery sales to Africa: Hermann
Schrattenthaler, Bruno Unger, Stefan
Buchner (from left)
Bauer cutter working
on the Johannes-
burg underground
 Two
stories
from
Elvis Kamgang Africa
he BAUER Group has over 700 em-
T ployees in Africa, most of them local
to the country in which they work. In
such an international concern, it is also
virtually inevitable that a number of staff
from Africa should also be encountered
working at the Group's headquarters in
Germany. So we asked two of them
Elvis Kamgang from Cameroon, close
to the Equator, and Elshersh Lotz-Moitty
from Egypt in North Africa the same
question: What brought you to Germany?
Elvis Kamgang gives an amusing reply:
"I inherited something of an afnity for
languages from my father. After having
learnt English and French at school,
when I was looking to choose where
to study in Europe and learn another
language, I narrowed it down to either
Spanish or German. And German soun-
ded like something there was no way
you could speak. That was the challen-
ge!" After having completed a language
course providing him with the eligibility
to study in Germany, and having had lots
of contact with Germans, he now says:
"German is not so hard at all; it's quite
logical in its structure. And nowadays I
even dream in German."
Elvis Kamgang was born and brought
up in the Cameroonian capital Yaounde.
After completing his Baccalaureate, he
came to study in Braunschweig and at
the Technical University of Munich, where
he also attended lectures by Professor
Thomas Bauer. He completed his stu-
dies at the Leipzig University of Applied
Sciences. A graduate in construction
engineering, his rst career experience
was working for the developers of the
Munich Airport Terminal II project, where
he again came into contact with Bauer.
He subsequently completed his degree
thesis in the Bauer Structural Enginee-
ring department. After working on a
number of large projects, he joined the
team headed by Paul Scheller which
successfully carried out the underwater
drilling off the coast of Scotland in 2011.
Elshersh Lotz-Moitty was born in the
Nile delta. He recalls: "From my aunt's
house you could see the Pyramids." Af-
ter graduating from high school he went
to study in Germany. "Germany is held in
the tallest of any Bauer drilling rig ever
produced. A drilling bucket with a 2.50
metre diameter was used to sink bores
down to a depth of 140 metres.
In 2005, the diamond exploration busi-
ness led Bauer to the Atlantic coast in
southern Namibia. Under the manage-
Elshersh Lotz-Moitty
ment of Lars Roesler, GB 50 and GB 60
grab units were deployed to produce
60,000 square metres of diaphragm cut-
very high regard in Egypt," he explains. off wall over a distance of 3.5 kilomet-
Another attraction was the challenge of
what is widely seen as a difcult lan-
guage to learn. The plan was to stay for
res. The walling blocked off the under-
water inow from the ocean, so making
the marshland manageable and enabling
three years, but he long ago acquired a open-cast diamond mining to be carried
German passport, and now says: "I've out. The work was carried out by a spe-
actually spent by far the biggest part of cially created Bauer joint venture, MBS
my life in Germany." After studying in Bi- Mineral Bulk Sampling.
berach and Stuttgart, he worked in the It has not all been about diamonds how-
commercial departments of a number ever. BAUER Spezialtiefbau has of
of construction companies. He joined course deployed drilling rigs and cutters
Bauer Maschinen in 2005, where he was on its specialist foundation engineering
responsible for the USA, Canada, Mexi- projects, and many other construction
co, Dubai and Africa; he subsequently contractors have made use of Bauer
moved to the Resources segment,
where he has worked ever since.
"The culture of Egypt is Arab, like all of
North Africa," Elshersh Lotz-Moitty says,
but in terms of political thinking Egypt is
very African. As late as the rst third of
the 20th century, Egypt and Sudan were
part of a single nation. During the Cold
War era, Egypt's pro-Soviet President
Nasser supported the independence
movements in Central and West Africa.
Apart from such political machinations,
Elshersh Lotz-Moitty believes Africa is
so vast that establishing and maintaining
links between the innumerable different
cultures is impossible. And Elvis Kam-
gang adds: "If I travel just 300 kilometres
away from Yaounde, I encounter an en-
tirely different culture, where people talk
differently, eat differently, and live an en-
tirely different life to what we experience
at home." It took a little time for the two
migrants to get used to German culture.
"In Africa much more is improvised," Elvis
Kamgang believes, "but once you have
understood and accepted German cul-
ture, it's easy to like too." When talk turns Exploration drilling for diamonds with a BG 48 dril
to the question of "home", both have very
similar attitudes. Elvis Kamgang states: "I equipment all across Africa. Back in
enjoy going home to see my family, but 1994, for example, Dywidag deployed
it's like going on holiday. I don't really the Bauer BA 220 reverse circulation
belong any more. Home is where your drilling rig on the renovation of a bridge
friends are; where you work; where you in Ghana. For a new harbour basin in
spend your life." Elshersh Lotz-Moitty North al Sukhna in the Gulf of Suez in
says: "My roots are in Egypt, but because 1998, Archirhodon Construction used a
I have been away for so long that is no BC 40 cutter to install a 38 metre deep
longer very relevant." And when he does diaphragm wall. In 2003, a newly deve-
go back to Egypt, he nds: "The places loped grab was deployed in Tabarka in
change, and that is painful to experience. Tunisia to seal a dam; and in 2007, con-
Memories change too " tractor Intrafor produced 48 metre deep

