Research and development

We develope for the future

The continuous development of our technical know-how is one of our most important success factors. Novel manufacturing methods and construction systems are developed at an early stage to optimize construction sites.

Concrete platform and innovations
Together with the Danish company Per Aarsleff A/S we developed a concrete platform for the transition piece. The advantage: Lower maintenance intensity compared to a steel platform. The transition sections of the Horns Rev 2 and London Array offshore wind farms are already equipped with these concrete platforms. We have significant patents on installation methods and the use of innovative materials. With our know-how we develop innovative installation methods in order to be able to offer adequate solutions for future challenges.

direct drilling method
An innovative system was developed for the low-vibration production of combined sheet pile walls, whereby the supporting elements can be directly drilled in with locks. With the use of this system, the extensive preparatory work required for the low-noise and vibration-free installation of combined sheet piling in the drilling process can be saved. The elimination of pre-drilling, the associated drawing process of the casing and the filling process of the intermediate space also offers an immense advantage with regard to possible deformations in the existing structure.

A current focal point is sound insulation during installation work on pile foundations and sheet piling. A special soundproof chimney was developed for this purpose. Optimally developed pile systems are essential for the implementation of complex foundations. Within the framework of various construction projects, special constructions were developed for this purpose. These include, for example, patented processes for the production of buckling resistant vibration injection piles and high-load-bearing tubular pile foundations.

anchor structures
The use of underwater anchoring structures is one way of making optimum use of sheet piling structures. Especially in Scandinavia and the Baltic States these horizontal anchors are used. In order to avoid this extensive work, it was possible to design and apply for a patent for an underwater anchor to be manufactured without the use of divers.

vibro piling
In cooperation with an international consortium of energy suppliers, the horizontal load-bearing capacity of driven and vibrated foundation piles was investigated in two test projects in Cuxhaven and Rödby (Denmark). In addition to installing the foundation elements, including the world's most powerful vibrator, a horizontal test load device loaded with 20MN was designed.

Innovative solutions

Exceptional challenges require special solutions. We are known for unique new construction methods and ideas - if necessary we do not use standard solutions, but combine different techniques, make new inventions (as our patents prove) and develop tailor-made special solutions.

Protection shield for the Elbe tunnel

The fairway of the Elbe was deepened more and more. To prevent dragging anchors from damaging the Elbe tunnel, a protective structure had to be built for the Elbe tunnel. The construction work in this special, sensitive environment required extreme precision. To secure the Elbe tunnel, 6 m long sheet piling was installed on both sides of the lowered tunnel elements. Between the sheet pile walls projecting approx. 1.50 m above the upper edge of the tunnel, an 80 cm thick protective layer of metallurgical slag was placed, which was still clamped with Colcrete mortar. Technical management Bilfinger Construction GmbH, Partner Heinrich Hirdes GmbH - Client: Free and Hanseatic City of Hamburg.

During the entire construction period, shipping traffic in the area of the New Elbe Tunnel had to be maintained without disruption at all times.

20 meters depth, 0.20 meters visibility, 3 knots flow velocity - the tolerance for threading in the sheet piles is max. 2 cm. Working only possible in daylight. At night, the jack-up platform must leave the construction site and find the exact position where the last screed was driven under water the next day!

Work from a jack-up platform - a fixed platform that stands still and is not exposed to waves, currents and the tidal range. On the island: ramming excavator that brings in the sheet piles under water, guided by a leader.

To find the exact position a DGPS equipment with inclinometer was installed on the leader and software was used which was specially developed for this construction site. Satellite technology is used in the search for the original driving point. The pile driving of the sheet piles is coordinated by DGPS (Differential Global Positioning). A variant of satellite navigation in which several satellites and a reference transmitter on land are used for exact positioning.