HIGH VOLTAGEPOWER STATION BUILT ON THE MUR

SPECIAL TRIPRAILCAR IN CLIMATE TEST

MEGA-SIZEASSEMBLY UNIT FOR

TURBO GENERATORS CONSTRUCTED

PHOTO: MARKUS LACKNER

REPORTAGE:TRANSPORTING AN AUTOCLAVE

03 NEWSLatest news from Felbermayr Holding

TRANSPORT &08 LIFTING TECHNOLOGY

Overland rail with 140-tonne cargo

10 TRANSPORTSPMT for supporting structure in use LIFTING11 TECHNOLOGYCrane trolley installed

12 IN PICTURESLifting the turbines for the Niklasdorf powerstation into place

CIVIL14 ENGINEERINGConstructing a power station in Niklasdorf

STRUCTURAL16 ENGINEERINGAssembly unit built

TRANSPORT &18 LIFTING TECHNOLOGY

Dry run for the 2014 Winter Olympic Games

20 BAUTRANSRostrum trailer in action

21 SARENOQuality is catching on

22 PORTRAITModel maker Walter Ludl

23 PERSONNELPromotions, new faces and retirees

Page 8:Transporting a hot-air oven

Page 14:Power station construction

Page 18: A colossus on rails

INFORMER2

Contents

Now, as you sit and read the tenth issueof Informer that lies before you, we cansay that 2012 has got off to an expansiveand innovative start for Felbermayr. Thebiggest change has been to fully acquirethe operational activities of the formerReinhold Meister Group, whose head-quarters are in Deggendorf. By doingthis, we have significantly expanded ourhydraulic engineering transport fleet aswell as our services for investigating andclearing arms and munitions, environ-mental engineering and landfill construc-

tion. In hydraulic engineering, we havebecome a major player in European in-land waterways. Our sincere thanks goto more than 230 employees and themanagement of the former MeisterGroup who have placed their trust in ourability to work together successfully. Inaddition, a European telematics systemfor our fleet management of long-dis-tance traffic was successfully launched.It is used to guarantee the best possibletransparency for our customers in termsof scheduling. This includes a special re-

porting system that significantly reducesbureaucracy. The cost-saving potentialassociated with this is both significantand necessary.

But where will we be after a further tenissues of Informer? Herein lies the prom-ise of future development. We are ea-gerly awaiting these future challenges,even if this will take great effort.

With this in mind, we wish you a wonder-ful, relaxing summer.

Dear readers,

Horst Felbermayr

Yours sincerely,

Horst Felbermayr DI

We’re expanding!We’re expanding!

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IN ONE STROKEExcavator tour with Horst Felix

Dredging work on the Main-Donau canal has required the massive deployment of ma-chinery from the Felbermayr department of hydraulic engineering. The use of the heavy-goods vessel Horst Felix enabled several tonnes of machinery to be transported to thesite in a single delivery. A barge was also coupled to the Horst Felix, meaning that therewas no need for an additional motor boat. The construction sites for the job, which ranfrom January to March, were the approach areas to the weirs at Kelheim and Rieden-

burg. In order to continue guaranteeing the required queueing system forshipping traffic, 65,000 tonnes of material were dredged, most of

which was utilised at surrounding depots and agricul-tural areas.

GIANTLinz columns completed

With a length of 71.5 metres and a total diameter of 3.9 metres, the columns produced by BIS VAM Anlagentechnik are among the largestever manufactured in the Felbermayr assembly units in Linz. Following raw production in the halls, the five columns, each weighing ninetytonnes, were transferred to the self-propelled transporter by indoor crane. They were then transported to the open-air storage areas sev-eral hundred metres away, where the final surface treatment was performed by the contractor company. In mid-May, the columns weretransferred to ships in the Felbermayr heavy load port, from where they were transported to their end destination in the United States ofAmerica. The geographical proximity of the Felbermayr manufacturing and warehouse halls and the heavy load port made it possible toprocess the order with the maximum possible cost efficiency for the customer.

SUCCESSFELBERMAYRSPONSORS SWIMMERS

Upper Austria’s successful swimming cham-pions look forward to breeding more suc-cess. Rest days are off the agenda for JördisSteinegger as she can be found poundingthe lengths in the pool at the Linz Guglsports complex seven days a week in prepa-ration for the London Olympics. Meanwhile18-year-old Christina Strigl’s training is notrunning ideally over the 50 m breaststroke.The multiple youth and junior national cham-pion missed the qualifying time for the Eu-ropean Long Course Championships by thesmallest margin of one hundredth of a sec-ond, thus also shattering her Olympic hopes– sufficient, however, to be crowned na-tional champion. Incidentally, Steinegger,who already booked her Olympic berth atlast year’s world swimming championshipsin Shanghai, has no fewer than 87 Austriannational titles to her name. Whether she hasalso managed to swim her way into themedals in the Olympic Games is not knownat the time of publication.