diaphragm walls for an underground rail-
way station in Johannesburg using a BC
40 trench cutter. Large-scale machines
were shipped to South Africa in the run-
up to the 2010 Football World Cup.
The reorganization of the BAUER Group,
including the establishment of the Re-
sources segment in 2007, brought a
change to Bauer Maschinen operations
in Africa. Its holdings in operating com-
panies were transferred to BAUER Re-
sources GmbH, and a number of rigs
were sold to that same company. Since
2010 Hermann Schrattenthaler has been
responsible for sales of specialist foun-
dation engineering machinery in Africa.
In addition, Lars Roesler, the Managing
Director of Bauer Technologies South
Africa, also acts as a representative for
Bauer Maschinen machinery sales.
PRAKLA Bohrtechnik GmbH has written
its own chapter of the BAUER Group
story in Africa with its well drilling rigs.
The long-standing Prakla company beca-
lling rig in South Africa
me part of the GWE Group in Peine back
in 2002. In 2004 Bauer Maschinen acqui-
red a majority share in it, taking full con-
trol in 2007. As part of the BAUER Group,
Prakla has manufactured around 100 rigs
since 2004. Prakla Managing Director
Alfred Widmann reports that "around
half were sold to Africa." In the last two
years the focus has shifted away from
the mining industry towards drilling for
water, most recently in Ethiopia.
Machinery manu-
facturing in Botswana
ased on initiatives from the Re-
B sources segment and the Deep
Drilling department, since 2010
BAUER Maschinen GmbH has a set of
new goals in Africa. The new joint ven-
ture company Bauer - De Wet in Bots-
wana recently began work under the
leadership of Deep Drilling department
head Walter Sigl.
Drilling rigs for the mining industry are designed and built in Rasesa
De Wet, a family business specializing
in drilling technology, was founded in
South Africa in the 1960s. It has been
based in Rasesa, Botswana for many
years. De Wet Drilling previously served
the markets in South Africa and Botswa-
na. Alongside water extraction, it was
involved in exploration for diamonds and
coal.
The company's founder still works in
the family business, together with sev-
eral brothers. Hentie De Wet is the Ma-
naging Director of Bauer - De Wet. Jan
De Wet and Stefan Hackl from Bauer
Maschinen together make up the joint
venture's "Innovation Team". Bauer - De
Wet was established in 2011, with
Bauer owning a 51 percent share. Un-
der Chairman Walter Sigl, a board was
set up comprising Rainer Rossbach as
nance director and Rudie De Wet as
the representative of co-shareholder De
Wet Drilling. De Wet employs more than
450 people. Bauer - De Wet has a staff
of approximately 40.
Bauer and De Wet are pursuing shared
goals in the design and manufacture of
deep drilling and blast-hole drilling rigs for
the African market. Development work
Bauer in Africa 17
on an initial two models is underway in
conjunction with Denith Engineering.
The hydraulics and electrics are being
contributed by Bauer Maschinen. Other
Bauer rms involved are TracMec, Haus-
herr and Eurodrill.
The joint venture is targeting the blast-
hole drilling rig specically at the mining
sector. Open-cast diamond mine opera-
tors need to widen the glory hole in order
to reach greater depths. This requires a
light, easily operated blast-hole drilling rig
capable of being set up and dismantled
rapidly. The rig named "Rhino 2200" is a
gigantic compressor with a matching ro-
tary drive. It drives a down-hole hammer
with large amounts of air from two diesel
compressors. The rig was designed and
built within 15 months, and is already in
operation at the Uruapa mine.
In 2012 the rst "Buffalo 90" well drilling
rig for markets outside southern Africa
designated "RB 90" was completed. In
its oil drilling rig variant, with the appro-
priate outtting, the same rig is desig-
nated TBA 100. The rig is mounted on a
trailer, which allows it to be very easily
transported by road despite its high load-
carrying capacity. This rig, too, incorpo-
rates all the synergy offered by the Bau-
er Maschinen Group.
In naming the rigs, the company likes
to play on Africa's "big ve" the lion,
leopard, buffalo, elephant and rhino
which, as Walter Sigl emphasizes, have
great symbolic value. And so it was that
this time around the rhino and the buf-
falo were duly honoured.
18 Bauer in Africa
Bauer Resources in Africa
ollowing the establishment of the
F BAUER Group's Resources seg-
ment in 2007, bundling all Group
operations relating to water, the envi-
ronment, energy and raw materials,
its focus immediately turned to Africa.
"The Resources segment has two key
areas of focus in Africa," reports Mana-
ging Director Johann Mesch: "Firstly,
we are a service provider to the mining
sector; and secondly, we help in the
extraction of water by supplying solar
pumps, pipes, lters and other acces-
sories from GWE (German Water and
Energy)." Mesch also sees good pros-
pects for environmental technology
not least in relation to water treatment:
"The synergies among the various divi-
sions of the Resources segment can be
ideally utilized in Africa."
Group Chairman Thomas Bauer adds:
"The acquisition of GWE in Peine a
key step towards the establishment of
the Resources segment enriched the
BAUER Group with its own separate
The BTSA team is using a Prakla RB 40 drilling rig on the Diogo project for Australian
mining company MDL in Senegal.
history of business operations in Africa."
The long-standing experience of GWE
in Africa is of vital importance to the fu-
ture work of the business. Many of the
key staff have experienced life and work
in Africa. Reiner Homrighausen tells
stories of well drilling and exploration
using Prakla drilling rigs in a variety of
different countries since the 1970s; Ste-
fan Ernst, international sales manager
of GWE, has for decades enjoyed close
working links with West Africa and the
Sahel zone.
Thus the extensive operations of Bauer
Resources in Africa combine the two
traditions of GWE on the one hand and
the mining business of Bauer Maschi-
nen on the other. The key pillar is the
subsidiary Bauer Technologies South Af-
rica (BTSA), founded by BAUER Maschi-
nen GmbH in 2005 and subsequently
merged into BAUER Resources GmbH.
The Managing Director of BTSA is Lars
Roesler, a man with a wealth of experi-
ence in Africa.
From his base in Johannesburg, Lars
Roesler heads a team of 75, including
engineers and technicians, who serve
the resources markets in a large num-
ber of countries. He views one of the
most successful decisions of recent
years as being the move into the parts
and service business. This enabled the
company to expand its service offer to
mining customers, also incorporating
equipment hire and operation. Projects
in Gabon and the Central African Re-
public were carried out with the aid of
rotary drilling rigs and Prakla drilling rigs.
In 2008, a cutter was deployed in Sierra
Leone for diamond exploration. In Lesot-
ho, the Resources segment worked at
an altitude of 3,000 metres to carry out
bulk sampling in kimberlite.
GWE likewise regards Africa as a mar-
ket which offers potential for growth.
Stefan Ernst has been supplying hand-
pumps to various countries throughout
Africa, as well as managing their instal-
lation, since the early 1980s. The rst
pumps were supplied to Sierra Leone
as part of a private initiative. Soon after-
wards, the German Agency for Technical
Cooperation GTZ nanced 900 of the
pumps, "some of which are still running
today." As Stefan Ernst points out, there
have been many advances over the ye-
ars since 2003 the pumps have been
solar powered and the gures are im-
pressive too. A number of major con-
tracts have taken GWE pumps to Ghana
and Eritrea, and in 2012 also to Nigeria.
What began as a business proposition
has in many areas grown thanks to the
BTSA Managing Director Lars Roesler,
second from right; on the right Reiner
Homrighausen
strong personal commitment of those
involved into genuinely valuable de-
velopment aid. Stefan Ernst illustrates
the point: "We supplied clean water to
a maternity unit, resulting in an immedi-
ate reduction in its previously high in-
fant mortality rate."
The pumps have to be installed, and
serviced, by the people locally. To that
end, Ernst reports, the company has
devised a training programme complete
with a graduation exam. The language
used is normally English, though fre-
quently users are illiterate, and so are
provided with visual instruction guides.
A key element for Stefan Ernst is to pro-
vide long-term support in maintaining
the systems; otherwise as in the case
of practices by some other organiza-
tions they would soon be left to decay.
Looking further ahead, GWE is focus-
ing on the major mining companies
and their need for dewatering and wa-
ter supply materials. As part of that
strategy, GWE Managing Director Falk
Olaf Petersdorf is also aiming not only
to supply PVC pipes from Europe but
also to have them made in Africa. In
Togo, the company is working on a
joint venture to recommission an old
factory which has seen better days.
The former pumpenboese production
facility was nationalized in the wave of
political change and subsequently went
bankrupt. The new government is now
interested in getting the plant back into
operation however. GWE is looking to
resume pipe production in 2013, prima-
Mining in Ghana. On the left Stefan Ernst
installing hand-pumps.

