Introduction of world construction methods and trends
Franz-Werner Gerressen,
Head of Method Development,
Tokyo, 2017-11-29

1Introduction of world construction methods and trends
Outline• Single Pass Piling - Looking for faster pile installation• Cutter Soil Mixing - Aiming for increasing depth achievements• Ground Improvement - Known techniques, further improvements• Automatization – Relieving the operator, achieving constant quality© BAUER Maschinen GmbH, D-86529 Schrobenhausen2Introduction of world construction methods and trends
Outline• Single Pass Piling - Looking for faster pile installation• Cutter Soil Mixing - Aiming for increasing depth achievements• Ground Improvement - Known techniques, further improvements• Automatization – Relieving the operator, achieving constant quality© BAUER Maschinen GmbH, D-86529 Schrobenhausen

3Classification
ProductionMulti Pass•••••

Bigger Depth
Bigger Diameter
Big Variety of Tools
Very flexible
Higher Operator QualificationnecessarySingle Pass•
••

•

Kelly

Higher Performance
Higher Automation Level possible
High Level necessary:• Jobsite Logistics• Concrete Quality• Reinforcement Design
Additional Equipment (Pump, AugerCleaner, Vibrator …)

Kelly + BTM
CCFA
Kelly + BV

FDP + Lost Bit
CFA© BAUER Maschinen GmbH, D-86529 Schrobenhausen

4Drilling Method
CFAIn CFA, a continuous flight auger with hollow stem isscrewed into the soil with controlled penetration rate.

After reaching the final depth, concrete is pumped
through the hollow stem with constant pressureduring pulling.

Finally the reinforcement cage is installed to desired
depth into the fresh concrete.

© BAUER Maschinen GmbH, D-86529 Schrobenhausen

5Drilling Method
CFASidewall support is done by the cuttings on theflights as well as by the pumped concrete.
The RPM to penetration rate is essential, to avoid
side wall erosion or cork screw effect.

Geology:• Shear resistance: cu > 15 kN/m²• No boulders• cohesive, non-granular soils
Usage:• Foundation• Pile walls (restricted)© BAUER Maschinen GmbH, D-86529 Schrobenhausen

6Drilling Method
CFA

Drilling
down

Extending

Drilling to
final depth

Concreting

Reinforcing
w/ vibrator© BAUER Maschinen GmbH, D-86529 Schrobenhausen

7Drilling Method
CCFA (FoW, CCFA-BTM)© BAUER Maschinen GmbH, D-86529 Schrobenhausen

8Drilling Method
CCFA (FoW, CCFA-BTM)
Two counter-rotating rotary's drive auger and casing.
The auger can be moved relatively to the casing.
Sidewall support by the casing as well as by thepumped concrete.
The vertical accuracy is enhanced due to thestiffness of the drill string.
Geology:• UCS < 20 MPa• No boulders• Cohesive, non-granular soils• Conveying can be improved with pressurized
airUsage:• Foundation• Pile wall, secant/tangent© BAUER Maschinen GmbH, D-86529 Schrobenhausen

9Drilling Method
CCFA (FoW, CCFA-BTM)

Setup

Drilling tofinal depth

Concreting

Emptying ofdrill string

Reinforcing
w/ vibrator© BAUER Maschinen GmbH, D-86529 Schrobenhausen

10Drilling Method
FDP© BAUER Maschinen GmbH, D-86529 Schrobenhausen

11Drilling Method
FDP - General
The loosened material is pushed into the side walls anddensified by the displacement body.
This effect leads to an increase in shaft friction and resulting
bearing capacity.
Additional advantages:• Minimized spoil• Reduced concrete overconsumption• Vibration freeGeology:• Displaceable soils• SPT N30 < 30 or CPT < 10 MPa• Non displaceable layers < 1.5 m• Socketing depth can be increased w/ auger
extensions
Usage:• Foundation© BAUER Maschinen GmbH, D-86529 Schrobenhausen