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EXPANSIVEFelbermayr expandsconstruction services

In March 2012, Felbermayr acquiredthe operational areas and equipmentof the Reinhold Meister group, whichhas its headquarters in Hengersberg,near Deggendorf. With this acquisition,Felbermayr is expanding its range ofservices in Germany with the additionof water and landfill construction, aswell as weapons clearance and explo-ration. The move has secured the jobsof 200 employees of the insolventMeister group. The companies arenow trading under Reinhold MeisterWasserbau GmbH, Müsing WasserbauGmbH, HAGN Umwelttechnik GmbHand Müsing KampfmittelräumungGmbH. Reinhold Meister Wasserbau isheadquartered in Hengersberg. Thecompanies Müsing Wasserbau andMüsing Kampfmittelräumung arebased in Bernau, while HAGN Umwelt-technik is based in Olching.

COMMISSIONINGSpecialised Civil Engineering in water

Extreme accuracy is the order of the day in the deployment of the two stilt-mounted pon-toons Barbara and Milena. Around 600 anchors are in use, each with a load-bearing ca-pacity of seventy tonnes. The reason for these pontoons is the basic commissioning ofthe ship lock system at the Kachlet power station in Passau. Special features of this jobinclude the extremely hard stone that must be drilled though, but also the fact that thedrilling machinery is located on the ships, which have to maintain their position withinjust a few centimetres despite the fluctuating water level, in order to ensure accuratedrilling. This is achieved by the »lifting piles« of the stilt-mounted pontoon.

HIGH PRESSURETRANSPORT OF PRESSED PARTS

A total of ten special and heavy transports were required for the delivery of pressed parts forthe »Voestalpine prefabrication« project. The first transports had already been delivered andpositioned in mid-November last year. All work involved in the general assembly of the presswas completed at the end of December. The project, run by Felbermayr subsidiary Wimmerin cooperation with Felbermayr Transport and Lifting Technology, was initiated in the plant ofpress manufacturer Schnupp in Lower Bavaria. Here the components, weighing up to85 tonnes, were loaded onto the low-loaders using hydraulic lifting gear and an indoor crane.

NEWS

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WIND POWERLarge crane in usearound Europe

This year, Felbermayr Transport andLifting Technology will constructaround 300 plants. This representsmore than double the number of ordersfrom the previous year. These plantswill mostly be constructed in Germany,Austria, Romania and the Ukraine. As aresult of this order influx, we have alsoadapted our vehicle fleet accordingly:Our range of new purchases also in-cludes six large cranes with maximumload capacities of up to 600 tonnes.Felbermayr Lifting Technology cur-rently has over 400 cranes in use.

ACTIVE SAFETY DAYEvent for the promotion of occupational health and safety

In close collaboration with HSEQ managers from the BISgroup, BIS-Gerätetechnik and Felbermayr Lifting Tech-

nology together held an »active safety day« at the start of Feb-ruary. Almost eighty people from leading companies in the

areas of mechanical engineering, equipment technology, and in-dustrial plant construction participated in the event, which took

place at six different stations. In addition to employees of FelbermayrLifting Technology, who provided information about skills and safety-

relevant aspects in the use of high-level access equipment, representa-tives from renowned manufacturers also held presentations on electrical

machinery, securing loads for transport, and personal protective equipment.

DIRTY WORKLIFTING TECHNOLOGY FOR LAUSSITZ COAL FIELDS

At the end of April, two cranes were used for the reconstruction of a belt system in the Laus-sitz coal fields. To move the load of around 105 tonnes, two mobile cranes with load capacitiesof 350 and 250 tonnes were used together. The use in the brown coal mining district was pre-ceded by the replacement of a 96-tonne drive in February. Extreme temperatures of belowminus 25 degrees hampered the work of men and machinery alike.

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RESPIRATORY EQUIPMENTSuction excavator tackles gas job

At the start of the year, the waste man-agement department deconstructed andthen disposed of two molecular sievesilos and twelve nitrogen buffer silos ata factory belonging to gas producerLinde in Linz. The silos measured up totwelve metres in length, with diametersof 4 and 2.5 metres. They were first dis-connected from the supply lines, liftedout with cranes, loaded onto trans-porters, and finally disposed of. Beforethis could happen, twenty cubic metresof filter granulate first had to be suckedout of the molecular sieve silos. Employ-ees were equipped with respiratory pro-tection to prevent any damage to health.

CONVOYTransport of pipe sections for cement works

At the start of January, Felbermayr transported eight pipe sections for a cement works inthe Swiss town of Untervaz from their production sites in Dessau and Ostrava. The cylin-drical pipes had diameters of up to 5.5 metres and a height of 3.10 metres, and weretransported on semi low-loaders with four-axle tractors. In order to pass obstacles suchas fences and guide rails, the pipes were loaded on a one-metre high transport saddle,providing a »floor clearance« of 1.5 metres while still not exceeding the maximum heightof 4.5 metres. Apart from the complete closure of the Pfänder tunnel, no other traffic di-version measures were required. The pipe sections, which weighed up to 55 tonnes,were loaded and unloaded with indoor and mobile cranes.

CROATIAPOWER STATION COMPONENTS INSTALLED

Just one among many successful projects in Croatia and Serbia, the installation of a turbineand a generator in the Sisak power station deserves a mention. Thanks to the well-rehearsedteam from Felbermayr’s Heavy Equipment division in Hilden, preparing the foundations forthe 195-tonne turbine and the 160-tonne generator was more or less a routine procedure. Ac-cording to the Felbermayr representatives for Croatia and Serbia, the customer also in partic-ular remembered the good preparation and particular dedication of the Felbermayr employees.