rily to serve the West African market,

though there are still a few hurdles to
be overcome.
Lars Roesler believes BTSA is making
good progress. In recent years it has
carried out projects in 14 countries in
sub-Saharan Africa, and the Resources
segment sees good opportunities in a
number of countries in West Africa. Gha-
na, especially, has become a key pillar of
the region thanks to its mineral resour-
ce wealth. In 2008 Bauer Resources ac-
quired its rst contract in West Africa,
to construct a gauge shaft and dewate-
ring borehole system for an open-cast
gold mining operation. The project was
launched in early 2009. The client for
ongoing exploration drilling works is the
Ghana Newmont mining corporation.
Follow-up contracts and strong demand
resulted in the establishment of Bauer
Resources Ghana in the rst quarter of
2010. Other projects are being handled
from the base in Ghana, primarily in Ivo-
ry Coast, Burkina Faso, Mali, Guinea,
Sierra Leone and Senegal.
 Projects of Bauer
companies in Germany
The sewage treatment plant of the mu-
nicipality of Straubing was provided
with a new ood protection system.

The dyke works involved installing

23,000 sqm of retaining wall with an in-
set sheet pile wall down to a depth of
15 m using the MIP technique. Above

The Sylvenstein dam, built between

1954 and 1959 for low-water control
of the river Isar, was in need of rein-
forcement. In 2012 Bauer constructed a
1 m thick diaphragm retaining wall down
to a depth 70 m. Above

In Munich, the "Forum am Hirschgarten"

complex is under construction in a new
quarter which has already seen 2,000
homes completed. Bauer executed the
15 m deep excavation pit, including uplift
retention, over an area of 100 x 100 m.
Above

In the heart of Frankfurt am Main,

the Historical Museum is being ex-
tended. The 10 m deep excavation pit
with 6,000 m of piling is retained by
35 m long graduated anchors. Right
 Projects in Germany 21
The construction work on the Luise-
Kiesselbach-Platz project in Munich
has been in progress since 2009. The
tunnel construction will eliminate inter-
sections from the trafc crossing point
in the south-west of the city. Bauer's
work is scheduled to be completed by
mid-2013. Below

As a preliminary measure for the new "Schwabinger Tor" investor project on Munich's
Leopoldstrasse, in Summer 2012 Bauer installed 30 bored piles up to a depth of
30 m. A BAUER BG 30 rotary drilling rig was used. Above

A number of new construction projects

are underway in Ingolstadt: on the
Schlosslnde site, the Audi Akademie,
and a conference centre with a ho-
tel and underground parking garages.
Bauer executed the foundation works;
pictured: at the historic Kavalier Dall-
wigk monument. See also the Bauer
Review cover picture. Below

Bauer Spezialtiefbau executed the retaining wall for a new health centre building at
the Vincentinum clinic in Augsburg. The works involved installing a 400 mm thick
MIP wall with 1,150 m of temporary anchors. The equipment used included a RG 16
and a Klemm KR 806 anchor drilling rig. Above

For the new triple-use sports hall

in Miesbach an excavation pit with
2,000 sqm of soldier pile wall and
1,000 sqm of intermittent pile wall with
shotcrete lagging was executed. A total
of 2,500 m of tie-back anchoring was in-
stalled. Left
 ThyssenKrupp in Essen is adding new
buildings to its Group headquarters
complex. For the foundations, 270
CFA piles were installed to a depth of
27 m using a BAUER BG 40. Left

Near Hoyerswerda in Saxony, the exis-

ting dyke works were remediated in
order to improve ood protection. The
contract involved installing 20,000 sqm
of MIP wall with embedded sheet pile
wall. Below

For the modernization of Berlin's Staatsoper "Unter den Linden", Bauer working as
part of a Joint Venture executed a trough excavation pit covering a 3,300 sqm base
area. The contract comprised a broad range of separate works, including the con-
struction of a diaphragm and retaining wall on the old building structure. Below

The Staatsoper "Unter den Linden"

project in Berlin also necessitated
uplift retention in the stage area. In
very tight working conditions, 95 GEWI
minipiles in 50 mm thickness and up to
18 m in length were executed. Below
 Projects in Germany 23

The Porsche plant in Leipzig is being

extended to handle production of the
new "Macan" model. For the founda-
tions of the new factory hall Bauer ins-
talled 1,800 mm thick piles with a total
of 6,200 m of bores (down to a depth of
40 m). Above

The Oelsners Hof is located in Leipzig between Nikolaistrasse and Ritterstrasse.

The site is being developed to create a covered shopping mall. Working in a very
tight space, Bauer executed the excavation pit as a bored pile wall to protect the In the area of the Bhl tunnel near Sie-
adjacent properties as well as installing the foundation piles. Above gen, 11,500 m of vibro-displacement co-
lumns were installed as a ground impro-
vement measure for the reconstruction
of the B 62 trunk road. A BAUER BF 13
vibratory rig with a TR 17 deep vibrator
were used. Above

In Coswig in the state of Saxony-Anhalt,

soil replacement bores were executed
in the grounds of a former paint factory.
A total of 5,300 cbm of contaminated
soil was transported to the Bauer Um-
welt soil treatment centre in Hirschfeld.
Left
24 SPESA - Spezialbau und Sanierung

At Cologne's Rheinau harbour complex,

the existing tied-back anchoring of the
quay wall had to be replaced prior to
constructing a new excavation pit, as
the wall extended into the planned new
pit. Permanent anchors 24 m in length
and made of 40 mm GEWI steel were
installed below the groundwater table.
Above

In Angelroda, Thuringia, SPESA is securing a slope cutting as part of a Joint Ven-

ture together with Schachtbau Nordhausen and NTG Bau GmbH. For the purpose,
anchors of up to 30 m in height are being installed using specialist equipment, and
more than 20,000 sqm of retaining netting is being laid. Above The downstream face of the Sengbach-
tal reservoir, built to supply drinking wa-
ter to the town of Solingen in 1903, un-
der-went renovation work. The remedia-
tion was carried out using the dry injec-
tion method. Finally the dam wall was
cleaned by high-pressure water jetting.
Above

In Arnstadt, a new main entrance was

built on to a shopping centre as part of
remodelling and extension work. The va-
lue of the works carried out by SPESA
was EUR 3.2 million. Left
 Schachtbau Nordhausen 25