12Drilling Method
FDP - Standard

Drilling
down

Extending

Drilling to
final depth

Concreting

Reinforcing
w/ vibrator© BAUER Maschinen GmbH, D-86529 Schrobenhausen

13Drilling Method
FDP - LostBit

Setup

Drilling

Drilling to
final depth

Reinforcing

Concreting© BAUER Maschinen GmbH, D-86529 Schrobenhausen

14Introduction of world construction methods and trends
Outline• Single Pass Piling - Looking for faster pile installation• Cutter Soil Mixing - Aiming for increasing depth achievements• Ground Improvement - Known techniques, further improvements• Automatization – Relieving the operator, achieving constant quality© BAUER Maschinen GmbH, D-86529 Schrobenhausen

15

Cutter Soil Mixing
Improvement in Depth Achievement - World Record Mixing Depth

Symmetric mixing wheels

Double cutter teeth© BAUER Maschinen GmbH, D-86529 Schrobenhausen

16Cutter Soil Mixing
Improvement in Depth Achievement - World Record Mixing Depth
project:

Eureka, California, USA; round retaining / cut-off wall for dismantlingof the Humboldt Bay Nuclear Power Plant

machine: BG 50 + BCM 10, BG 40 + BCM 10

reactor© BAUER Maschinen GmbH, D-86529 Schrobenhausen

17Cutter Soil Mixing
Improvement in Depth Achievement - World Record Mixing Depth

mixing depth:max. 53 m

method:2-Phase5 overlapping
CSM rings
reactor(has to bedismantled )36.5 m1000 mmmax. 53 m

mixing width:

retainingwall function

cut-off wall
functionclay© BAUER Maschinen GmbH, D-86529 Schrobenhausen

18

Cutter Soil Mixing
Improvement in Depth Achievement - World Record Mixing Depth© BAUER Maschinen GmbH, D-86529 Schrobenhausen

19Cutter Soil Mixing
Improvement in Depth Achievement - World Record Mixing Depth
project:

Shanghai, China; installation of 3 test panels with 80 m depth

machine:
MC 64 +
TandemCuter(BCM 10)© BAUER Maschinen GmbH, D-86529 Schrobenhausen

20Cutter Soil Mixing
Improvement in Depth Achievement - World Record Mixing Depth
mixing width:

1200 mmmixing depth:

80.11 mprocedure:

2-Phase; fresh-in-hard with 30 cm overcut© BAUER Maschinen GmbH, D-86529 Schrobenhausen

21Introduction of world construction methods and trends
Outline• Single Pass Piling - Looking for faster pile installation• Cutter Soil Mixing - Aiming for increasing depth achievements• Ground Improvement - Known techniques, further improvements• Automatization – Relieving the operator, achieving constant quality© BAUER Maschinen GmbH, D-86529 Schrobenhausen

22Ground Improvement
Soil Conditions
ClaySilt

SandGravel

Stone

Dynamic Compaction

10
Vibrodisplacement
20

Cohesive soil30

Vibroflotation

Granular soil4050 Depth© BAUER Maschinen GmbH, D-86529 Schrobenhausen

23Ground Improvement
Bauer Dynamic Compaction• By drop weight in granular, non-cohesive soil
• Improvement depth up to 12 meter

Depth [m]qc [MPa]

Treatment depth
It can be estimated using the following formula
𝑫𝑫𝑫𝑫𝑫𝑫𝑫𝑫𝑫𝑫 𝒎𝒎 = 𝒂𝒂 𝒙𝒙 (𝑾𝑾𝒙𝒙 𝑯𝑯)

𝒂𝒂 = 𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄 𝒇𝒇𝒇𝒇𝒇𝒇𝒇𝒇𝒇𝒇𝒇𝒇 𝟎𝟎. 𝟑𝟑 … 𝟎𝟎. 𝟔𝟔

𝑾𝑾 = 𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅 𝒘𝒘𝒘𝒘𝒘𝒘𝒘𝒘𝒘𝒘𝒘𝒘 [𝒕𝒕𝒕𝒕]
𝑯𝑯 = 𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅 𝒉𝒉𝒉𝒉𝒉𝒉𝒉𝒉𝒉𝒉𝒉𝒉 [𝒎𝒎]