COMBINATIONTRANSPORT ANDLIFTING TECHNOLOGYFOR BRIDGE SUPPORT-ING STRUCTURE

Earlier this year, Felbermayr transportedninety reinforced concrete girders each witha weight of eighty tonnes for a bridge con-struction project north-east of Bucharest.Strictly speaking, the transport was an inter-nal task within the building site: the forty-metre long and two-metre high elements ofthe supporting structure were transportedover roughly three kilometres. The job poseda particular challenge due to the unsecuredsubstrate and gradients of over ten percent.For this reason, a tractor and a pusher werealso used for the transports, which were per-formed step-by-step. The majority of the ele-ments were lifted using two cranes with amaximum load capacity of 250 tonnes. Forthe larger components, a 500-tonne cranewas also brought in to assist the 250-tonner.The opening of the 160-metre-long motorwaybridge is scheduled for autumn of this year.

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HIGH VOLTAGEEARTH CABLE FOR HIGH-TECH GRIDCONTROL CENTRE IN UPPER AUSTRIA

In mid-March, Felbermayr Civil Engineering began work to set up a high-voltage cable forEnergie AG. The cable, which is around five kilometres in length, leads from Hörsching to

the Wegscheid transformer substation. As part of the project, 2,500 metres of PVC tubingwith a diameter of 200 millimetres were laid under the ground. Tubes for optical fibres fordata transfer were also laid in parallel. To ensure mechanical protection of the high-voltage ca-bles, the tubes are embedded in lean concrete. Significant challenges were posed by crossingpoints with various gas, electricity, and water pipes: Since the empty tubes had to be laid ata minimum depth of 1.65 metres to ensure the required coverage, engineers had to dig downto 2.40 metres until they were below the existing cables. The suction excavator from the Fel-bermayr Waste Management division proved to be the ideal tool for exposing existing cables.Thanks to the suction excavator, the cables could be safely sucked free, virtually excludingany possibility of damage. The cable is set to go live at the end of the year, thus completingthe last section of the renovation of the 110-kilovolt cable »Timelkam-Wegscheid«.

SAFETYInnkreis motorway expansion

At the start of April, the Felbermayr Civil Engineering division began work to expand aseven-kilometre section of the Innkreis motorway between Meggenhofen andWeibern in Austria. The construction project includes expanding the lanes to a widthof 3.75 metres, as well as constructing a full-width hard shoulder measuring 3.50 me-tres. This requires an increase in the crest width from 24 to 30 metres. The width ex-tension work also requires the adjustment of twelve bridges and water conservationsystems. The adaptation and extension of noise protection measures is also particu-larly important. The project is set to cost some twenty million euros, and is scheduledfor completion in June 2013.

COUNTER-TERRORISMPLANETRANSPORTED FORDEPLOYMENT EXERCISE

At the start of May, Felbermayr subsidiaryBauTrans transported a Boeing 737 for theBudapest counter-terrorism centre. Fortransport, both wings were detached fromthe fuselage and transported on mega trail-ers through Budapest to the counter-terror-ism centre. The 3.80-wide sections were,however, relatively easy to transport com-pared with the fuselage. Considerablymore precautions were required for thefuselage, which measured 33 metres long,8.50 metres wide, and 4.90 metres high.These included the temporary dismantlingof barriers, traffic lights, and various trafficsigns around the capital, as well as liftingcables using lifting platforms. Two mobilecranes were used at each site for loadingand unloading the 23-tonne fuselage.

SMOOTH RUNNINGTransport of containerfor oil refinery

In February, Felbermayr began thetransport of thirty components for anoil refinery in Russia. Destination: thetown of Syzran, approximately 900 kilo-metres south-east of Moscow. Startingpoint: the town of Penza, approxi-mately 300 kilometres away. Up tothirty tonnes of heavy goods weretransported by road alone, with diame-ters of up to 5.85 metres and a heightof 4.80 metres.

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TRANSPORT AND LIFTING TECHNOLOGY

INFORMER8

The boom for the transfer of the auto-clave, weighing 140 tonnes, towers48 metres in the air. For the transfer withan unloading height of 30 metres, a Liebherr LR 1600 crawler crane was used.

The rapid growth of the Upper Aus-trian aeronautical component man-ufacturer FACC has given rise to a

large-scale investment programme, whichalso includes the expansion of existingmanufacturing capacities. The autoclaverequired by the plant was manufactured inCoesfeld in Germany and transported byship to Austria. Due to the adverse condi-tions, it was more than two weeks beforethe autoclave arrived in Aschach an derDonau. This also delayed the road trans-port by several days. »Due to the sinkingof another ship, the Danube was impassi-ble for our ship for several days«, ex-plained project manager Günther Wimmer,who was responsible for the transport onthe Felbermayr side. Since several othercompanies were involved in the transportfor the purposes of traffic diversions andclearing the roads, a high level of commu-nication skill was required. According toWimmer, »we had to lift several thousandcables and dismantle numerous trafficsigns and traffic lights, all of which re-quires specialists who we had to co-ordi-nate all over again.« Transport approvalsalso had to be altered. »Everyone wasvery cooperative«, Wimmer is pleased to

report on the successful cooperation withcompanies, authorities, and executives.