West of Berlin, near Brieselang, the trafc on the A10 orbi-

tal motorway is carried by a new bridge over the Havel canal.
Schachtbau Nordhausen was responsible for the complete
construction of the bridge structure. Above

The reinforcement of the Ludwigshall shaft, a 680 m deep disus-

ed potash mine shaft in the southern Harz mountains region,
has been contracted to Schachtbau Nordhausen working in a
Joint Venture with Bergsicherung Ilfeld GmbH. Pictured: Pre- The Konrad mine shaft near Salzgitter is being developed into
paratory work prior to blowing up the shaft pillar. Above a nal storage facility for low and medium level radioactive
waste. The initial work was carried out by Schachtbau Nord-
At the Wendefurth pumping station in hausen together with Feldhaus Bergbau GmbH Co KG. Above
the Harz mountains, SCHACHTBAU
NORDHAUSEN Bau GmbH carried out
remediation works. Damaged concrete
was removed by the ultra-high-press-
ure water jet method and the damaged
areas were restored with shotcrete.
Below
 Bauer Maschinen
in-house exhibition 2012
Notable new
developments
he tradition of the Bauer in-house
T exhibition in presenting new equip-
ment developments goes back 25
years. This year's four-day event held in
Schrobenhausen in early May attracted
well over 2,000 visitors from 72 coun-
tries a big increase on the previous
year's gures.
At the opening ceremony in the presence
of numerous invited guests, Thomas
Bauer, Chairman of the Management
Board of BAUER AG and also President
of the German Construction Industry Fe-
deration, set forth the current position of
the company and reviewed the general
state of the construction industry, sta-
ting that he saw very good prospects for
growth on global construction markets.
Mayor of Schrobenhausen Dr. Karlheinz
Stephan also addressed the gathering.
He emphasized the importance of Bauer
to the town and the surrounding region,
and expressed his pleasure at how the
Bauer in-house exhibition also benets
the wider local community. As he put it,
the event brings a touch of international
air to the town's streets and squares
for a few days a year.
The most distinctive visual features
of the exhibition were the massive ro-
tary drilling rigs and pile-drivers on show
outside. At the opening, BAUER Maschi-
nen Managing Director Dieter Stetter
highlighted the innovations introduced
to many of the machines on show and
stressed the innovative strength of all
the companies forming part of the Bau-
er Maschinen Group. He also pointed
out the reorganization of the drilling rig
range, with the creation of the Value
Line and PremiumLine. The split into the
two lines was made so as to respond
in a more targeted way to the differing
market-specic requirements.
The two lines share basic principles
which are top priorities in terms of the
Bauer BG series. They include, rst and
foremost, quality, cost-effectiveness and
performance capability; high safety stan-
dards; service friendliness; environmen-
tal compatibility; and long service life.
The in-house exhibition once again this
year featured new developments from
all the subsidiaries of the Bauer Maschi-
nen Group. Outstanding among them
were new units from RTG Rammtech-
nik GmbH. RTG's pile-drivers mounted
on the BS 65 RS base carrier with Eco units. PRAKLA Bohrtechnik GmbH pre-
mode feature technical advances incor- sented the new RB 15 well drilling rig,
porating new sound-proong systems. which in accordance with customer wish-
A ap on the side of the machine can es was mounted on a crawler base.
be opened during operation which cuts Blast-hole drilling rig specialist Hausherr
sound emissions by 15 Decibels, repre- exhibited its HSB 3000 model.
senting a major reduction compared to With the MC series, Bauer Maschinen
conventional sound-proong measures. has in recent years introduced onto the
Another unit presented at the exhibition market a exible base carrier unit for a
was the RTG MR 150 vibrator featuring wide range of specialist foundation engi-
the AVM system, which is capable of ad- neering applications. The MC rigs are wi-
apting to specic ground conditions. dely used as base units in different sizes
The small-diameter drilling rig technol- for trench cutters or for the y drill. At
ogy from Klemm Bohrtechnik was also the in-house exhibition the MC 96 was
on show, in the form of the KR series congured with a Pileco diesel hammer.
 In-house exhibition 27
The MC 64 base carrier was presented
in conjunction with a low-headroom cut-
ter capable of working in tight spaces
beneath bridges or under power lines.
MAT Mischanlagentechnik GmbH pre-
sented its broad range of products ex-
tending from desanders, through batch
mixers to decanters and hose pumps.
ABS Trenchless exhibited a horizontal
thrust boring machine for laying new
pipes. Also on display were hydraulic
hammers from Fambo.

The machinery demonstrations on the

outdoor training grounds in Aresing,
showing a variety of different tech-
niques, were particularly popular. Every
day more than 200 spectators viewed
the demonstrations which were presen-
ted by Franz Werner Gerressen.
The new vibrator MR AVM with active
vibrator management on a xed leader
rig RG 25 S, drilling with KLEMM KR
806-3 with a Vibro-rotary drive and de-
monstrating rock drilling with air-driven
Multi Hammer Drill (MHD) on a BG 15 H
created big interest.
Three applications of MC foundation cra-
nes were also shown: Pile driving with
a FAMBO Hammer in a freely suspen-
ded frame on a MC 64, bored piling with
the FlyDrill BFD 2000 on a MC 64 and
Dynamic Compaction BDC with the big
foundation crane MC 128.
Other divisions of the Bauer Maschinen
Group presented their products in the
Old Welding Shop which had once again,
as in previous years, been transformed
into a colourful, bustling exhibition hall.
Featured exhibits included rotary drives
from Eurodrill, as well as the associated
machine and site electronics. A number
of specialist departments and business
units also exhibited their products and
services, including the Parts & Service
department, BAUER Training Center
GmbH and the recently established Deep
Drilling department. The new underwater
drilling technique was also presented.
28

Equipment in customer use

Azerbaijan Our customer Azerkorpu
deployed a BC 40 trench cutter and a
grab to execute 40 to 60 m deep dia-
phragm walls for the Memar Ajami un-
derground railway station in Baku.

Germany In Hamburg, Europe's lar-

gest drawbridge, the Retheklappbrcke,
is being rebuilt. Our customer Neidhardt Japan Japanese TV has its own ver-
Grundbau is deploying two Klemm drilling sions of "Candid Camera" type shows.
rigs to install 420 grouted piles of up to In one bizarre duel, an umbrella is put up
30 m in length and 50 ground anchors in against a wind machine. Our customer
lengths between 30 and 50 m. Technos sent one of its Bauer quattro-
cutters to pull on the cable against an
Netherlands Hoffmann Groep based 'opponent' from Nippon Shario.
in Beek en Donk successfully deployed
the CSM technique in Nijmegen using
a RG 16 rig.