© BAUER Maschinen GmbH, D-86529 Schrobenhausen

24Ground Improvement
Bauer Dynamic Compaction
Applicable in:• Loose, non-cohesive soils• Landfill deposits• Special wastes••••

Pounder weights range from 6 - 40 tons
Drop heights range from 10 - 30 meter
Backfill material 2 - 200 mm
Automatic quality control (drops, energy)© BAUER Maschinen GmbH, D-86529 Schrobenhausen

25Ground Improvement
Vibrodisplacement - Bauer Flying Vibro© BAUER Maschinen GmbH, D-86529 Schrobenhausen

26Ground Improvement
Vibrodisplacement - Bauer Flying Vibro• Penetration depth up to 35 m (MC 96)• Column diameter 900 mm - 1200 mm• Dual material tube
• Hydraulically powered by base unit
• Quality control by B-Tronic• Additional winch for material hopper© BAUER Maschinen GmbH, D-86529 Schrobenhausen

27Introduction of world construction methods and trends
Outline• Single Pass Piling - Looking for faster pile installation• Cutter Soil Mixing - Aiming for increasing depth achievements• Ground Improvement - Known techniques, further improvements• Automatization – Relieving the operator, achieving constant quality© BAUER Maschinen GmbH, D-86529 Schrobenhausen28

Automatization
Relieving the operator, achieving constant quality

Assistance systems at BAUER
Advantages of assistance systems-Eases work for operator
Helps prevent operating errors
Increases drilling performance through quick control processes
Reduces the wear (of the machine and the drilling tool) and protects the machine
Reduces dependence of the drilling performance and production quality on
qualification and condition of the operator on that day© BAUER Maschinen GmbH, D-86529 Schrobenhausen29Automatization
Relieving the operator, achieving constant quality
Available assistance systems
Over 20 different
assistance systems
are used inBAUER machines© BAUER Maschinen GmbH, D-86529 Schrobenhausen30Automatization
Relieving the operator, achieving constant quality

Adaptive Kelly Speed AssistantInitial situation – kelly drilling:- Reduction of the winch speed at the transitions during extension and retractionof single kelly sections, in order to protect the material- Reduction of the winch speed before ground contact, so that the drilling tool is notdamaged- Monitoring during retraction, that the kelly bar does not get locked accidentally- Direct stop in case of a fault- The deeper the borehole, the more active control and monitoring is needed

The adaptive Kelly Speed Assistantautomates the controlledextension and retraction of the kelly sections© BAUER Maschinen GmbH, D-86529 Schrobenhausen

31Automatization
Relieving the operator, achieving constant quality

Adaptive Kelly Speed AssistantCustomer benefits:- Reduction of wear and damage prevention,- since operation is always with material-friendly, optimum, controlled winchspeeds- since the last depth is reached at a reduced speed- Increase in drilling performance,- since work is carried out at a constant, optimum speed the entire day- since speed control during the lowering process (in slurry-supported boreholes)
prevents slack rope.

- Damage prevention- since pulling up of a locked kelly bar is prevented.
- since the risk of the kelly bar falling is eliminated© BAUER Maschinen GmbH, D-86529 Schrobenhausen32Automatization
Relieving the operator, achieving constant quality
Operating screen for satellite based positioning© BAUER Maschinen GmbH, D-86529 Schrobenhausen

33

AutomatizationRelieving the operator, achieving constant quality
Exemplary B-Tronic display - drilling assistance for single pass method

Penetration
speedm/min

Definedpenetration
rate during
drilling
Actualpenetration ratemm/U
Torque %© BAUER Maschinen GmbH, D-86529 Schrobenhausen34

Automatization
Relieving the operator, achieving constant quality
Exemplary B-Tronic display during the concreting process in automatic
extraction mode

© BAUER Maschinen GmbH, D-86529 Schrobenhausen

35Introduction of world construction methods and trends

Franz-Werner Gerressen,
Head of Method Development,
Tokyo, 2017-11-29