Obstacles to crane deployment

Even several days before the ship docked,the crane required for transferring the au-toclave from the ship to the low-loader wasalready a hot topic of conversation in the re-gion. Due to the unloading height of aroundthirty metres, a 48-metre-high giant cranewith a maximum load capacity of 600tonnes was placed in position. However,the project faced a further problem: »Gusts

of wind nearly caused the whole lifting op-eration to fail«, reported Wimmer. But afterabout an hour, the weather settled and the140-tonne autoclave was transferred fromthe ship to the low-loader. The four-dayheavy transport by road was then finallyable to begin.

»Fly-over« usedfor crossing bridges

Including the tractors and pushers, thetransport reached a length of almost fortymetres. The 6.5-metre diameter of the au-toclave further heightened the challengefor Wimmer and the team: »We had to dis-mantle traffic lights, lift large numbers ofcables, and take down signs.« But this stillwas not enough. The load capacity of somebridges was not sufficient for weight of thetransport, despite its weight distributionover twenty axles. »These bridges wereovercome using a »fly-over«. In this case, a»bridge« is constructed over the bridge,which only places the weight on the foun-dations, or more precisely on the abut-ments«, Wimmer explained. For unloadingand the final positioning in the plant, twomobile cranes were used. The autoclave isset to be commissioned in July. It will pri-marily be used for drying the power planthousing of Boeing and Airbus planes.

Transport of hot air ovenfor the aviation industryIn early April, Felbermayr transported a 140-tonne autoclave from Aschach an der Donau to the FACC AG plant in

Upper Austria, a journey of around 100 kilometres. In addition to adverse weather conditions, there were also nu-

merous side streets and traffic diversions to overcome.

INFORMER 9

TRANSPORT AND LIFTING TECHNOLOGY

Five bridges were crossed with the use of a »fly-over«. The load capacity of the bridges wouldotherwise not have withstood the full weight of the 220-tonne transport.

The transport height of 7.64 metres re-quired a large number of cables to be lifted.

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Power plantextension in SloveniaFrom February until the end of May, employees from Felbermayr Transport and Lifting Technology were in action

at the Slovenian power station in Sostanj. The assembly of supporting structure elements required the use of the

self-propelled transporter and the crawler crane LR 1750.

The Slovenian coal-fired power sta-tion in Sostanj is set to be com-missioned in two years’ time.

Following completion, the old heatingblocks are to be gradually removed fromthe grid. The decommissioning of theseolder power station components is in-tended to further improve the air-qualitysituation surrounding the power stationand hence also in the neighbouring regionof Kärnten.

SPMT and crawlercrane as a package

»Before we reach that stage, however,my colleagues on the building site stillhave several thousand tonnes of steel tomove«, Michael Lehner from the Felber-mayr Project department described thesituation on the building site at the startof February. Today, three months later, thesupporting structure elements for extend-ing the coal-fired power station are fullyconstructed and the actual power stationcomponents can be installed. The mainmachinery used on the building site werean LR 1750 crawler crane and the self-pro-

pelled transporter in various configura-tions. »Transporting the crane took around36 HGV transports.« These travelled viaSuben and Spielfeld to their destination inSostanj, which is located around fifty kilo-metres south of the border with Kärnten.The transport of the self-propelled trans-porter, or SPMT for short, required a fur-ther five HGV loads. For lifting theapproximately 180-tonne cross beamsand twelve further supporting structure el-ements weighing between 100 and120 tonnes, the crawler crane SL-56 ver-sion was used. Lehner reported, »in brief,this means that we needed to use a 56-metre-long lattice jib and 215 tonnes ofballast.« If we consider that the lifting op-eration was performed as a tandem lift to-gether with another crane, and just oneunloading height of 18 metres with a max-imum suspended load of 65 tonnes had tobe overcome, this is also perfectly suffi-cient. »Normally, we wouldn’t use a cranewith a maximum load capacity of 750tonnes for this job, but we would use a600-tonner instead.« However, since thiswouldn’t have been possible for logisticalreasons, the LR 1750 was used.

1,300 horsepower

Before lifting, the steel girders, eachmeasuring around 28 metres long by amaximum of eight metres high and fourmetres wide, were placed in position bythe self-propelled transporter. Due tothe different dimensions involved, theSPMT was reconfigured between oper-ations. For the two girders, two lots ofparallel-coupled six-axle modules withtwo 450 PS powerful drive units wereused, and for the twelve beams, threelots of six-axles with three drive unitswere used. These different configura-tions were the result of the load-bearingcapacity of the base plate, on which the160 metre-high power station block is constructed. After commissioning of the600-megawatt-producing block six in2014, block one with thirty megawattsand block four, with 275 megawatts areto be removed from the grid. The thirty-megawatt block two was already re-placed in 2008 by the commissioning oftwo gas turbines. Block five, with apower of 345 megawatts, is to remainas a reserve.

TRANSPORT

INFORMER10

Space restrictions on the construction sitemeant that the SPMT (self-propelled mod-ular transporter) was the machinery ofchoice for transporting the steel girders.