Germany Energy company Vatten-

fall Europe Mining AG is opening up a
new open-cast brown coal mine in the
Welzow-south area of the Lausitz regi-
on. Working to the client's specication, Vietnam In Saigon, our Singapore-
Bauer Maschinen is manufacturing a based customer Rioby Kiso is deploying
trench cutter for a 10.6 km long retai- Australia In Sydney, our customer a grab mounted on a GB 46 base car-
ning wall to protect the ground-water. Civil Foundations deployed a BG 30 and rier to install barrettes in thicknesses of
The cutter the second of its kind be- a RG 25 S to construct a 640 mm thick up to 1,200 mm for the foundations of
gan work in the early Summer of 2012. CSM retaining wall for the underground what will be a 55-storey high-rise tower.
The rig, mounted on a MC 128 hydraulic parking garage of a shopping mall.
cable excavator with a 400 kW electric
motor, is able to cut trenches down to
a depth of 120 m. See also back cover.

China In Shenzen, our Chinese cus- USA In Houston, Texas, our customer
tomer Suifong Foundation deployed a RECON Remedial Construction is in-
BG 25 and a BG 30 to sink the foundati- stalling sheet pile wall sections. Prelimi-
on piles for the new police headquarters nary drilling is being carried out for the
down to depths of 27 m. The drilling was individual piles, which are being driven
executed in ultra-hard granite of 150 down to nal depth using a Pileco die-
MPa with specially designed roller bit sel hammer on a RG 20 S pile driving
core barrels. rig.
 The PremiumLine concept

Leading technology for speci-

alist foundation engineering
t the 2012 in-house exhibition

A Bauer Maschinen launched its

new ValueLine and Premium
Line concept for the BG drilling rig se-
ries. The ValueLine is optimized for kelly
drilling. The PremiumLine, as the name
suggests, is a high-end range incorporat-
ing multifunction rigs for a wide variety
of applications.
The range extends from the BG 12 up
to the BG 50. It enables all rotary drill-
ing techniques to be implemented, in-
cluding kelly drilling with and without a
casing oscillator, the classic CFA (Conti-
nuous Flight Auger) system and CCFA
(Cased Continuous Flight Auger) drilling,
as well as soil displacement pile drilling.
The rigs can also be exibly deployed The BG 42 on the Luise-Kiessel-
bach-Platz construction site in
for all kinds of soil improvement, such
Munich
as CSM (Cutter Soil Mixing) or depth
vibration. BC trench cutters can also
be attached to them. They can be used
to execute all commonly encountered
foundation engineering techniques, and
can be adapted to a wide variety of dif-
ferent soil types.
All PremiumLine rigs can be tted with
a Tier IV i engine conforming to the
highest exhaust emission standards,
though for all models intended to be
used in markets where emissions are
not regulated a standard Tier II or III
engine is available. The base carrier
units for the PremiumLine are specied
to attain the lowest noise emission
values in their class.
The main winches for the Premium
Line rigs feature high pulling forces and
wide drums. A drilling and pulling assist
function aids handling in Single pass
drilling operations. State-of-the-art elec-
tronic systems make the rigs easy to
control and highly responsive. The new with low wear. A tablet PC with built-in rigs enable operators to work in a stress-
Bauer B-Tronic generation 4.1 is an en- wireless functionality comes as stand- free environment, without becom-
hanced variant, featuring monitoring ard in the new PremiumLine cab. ing fatigued. A new cab design and
of the winch pull and hoisting speed, Safety features include anti-topple ergonomic layout provide the ideal de-
a torque indicator and error message guards, an integrated step-ladder up to gree of visibility for operators. This also
display as well as a diagnostic assist. the uppercarriage and handrails, as well includes cameras which enable proce-
The PremiumLine models are also as walk-on platforms on the uppercar- dures to be monitored on-screen. Rear-
equipped as standard with Bauer's kelly riage. The service hatches on the side of view cameras permit operators to mo-
visualization system, which provides the uppercarriage are of lift-up design. nitor the rear end and right-hand side
operators with full assistance to ensure Maximum attention was paid to ease of of the rig, and the main winch reel-in is
the kelly bar is operated optimally and handling and to health and safety. The likewise monitored by a camera.
 Lebanon Bauer Lebanon is const-
ructing one of the deepest excavation
pits in Beirut, extending to a depth of
30 m. The works include a bored pile
wall, as well as anchoring, grouting,
earthworks, soldier pile walling with
struts, and ground-water control. The
project is scheduled for completion in
January 2013. Below

Qatar In Doha, Bauer executed the excavation pit and foundations for a 2,400
space underground parking garage at the Souq Waqif along the Corniche Road. In
addition to 1,220 foundation piles, a secant bored pile wall was installed and tied
back with three layers of temporary anchors. Above

Saudi Arabia Bauer executed the

foundations for the Diamond Tower in
Jeddah. This involved installing 158 skin
grouted bored piles in 1,500 mm diame-
ter down to a depth of 40 m. The project
was executed in six months, completing
in May 2012. Above
Lebanon The Beb Bachoura site in the heart of Beirut's Central District will ul-
timately be a 13-storey building with an additional seven underground levels. For
the 22 m deep excavation pit Bauer constructed a bored pile wall comprising
3,150 lin.m of piling. The works also included shotcrete installation, soldier pile wal-
ling with struts, 7,500 m of anchoring and ground-water control. Above

Specialist foundation
engineering projects on
all continents
 Bauer International 31
The construction of a power station
in Abu Dhabi for the Emirates Alumi-
nium Company required soil improve-
ment measures. Bauer opted to install
60,000 m of vibro-cast-in-place columns
using four vibrator units. Below

UAE Bauer executed the foundations for the spectacular Nation Tower in the centre
of Abu Dhabi. The contract involved installing a secant bored pile wall with tie-back
anchoring as well as 84 bored piles in 900 mm diameter. Two BG 28 rigs were deploy-
ed on the job. Above

Bauer International carried out the specialist foundati-

on engineering works for the new electricity substation in
Abu Dhabi. In just four months, 211 lin.m of secant bored
pile wall with permanent anchors was installed for an 18 m
deep excavation pit. The work was carried out using three
BG 28 units and three Klemm anchor drilling rigs. Above

Bauer International was awarded the contract to execute an

excavation pit for the Residential Tower in Abu Dhabi. The pro-
ject involved installing 207 bored piles, a secant bored pile wall,
retained by 66 permanent anchors, as well as a soldier pile wall
with horizontal struts. Right

The Midein Umm Al Quwain

residential and business tow-
er block in Dubai was foun-
ded on 40 m deep piles of
1,200 mm diameter. Completi-
on of the project was delayed
owing to the serious nancial
crisis. Below
 Singapore For the Market Street To-
wer project, Bauer deployed as many
as four drilling rigs at a time to const-
ruct a secant pile wall for the excavati-
on pit and to install foundation piles in
3.50 m diameter. Above