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Cranes at work atan ore storage yardPlatforms and mobile cranes provided by Felbermayr Lifting Technology were used to install a new crane trolley

for feeding Voestalpine Stahl’s blast furnaces. The works, commissioned by LogServ, were completed at the end

of January with the installation of a new crane trolley weighing approximately 75 tonnes.

Countless tonnes of iron ore are de-livered by rail and boat toVoestalpine Stahl in Linz every

year. A so-called crane trolley is beingused to feed the blast furnace with thehigh-quality raw material used to producesteel. To meet growing demands, a newsystem will be installed on the rail-mounted portal.

Seventy percent faster crane trolley

Before dismantling the current system, thelifting device that used to weigh some 69tonnes was lightened by about ten tonnesby dismantling various components. Fi-

nally, an LTM 1500 and an LTM 1130 wereused in the dismantling process. »The twomobile cranes shared the remainingweight, fifty and nine tonnes respectively,and lowered it safely and gently to theground,« reported the head of operations,Gottfried Hrast. The cranes had to copewith around 116  tonnes when lifting thenew handling unit. »They were already onsite for several weeks to assemble the trol-ley,« explained Hrast, who also supportedlifting the new trolley technically. This wascompleted within a few hours. At the be-ginning of February, the new and approxi-mately seventy percent faster crane trolleycould be put into operation.

INFORMER 11

LIFTING TECHNOLOGY

The 116-tonne crane trolley was lifted in to place within a few hours using two mobile cranes.For the pre-assembly on the construction site, mobile cranes were also put in place, whichtook several weeks.

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CIVIL ENGINEERING

INFORMER14

Niklasdorf power station

To be able to build the power station, theRiver Mur had to be redirected. This happened

using so-called box cofferdams that were con-structed using 16-metre-long sheet piles. Overall, the

dam is 10 metres wide and 170 metres long. Some 8,000 cubicmetres of gravel were excavated from the River Mur for the filling.

The River Mur is one of the biggestproviders of renewable energy inStyria. With a new power station

downstream from the Leoben power sta-tion, NEL (Niklasdorf Energie & Liegen-schaftsverwaltungs GmbH) will increase itsstandard operation power generation fromapproximately 10.5 gigawatt hours per yearto around 19.8 gigawatt hours from the be-ginning of 2013. This means that about3,000 additional households can be sup-plied with energy.

Weir fields

Demolition signalled the beginning of theworks: In the area where the power stationis to be built, there was a concrete pro-tected building as well as a scour outletthat had to be demolished before construc-tion on the weir fields could begin. Then theconstruction site near the left bank of theRiver Mur was drained to be able to buildthe weir system. This construction phaselasted from May until October 2011. Thefoundation pits then had to be excavated.At the same time, the area under thepower station was also deepened, accord-ing to Ellmer. To complete the two weirfields, 4,700 cubic metres of cement wereused in an area covering 1,600 square me-tres. These works were completed in Oc-tober. Now the weir fields could beflooded. The River Mur was diverted from

the right to the left bank using the so-calledbox cofferdams. Ellmer explained that »16-metre-long sheet piling was used.« As a re-sult, a dam that is ten metres wide and 170metres long was constructed. Some 8,000cubic metres of gravel were needed tobackfill it, according to Ellmer. The gravel ex-cavated from the river bed was used theredirectly and so avoided unnecessary trans-portation. This was followed by the hy-draulic steel construction using a shellalong the back of the weir as well asmounting the so-called wearing plates onthe inside of the weir fields. To protect thematerial from deterioration during the sec-ond construction phase, the two weir flapswill only be assembled at the next periodof low water. If we consider that the waterflow rate in the River Mur can fluctuate be-tween 50 and 580 cubic metres per secondat high water, this was also inevitable. Inaddition, on the weir side, an ecologicalcompanion channel has been built for largerwater inhabitants such as otters. »Two fishladders will also be built on the right-handriver bank,« added Ellmer.

Raised water encroachment inthe foundation pits delays project

With the construction of the plant’s centrepiece, the power station and intake struc-ture were started in November. Next, a 17-metre-deep foundation pit was exca-

vated. This meant additional sheet pilingwas necessary for the pile driving. The sub-soil also had to be additionally sealed usingjet grouting. Ellmer explained: »Using alance, a special kind of cement wassprayed three to four metres into theground. In our case, we used 400 cubicmetres of jet-grouting cement.« Yet thiswas still not enough. Then eight pumpswith a total power output of 600 litres persecond were used to keep the foundationpit dry. When building the power station,river bank walls and the intake structure,12,000 cubic metres of concrete and1,600 tonnes of reinforcement were used.This does not include the so-called filterconcrete that was used underneath thefloor plate to a thickness of about thirtycentimetres. »This permeable layer stopspressing water from accumulating on theunderside of the floor plate,« is how Ellmerexplained this damage-prevention measurethat is particular to power stations. At thebeginning of July, the turbines were readyto be lifted. »Following this, we installedthe scour outlet with a »segmental gate«to transport floating debris and detrital fromthe upstream water to the downstreamwater, as well as to control flood water.«Filling the foundation pit and building a fishladder will signal the conclusion of the firstconstruction phase in November. It isplanned that the power station will be putinto operation for testing at the beginningof January 2013. Then the »compact bulbturbines«, manufactured and installed byANDRITZ Hydro, will then rotate for thefirst time and produce electricity.