Bhutan In the Kingdom of Bhutan, the 1200 MW "Punatsangchhu-1 HEP" diversi-

onary hydro-electric power station is currently under construction. The main dam is
being constructed in a 70 m deep inward-sloping pit on the adjacent rock face. The
upstream cofferdam is being sealed with a diaphragm retaining wall cut down to Australia The city of Brisbane is look-
depths of 90 m for the purpose. Above ing to ease its trafc congestion by con-
structing a 4.6 km tunnel. BAUER Foun-
dations Australia Pty Ltd was contracted
to install a secant pile wall with rock so-
cketing. Above

Thailand In Bangkok, 511 foundation

piles in differing diameters as well as
160 barrettes with depths of as much as
55 m were installed as part of works to
extend the Blue Line on the city's MRT
rapid transit system. Three BAUER BG 24
rigs and three hydraulic grabs worked on
the project for 16 months. Left
Malaysia Icon City in the Petaling Jaya district is set to
become a new landmark of Kuala Lumpur. Bauer Malaysia
executed the excavation pit and foundations. A total of 10 BG
rigs were deployed to install 1,283 bored piles. The works also
included 735 lin.m of diaphragm wall, 500 lin.m of sheet pile,
as well as earthworks. Right

Vietnam For No Bai Airport in Hanoi, Bauer Vietnam in-

stalled 250 bored piles under polymer support with differing
drilling diameters down to 38 m and up to 6 m rock socketing.
Below

Philippines In Davao City, Bauer is carrying out vibrocom-

paction work on contract from First Balfour Inc. Three rigs are
being used to compact 100,000 lin.m with a maximum depth
of 18 m. Above

Indonesia As part of the works to extend the port instal-

lations on Batam Island, Bauer Pratama Indonesia was con-
tracted to install 140 foundation piles. In the second phase
a quay is scheduled to be built in the form of a secant bored
pile wall. Below
34 Bauer International

Hungary Bauer executed the foun-

dations for the IKEA furniture store
in eastern Zagreb. The overall project
involved sinking nine core bores down
to 40 m, ve test piles, 46 CPT tests,
as well as geological surveying. Below

Turkey Marmaray is one of the biggest projects being undertaken by the Ministry
of Transportation in Istanbul. Bauer carried out grouting to secure the excavation
between two parallel-running tunnels. Above

Georgia In Anaklia, fully cased foun-

dation piles down to a depth of 15 m
were installed for a new police stati-
on. The work was carried out using a
BAUER BG 15. Below

Hungary Bauer installed parallel bored pile walls to act as a retaining dam be-
neath the rkd shopping centre in Budapest while the complex remained open for
business. Working under difcult conditions, horizontal and inclined anchors were
installed. The works also included the dewatering system and a nailed shotcrete
slope retention wall. Above

Bulgaria As part of the construction

works on the 173 km Struma Highway
from Soa to the Greek border, Bauer
Bulgaria was contracted to install 24 m
deep foundation piles for a bridge. Four
static pile load tests were carried out for
the purpose. Right
Russia For the new "Chodinskije Polje" metro station const-
ruction in Moscow, bored piles in 1,200 mm diameter were
installed down to a depth of 47 m in the rst quarter of 2012.
The work was carried out using two BAUER BG 40 rigs and a
BG 28. Above
Georgia Bauer Georgia Foundation was contracted to ex-
ecute bored piles under water load for a 28-storey building in
Batumi. The work was carried out using a BAUER BG 28 dril-
ling rig. Below
 Austria In the area of the Vienna
North railway station, near the Pra-
terstern, to secure a stretch of track a
200 m length of intermittent bored pile
wall down to a depth of 17 m was ins-
talled using the CFA method. The work
was carried out in July 2012 on contract
from the Austrian Railways Infrastruc-
ture division. Below

Austria In Innsbruck, developer Genz is constructing the Village Mhlau residenti-

al park. A total of 4,600 m of CFA piles were installed for the excavation pit retention
and foundations. The foundations for the area bordering the building were executed
under tight working conditions with 200 m of ductile piles. The work also involved
700 sqm of soil nailing. Above

Austria Bauer Austria executed the

foundations as part of the work to extend
the BWT facility in Mondsee on behalf
of contractor Kieninger Ges.m.b.H. The
work involved installing 2,000 m of cased
piles, 2,900 m of CFA piles and 9,000 m
of ductile piles. Below

Italy A collaboration between Bauer Umwelt and Bauer Spezialtiefbau Austria saw
replacement bores being executed to clear pollution on a former industrial site in
Milan. This prepared the site for redevelopment. Above

Netherlands In Heel, on the west

bank of the Maas, Bauer Funderings-
techniek installed 237 GEWI piles in
63.5 mm diameter and 17 m in length
working from a pontoon. Left
 Bauer International 47

Switzerland In Zurich City West, developer Swiss Life is

constructing the Zlly high-rise residential tower. The site of
the former distribution centre was found to be contaminated.
Bauer rst carried out replacement bores, then executed the
foundations for the new building with 58 bored piles. Above

Switzerland On behalf of Alp Transit Gotthard AG, Bauer

is installing 255 large bored piles in 1,200 mm diameter and
in lengths from 20 to 25 m for the foundations of the 1 km
long viaduct at the Camorino rail junction near Bellinzona. The
works are scheduled to run until July 2013. Above

UK In the heart of the city of London, on Liverpool Street,

Bauer faced a particularly tough challenge: to remove 24 bo-
red piles of a substantial 1,300 thickness and 35 m in length
from the ground. A specially developed drilling tool known as
an annulus cutter enabled the piles to be exposed and pulled
out. Left
48 Bauer International

USA The Center Hill Dam in Tennessee is in need of exten-

sive rehabilitation. Deep cracks and caverns have opened up
around the dam. A permanent solution involving retaining
walls is currently being installed. Above

Canada In Calgary, Alberta, Bauer Canada executed the

foundations for a natural gas power station. The main task was
to install 1,075 bored piles in 600 mm diameter and at depths
between 10 and 19.5 m. Above

Panama An articial island has been created in the Bay of

Panama. BAUER Fundaciones Panam S.A. is carrying out the
vibrocompaction work, executing some 12,800 compression
points with an average depth of 15 m in just four months. At
peak times, four deep vibrators are in operation simultaneous-
ly. Above

Colombia In Medellin, Bauer Fundaciones Colombia was

contracted to execute shafts to retain contaminated water.
The work, involving the installation of a diaphragm wall, was
carried out using a rope grab. Left
 "Schrobenhausener Tage" conference 2012
"Innovation is the key"
presentation on construction
A techniques is not exactly thrilling,
but it can be highly interesting
and not just for industry specialists. The
fact was indicated by the "Schrobenhau-
sener Tage" event held at the Bauer confe-
rence centre in May 2012. Some 600 peo-
ple attended the series of presentations.
And as host Walter Haus pointed out, the
key theme yet again was "Innovation".
Peter Teschemacher, Managing Direc-
tor of Bauer Spezialtiefbau, reported on
Bauer construction companies around
the world which had suffered a number
of setbacks during 2011. The pro-democ-
racy demonstrations in Egypt and Libya
brought a number of major construction
sites to a standstill. The nuclear accident
in Fukushima, Japan, is at least likely to
have some positive effects, in that the
resultant reversal of energy policy in
Germany will give rise to new construc-
tion projects.
Many of those attending found the pre-
sentation by Yvonne Ainsworth particu-
larly striking. The manager of Bauer's
projects on the London underground
spoke about "extreme production tol-
erances". And "extreme" was certain-
ly a recurring theme. She detailed the
extremely tight working conditions, the
extreme safety constraints, extremes
of load-bearing capacity, and extreme
tolerances. She highlighted the extreme
accuracy down to the centimetre and
even millimetre with which the steels
used for reinforcement cages have to
be gauged so that the concrete pen-
etrates into all the gaps.
Andreas Bugiel presented a prestigious
project in Duisburg harbour: the future
State Archive of North Rhine-Westphalia.
He set forth all the difculties encoun-
tered, including unfavourable ground
conditions, tight scheduling, ooding, and
special proposals and substitute procedu-
res for which machinery had to be held
in reserve. Tender engineer Stefan Jger
gave a presentation detailing the rein-
forcement works on the Sylvenstein dam
in Bavaria. See also the report on page 20.
Bauer Spezialtiefbau director Harald
Heinzelmann, head of the Bauer Re-
search Board, presented a talk on tech-
nical possibilities. Based on the motto
"Good is not good enough forever", he
explained why innovation is a never-
ending process for Bauer. The necessity
for research was stressed by Thomas
Boeck in his presentation on "Silica gel
for environmentally friendly building."
Taking a historical view, he recalled how
Bauer's successful soft gel blanket had
been banned in Berlin in the late 1990s,
forcing the company to rethink its re-
search. It was, after all, vital to provide
Hans-Joachim Bliss, second from left, hosted some 70 visitors at the parallel-running
"Schrobenhausener Tage" conference event held in English.
horizontal sealing in excavation pits. This
led to the creation of the new, environ-
mentally friendly technique, which was
subsequently approved by the construc-
tion supervisory authorities.
Andr Seidel highlighted how quality as-
surance is the key to success in the MIP
(Mixed-in-Place) technique as in all other
areas. He also pointed up the necessity
for accurate, detailed data acquisition
and evaluation. Martin Heinrich gave a
presentation on the execution of a pro-
ject in Alsace, on the border between
France and Germany, detailing the lead-
ing-edge technology which had to be
Peter Teschemacher
applied in order to regain control of the
seepage water from a dam by means of
a MIP retaining wall.
Project manager Paul Scheller report-
ed on a special technical success. In
Summer 2011, mono-pile foundations
for a tidal turbine were successfully in-
stalled in a test area on the sea bed off
the coast of northern Scotland. Bauer
Maschinen had developed an entirely
new underwater drilling rig in just a few
months, and the foundation works were
subsequently carried out by Bauer Spe-
zialtiefbau. The 23 metre long, 2 metre
diameter mono-pile was grouted into an
11 metre deep rock socket with high-
strength mortar. Working from a special
ship tted out with electronically cont-
rolled engines capable of holding its po-
sition even in rough seas, the pile was
installed in a single operation.
The specialists from BAUER Resources
GmbH gave presentations on environ-
mental technology, well engineering and
mining. Wilfried Haarman presented
new potential applications for glass-rein-
forced plastic (GRP) pipes. The corrosi-
on-proof pipes are ideal for use in the oil
and gas and geothermal energy sectors.
Dr. Uwe Schlenker revealed how a reed-
bed treatment plant previously thought
of as a stationary installation can be
quickly and successfully turned into a
mobile, temporary facility, such as for a
hotel. Holger Itzeck, from Bauer Resour-
ces in Canada, reported on the response
to a geological emergency. A slope had
slipped at the open-cast Highland Val-
ley Copper mine. The site, at one of the
world's biggest copper mines, was sta-
bilized by installing vertical drains using
a BG 36.
The "Schrobenhausener Tage" confe-
rence event ran concurrently with the
Bauer Maschinen in-house exhibition. In
his presentation, Managing Director Die-
ter Stetter set forth the detail features of
the new developments on show.
 Resources
a multi-faceted segment

In Tulves in the Alto Adige (South Tyrol)

region of northern Italy, Foralith is drill-
ing to survey the geology of the Brenner
base tunnel. Above

In the town of Nortorf in Schleswig-Hol-

stein, the site of a former gasworks was
remediated. Above

A seepage water plant was construc-

ted for the Gallenbach landll site near
Augsburg. Pictured: the audit in front of
the plant. Right
 Bauer Resources 41
The purpose of the Disi Amman project
is to supply water to the Jordanian cap-
ital Amman. To that end, Resources
unit Site Group is drilling 55 ground-
water wells, as well as additional con-
trol wells down to a depth of 600 m.
Below

Bauer Umwelt is remediating the 160,000 sqm site of a former oil renery on behalf
of the municipality of Wedel. The key task is to excavate 75,000 cbm of contamina-
ted soil, down to a depth of 4 m in places. Above

At the Biswurm incinerator site in Vil-

lingen-Schwenningen during the peri-
od from 1960 to 1974 cable insulation
and solvent residues were incinerated,
contaminating the ground. Bauer Um-
welt is now carrying out remediation
work applying a vapour-air inltration
(VAI) system. Below

Esau & Hueber installed a fully automated stainless steel brewhouse at the
Belhaven brewery in Dunbar. This increased the annual production capacity of
Scotland's largest ale brewery by 50 %, while at the same time cutting its energy
costs. Above