Since February 2011, employees of the Felbermayr »Salzburg Construction«

division have been working on expanding and constructing a power station

on the River Mur. In combination with the old site, the power station – lo-

cated in Niklasdorf in Styria – will produce approximately 3,000 kilowatts

of power once it is put into operation in January 2013.

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CIVIL ENGINEERING

To stop the concrete from drying out toosoon, it was watered generously andcovered with plastic sheets.

When redirecting the River Mur, an exca-vator with a pile driver was used so that thepile sheets could be inserted.

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Constructing industrial prem-ises for generator productionClose to Linz’s heavy load port, Felbermayr Structural Engineering is currently building a logistics and assembly

unit for the globally active technology group ANDRITZ. The units, which are configured to produce turbo generators,

should be completed by the end of August.

On 2nd November 2011, the exca-vators first started to constructthe logistics and assembly unit,

about 300 metres from the Felbermayrheavy load port in Linz. But the

3,207 square-metre area was first examinedin minute detail. This was due to a heavybombardment during the Second WorldWar: A search for munitions was carriedout. »Using a ground-penetrating radar, the

search resulted in 217 suspicious cases,that were all discovered up to 1.5 metresunderground,« explained site managerMarkus Pointinger. Despite this meticuloussearch, fortunately nothing was found.

STRUCTURAL ENGINEERING

INFORMER 16

The logistics and assembly units cover3,207 square metres. The structure wasbuilt using an aluminium and steel com-posite and prefabricated concrete blocks.

Soil compaction for the foundations

Due to its low load-bearing capacity, thehistorically important ground not far fromthe »Voestalpine Stahl« premises alsoneeded special precautionary measuresand had to be adapted using 214 so-called concrete darning columns and 208ductile posts to meet the required staticconditions. »The ground was compactedover an area covering forty centimetresand then finally filled with concrete,«said Pointinger as he explained the pro-cedure involving the concrete pillars thatreach six metres into the ground and willfinish under the future floor plate. Eventhis was not enough for the area that willbe used for the future test field founda-tion for the generators, which will weighup to 500 tonnes, and the soil wasadapted accordingly using gravel and the

vibro displacement compaction method.When constructing the support founda-tions, upon which the actual unit will beconstructed in the future, additional duc-tile posts with an 18-centimetre diameterhad to be assembled under the colloiddispersions. These cylinders, made ofsteel, will reach eight to ten metres intothe ground and will provide the founda-

tions for the future unit’s load-bearingstructure with the necessary support. In-cidentally, 26 support foundations thatcovered eleven square metres and are ametre high had to be constructed. Thenecessary reinforcement equalled 1.3tonnes per foundation. This meant thatan additional 27 tonnes of building steelwere added to the test field foundationsthat cover about one hundred square me-tres. »That equates to about two trucktransporters,« illustrated Pointinger.

The plant’s centrepiece

Covering an area of about 300 squaremetres, the test field foundations thatare located in the construction pit are re-ally the unit’s centrepiece – the individualhigh-tech components for the 500-tonnevoltage transformers will be assembledhere and then checked for functionality.»To build this area, sheet piling of up toten metres in length had to be rammedinto the ground due to the ground waterlevel,« said Pointinger when explainingthe measures used to keep the pressingwater out of the foundation pit. The floorplate and the almost five-metre-highwalls were transformed into a so-called»white bath« using special joint stripsand waterproof concrete. »Comparedwith the »black bath«, this proceduredoes not require any additional sealant toprevent pressure water from flowing intothe pit,« explained Pointinger when de-scribing the cost-saving but high-qualityprocedure. When forming the 35-cen-timetre-thick concrete walls, an MK 88

mobile construction crane was used. Thiscrane unites the advantages of a towercrane with those of an automatic cranethanks to its high load capacity.

Prefabricated concrete units used for fast construction progress

The steel composite supports, whichare more than twenty metres high, weremanufactured by the Gunskirchen-basedprefabricated concrete unit manufac-turer Oberndorfer and were lifted in toplace with a Felbermayr crawler crane.In total, 26 pieces that weigh approxi-mately 55  tonnes were manufacturedand processed. This high number wasnecessary to correspond with the statis-tical calculations for using an indoorcrane with a load capacity of 300tonnes. Furthermore, thirteen binders(that weigh twenty tonnes) were liftedusing the LR 1200 crawler crane for theroof construction as well as the sidewalls, that are made of aluminium andsteel composite, and its respective insu-lation. In May, the 40-centimetre-thickfloor plate was covered with concrete.Felbermayr’s work will conclude at theend of August when the outdoor facili-ties are completed.

INFORMER 17

STRUCTURAL ENGINEERING

Approximately 1,300 metres of channelswere laid in total.

The 2.5-metre-high test field founda-tion was reinforced with 27 tonnes ofbuilding steel.

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Regional trains of the type DesiroRUS manufactured at the Siemensplant in Krefeld travel at speeds of

up to 160 kilometres per hour. In order todeliver a total of 38 trains, each consistingof five coaches, the coach sets at the Fel-bermayr heavy load terminal in Krefeld arebeing transferred via Amsterdam to UstLuga, so that they can be transported fur-ther on a barge until the middle of nextyear. The stationary cane »Big Rocky« anda mobile crane were used for the lifting op-eration in Krefeld.