Bauer Water has developed a mobile

decontamination plant to handle Natu-
rally Occurring Radioactive Materials
(NORM). The plant cleans contami-
nated casings from the oil and gas in-
dustry ready for re-use. Right
42
Safety first!
t's all about taking responsibility: Heinz
I Kaltenecker, responsible for HSE on
the Management Board of BAUER AG,
explains the company's recent reorganiza-
tion: "Everything that we previously often
designated merely under the umbrella
term "Safety" has now been incorpo-
rated into a comprehensive, unied HSE
(Health, Safety, Environment) system. A
key aspect which we are currently rolling
out worldwide throughout the Group is
the fundamental policy principle that all
persons in positions of authority must
YOUR SAFETY
IS IN YOUR HANDS
WORK
SAFELY
TODAY
ensure that staff and visitors in the areas
for which they are responsible do not suffer
any harm to their health or accidents, and
that protection of the environment must
also be an integral element of all related
measures." Under Heinz Kaltenecker the
HSE department, headed by Florian Dau-
benmerkl, has been strengthened with
additional personnel. The BAUER Group's
HSE team includes Stephan Walter, who
is responsible for Bauer Maschinen, and
Frank Jakob, responsible for the con-
struction sites of Bauer Spezialtiefbau.
The international projects of the Con-
struction segment are the responsibility of
John Holland. Dr. Edzard Peters is head of
HSE and Quality for Bauer Resources. The
basic requirement underlying the concept
is that everyone should take personal re-
sponsibility for HSE on an individual level.
That begins with the senior management
of each Group company implementing
efcient HSE systems, and extends to
the individual employees checking their
working environments for potential HSE
hazards prior to starting work. A key pillar
of the HSE system is personal protective
equipment (PPE). It not only provides pro-
tection against injury, but wearing it also
sends out a signal, demonstrating the
individual's awareness of HSE as an inte-
gral part of the corporate culture. Stand-
ardized HSE procedures help in potentially
dangerous situations, such as when ope-
rating electrical systems or construction
LUCKY HANDS ARE WELL
PROTECTED!
KEEP YOUR HANDS SAFE
machinery, dealing with waste and emis-
sions, and handling chemicals. In order to
boost awareness of the relevant issues,
a series of posters have been developed
and put up in many locations throughout
the company reminding everyone of the
need to comply with HSE procedures. The
safety of visitors is also the responsibility
of the company personnel hosting them.
All visitors to construction sites or ma-
chine factory premises are briefed on the
relevant safety rules, provided with appro-
priate personal protective equipment and
advised of emergency escape routes and
assembly points. All plants locations have
extensive safety clothing equipment, in-
cluding goggles, shoe safety caps, high-
visibility jackets and helmets, to kit out
even large visitor groups accordingly.
he question of energy supply is,
T and will remain, a key issue for the
global economy. Rising demand
makes it essential to sustain and con-
tinually advance scientic research.
This includes increasing the amount
of energy generated from renewable
sources as well as exploring and extrac-
ting the enormous energy resources to
be found underground. New technical
possibilities have opened up in these
elds over recent years enabling pre-
viously insurmountable problems to be
overcome.
Geothermal energy
In some countries there are water-
bearing horizons at depths of 1,000 to
4,000 metres where the ground-water
is heated to above 100 degrees Celsius
solely by the Earth's naturally gener-
ated geothermal energy. This hot water
can be used to generate power or for
distant heating systems. This kind of
geology is to be found to the south and
south-east of Munich and in northern
Germany, as well as in countries such
as Turkey, Iceland and Indonesia.
Oil and gas
The extraction of oil and gas from below
ground has been carried out in its tra-
ditional forms over recent decades, yet
such methods have to date yielded just
20 to 30 percent from the easily acces-
sible sources. As oil and gas prices rise,
it makes sense to drill in much tighter
grids in order to exploit the existing de-
posits more efciently.
Entirely new mining methods are today
enabling oil and gas to also be extract-
ed from rock, so opening up new pro-
spects in terms of usable raw material
resources. However, mining in such
areas demands much more drilling and
more technical effort and expense to re-
lease the hydrocarbons than in the case
of conventional methods.
Gas from coal seams
In many countries around the world it
is possible to extract the gas continu-
ally being produced by coal from under-
ground seams. Relatively small quanti-
ties are extracted, though over a long
period of time, so power stations can
be run continuously.

Deep drilling
All these advances will in future create
a strong market for drilling rigs capable
of reaching great depths. Based on its
extensive know-how in drilling in the
specialist foundation engineering and
well engineering sectors, ve years ago
Bauer decided to start developing and
marketing special drilling rigs for deep
applications. The Bauer Deep Drilling
department was born.
Bauer deep drilling concepts
Subsequently the rst deep drilling rig,
the TBA 300, capable of drilling down
to depths of around 5,000 metres, was
developed. Since deep drilling rig cus-
tomers impose the highest demands
in terms of functional safety, an exten-
A new market
sive testing and trialling programme
was undertaken prior to launching the
rig. At the Bauer site in Edelshausen a
1,500 metre deep bore was sunk, and
over a period of many months all the
rig functions were tested in detail. This
deep bore thus also provided a test bed
for future developments extending well
beyond the conventional standard. The
test bore is also made available to ex-
ternal partners wishing to conduct trials.
The rst Bauer deep drilling rig was
sold to Venezuela, and is now opera-
ting successfully. The range has since
been extended with higher and lower
end models. The TBA 200 is a smal-
ler version, capable of drilling down to
3,000 metres. The TBA 100 was desi-
gned as a highly mobile rig for depths
down to around 2,000 metres. A tech-
nical interlinking of the feed mechanism
and winch turned the TBA 300 into a
TBA 440. A new TBA 440 M2 with an
automated pipe handler for duplex
strings is currently under construction.
When this rig series was launched, it
was found that the selling process is
lengthier and very much more time-
consuming than for other categories
of machine. One reason for this is that
the markets are quite diverse in terms
of the technology being used: On the
one hand, the oil and gas industry pri-
marily employs older rigs which no
longer fully conform to state-of-the-art
safety standards; on the other hand,
potential customers are still unaccusto-
med to high levels of automation. This
makes it difcult to sell. It takes a lot of
time to clarify all the essential details,
and customers also take more time to
make such decisions than Bauer's sales
teams are used to from the specialist
foundation engineering market. Con-
sequently, sales of deep drilling rigs in
this start-up phase have to date not yet
been satisfactory.
Based on the sale of the rst deep drill-
ing rig to Venezuela, followed by six of
the smaller TBA 100 rigs to China (whe-
re they are marketed as the RB 90 for
mine recovery applications) as well as
the many interesting customer con-
tacts established, the management is
optimistic about future prospects.
Imprint
Published by: BAUER AG
86522 Schrobenhausen, Germany
Phone: +49 8252 97-0, Fax: 97-1359
E-mail: redaktion@bauer.de
November 2012 BAUER REVIEW
Published once a year
Responsible for content and editorial:
Prof. Thomas Bauer, Franz J. Mayer, Ruth Wallner
Layout: www.winfried-moser.de
Typesetting: BAUER AG, Media Design
Photos: F. J. Mayer, R. Wallner, W. Moser, P. and
S. Teschemacher, F. Bauer, A. Christa, M. Adnan,
H. Schwarzweller, I. Cullen and other BAUER
Group staff, Bauer Archive, Getty Images
Front cover: Schlosslnde construction site
in Ingolstadt
Back: Vattenfall trench cutter, see also page 28
Printed by: Kastner AG, Wolnzach
www.bauer.de