»Lastoschka« gone astray

However, every end and centre coach firsthad to go on a »special trip« to the Rail TecArsenal climate chamber in Vienna, wherethey underwent a comprehensive climatetest. Then finally the trains, which arecalled »Lastoschka« in Russia (meaning:swallow), must brave temperatures of upto forty degrees below zero and demon-

strate their merits for the Winter OlympicGames 2014 in Sochi. »The units in Krefeldwere shipped to Austria along the Rhine,

Main and Danube Rivers and thenonce there, theywere lifted on

TRANSPORT AND LIFTING TECHNOLOGY

INFORMER 18

A colossus on rails istested in cold weatherIn mid-February, the transfer of 190 railway coaches began at the Felbermayr heavy load port in Krefeld. Two of

the vehicles destined for Russia were transported to a climatic chamber in Vienna for winter testing, as requested

by the Krefeld-based logistics firm Schenker.

At the Felbermayr heavy load port in Krefeld, a total of 190 Desiro RUS coaches are loadedonto barges.

Thanks to excellent preparation, the twocoaches were transported from the roadvehicle to a barge within a few hours.

to train-carrying road vehicles using a pairof mobile cranes«, explains Sascha Golu-bich, the Head of Operations. The cranesused were a LTM 1400 and a LTM 1350.»Because of the local circumstances, thenearly 25-metre-long carriage had to bethreaded between the crane telescopes ata width of 15 metres«, said Golubich whenexplaining the difficult operating condi-tions. After about three hours, the twounits weighing approx. 56 tonnes wereloaded with centimetre precision on to 10and 12-axle trailers and secured for onwardtransport to Vienna.

A night trip to the climate test

Due to their size, it was only possible to trans-port the coaches at night: The FelbermayrTransport division in Wels said that theyneeded two nights to transport the shipmentnearly fifty kilometres. In addition to imple-menting traffic control measures, two over-head power lines had to be raised for the trainalong the route through Lower Austria. When,early in the morning on the second day, theshipments arrived at Rail Tec Arsenal (RTA) inthe 21st municipal district of Vienna, two Fel-bermayr cranes had been fully set up andwere standing at the ready with their boomsin the air. »Because the radius was small,only two cranes, each with a hundred tonnemaximum load capacity, were required forunloading and relocating on the RTA track«,says Golubich, who fulfilled the conditions ofhis contract by doing this. Siemens engineerswere also there to ensure a successful out-come, as they are responsible for the techni-cal design of the high-tech passenger trains.The test results were also a reason for cele-bration, because they mean it is possible forthe Winter Olympic Games to be hosted inSochi in 2014. At any rate, nobody will com-plain about the cold in the nearly 127-metre-long and approx. 260-tonne trains. Andsufficient comfort is guaranteed in the 3.48-metre-wide and 4.85-metre-high colossus.

After the climate test, the coach sets at the Alberner port were transported from a road vehicle to a barge. Two cranes with a maximumload capacity of 350 and 400 tonnes were used for this.

INFORMER 19

TRANSPORT AND LIFTING TECHNOLOGY

After transporting the two rail wagons,two additional heavy lift items were trans-ported on behalf of the Styrian apparatusengineering company ACE, whose head-quarters are in Lieboch. The nearlyeighty-tonne steel constructions are des-tined for Shanghai.

In the climate wind channel at Rail Tec Ar-senal in Vienna, Siemens tested the new re-gional Desiro RUS multiple unit for RussianRailways (RZD). The tests using artificialwind, ice, rain and snow were conducted atbetween -40 and +45 degrees Celsius.PH

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W hen they were moved inter-nally at the end of March,the transporters got an im-

pression of the container dimensions:»At the time we had to move thecolumns from the production plant to theprocessing location,« said Jürgen Stein-brecher, working for Felbermayr’s Trans-port division in Wels. Once they hadarrived, the steel components for thefinal surface treatment were unloadedusing two mobile cranes in tandem. Thecylindrical reactor, whose length had tobe divided, began its journey to the so-called »Bavarian chemistry triangle«.»The components that were 33.5 and37.5 metres long and had a diameter of3.6 metres were still very impressive andweighed 45 and 75 tonnes respectively,«said Steinbrecher when explaining thechallenging dimensions. The steel com-ponents were transported step-by-stepusing a 12-axle trailer that could be ad-justed to the length of the load using a21-metre extendible trailer.

Negotiating tight bends

For the third consignment, a so-called ros-trum trailer was used. »This transport ve-hicle from BauTrans is the only one inAustria and can raise loads up to 1.5 me-tres high.« This is a characteristic that was

often required due to tight bends and cor-ners. A further benefit of this rostrumtrailer is the possibility of transportingself-supporting sections. »The connectionbetween the front and rear axles is thenguaranteed by the load itself,« explainedSteinbrecher. This was a variation thatwas also used when transporting the41.19-metre-long and over 4-metre-widecolumn. Including the tractor, the convoywas more than 73 metres long and wasover five metres high and wide. Takingthese dimensions into consideration, is itunderstandable that many road trafficsigns and traffic lights had to be removed.This is something that takes a lot of timewhen planning the details and also callsfor professional teamwork between all

businesses involved. In addition to thethree large convoys, five smaller convoysthat were up to 38 metres long were alsotransported from the Austrian plant engi-neering company Kremsmüller toBurghausen. Alongside the convoy, a highlevel of technical perfection when liftingthe reactor, which was transported in twoparts, is also required. When it is fully as-sembled, it will reach a height of morethan seventy metres and will only just beshorter than Burghausen’s 79-metre-highchurch steeple. Following this, the 41-metre-long column was placed on its des-ignated area with pin-point accuracy.Incidentally, the lifting work was carriedout using the LR 1750 crawler crane fromFelbermayr’s Project department.

Rostrum trailer in actionIn April, together with the subsidiary company BauTrans, Felbermayr transported three columns that were approx-

imately forty metres long from Steinhaus near Wels to the Wacker Chemie factory in Burghausen, about 140 kilo-

metres south of Steinhaus.

TRANSPORT AND LIFTING TECHNOLOGY

INFORMER 20

The BauTrans rostrum trailer enabled the load to be lifted up to 1.5 metres above street level.This also makes getting round corners possible.

To transport the columns, they werebraced self-supportingly. The load wasthus connected between the axle lines.

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A sign that builds confidence!

Qualified specialists are working on Sareno’s construction sites. As a mark of quality for all firms who employ

EIFS-certified specialists, Qualitätsgruppe Wärmedämmsysteme (QG WDS) has put forward a new trademark. It

should build confidence and show that EIFS safety and quality is important to these firms.

B eing a certified EIFS specialistmeans that during their training,in which they cover the physical

and chemical structural basics, the em-ployee has become acquainted with theassembly, function and standardised ex-

ecution of an exterior insulation finishingsystem, or EIFS. This seminar must berenewed every three years by attendinga refresher course.

From the beginning

Sareno supports the certification of EIFSsite personnel right from the beginning.This is because great expertise is nec-essary here. Therefore, site personnelsat this exam and can now proudly callthemselves »certified EIFS specialists«.

The new mark of quality

There is detailed information about thequality mark at www.waermedaemm-systeme.com. You can also meet themost recently certified Sareno employ-ees here, as representatives of all em-ployees: Daniel Eisschiel, FranzFischer, Herbert Fischer, GünterGabriel, Johannes Gabriel, RobertRammelmüller, Stefan Rührnößl, Diet-mar Salzer, Walter Salzer, AndreasSchwarz and Herbert Siegl. This meansthat almost all Sareno’s site personnelare designated specialists.

INFORMER 21

SARENO

There is more information on Qualitätsgruppe Wärmedämmsysteme on their website:www.waermedaemmsysteme.com

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Asmall hobby makes everythingbetter. That’s the opinion of Wal-ter Ludl, whose collection is one

of the biggest in the Republic of Austria.He became passionate about mini modelsaround thirty years ago. At the time, Ludl,who is now aged 64, worked at theKaprun power station as a structural main-tenance technician. It was the job thatsparked his passion and also laid the cor-nerstone for his small »private museum«.Incidentally, schools often visit the collec-tion when on a trip.

»Private museum«covering fifty square metres

The models are stored just next to the bed-room in an area covering about fifty squaremetres. What does his wife think? »Mywife shares my hobby with me,« says Ludl,but after a short pause he corrects himself.»Let me put it this way, she accepts it«, headds smiling to himself. There is no need toworry about having to put a stop to Ludl’spassion due to lack of space, though: »Thestoreroom is filling up, but there is stillroom for storage,« he says. Mr Ludl is now

somewhat more

selective when it comes to choosing whichmodels he copies. He is increasingly optingto reproduce extremely heavy vehicles.

Cellar workshopfor making transformers

Father to two grown sons, he has al-ready build about 50 models him-self. He taught himself the manualskills of painting and milling. MrLudl has recently put the drill inhis cellar workshop to one sidemany times, though: »A goodfriend has already helped mewith a 3D mill. That makes itall easier.« But Ludl does notmake things easy for him-self. The jewel in his home-made collection is a transport convoythat is over 110 centimetres long, a replicaof the original that was used to transportthe transformer for the Limberg power sta-tion in 2010. He did not count the manyhours. But it did take half a year before his»greatest work« was completely finished.The transformer, a masterpiece made ofaluminium, was finished by hand and was

an exact copy of the rostrum trailer. Thetrailers were re-built and re-painted. To getaway from the painstaking work under amagnifying glass, Ludl also enjoys cycling

from time to time. And even then hehas to do something extra:

from Salzburg toRotterdam or Vi-

enna, for example –»to look at models,«

he says.

Entitled »Big Machines ona Small Scale«, there is still

a special exhibition display-ing about one hundred mod-

els from Ludl’s home work-shop until 31st October 2012. The exhi-bition is being held at the Kaprun Mu-seum. Covering an area of about fortysquare metres, it is also possible to seefour Felbermayr convoys that have beenfaithfully reproduced. More information:www.kaprunmuseum.at

Somethingbig madesmallMore than a thousand models form Wal-

ter Ludl’s collection in Kaprun. The ma-

jority of the exhibits are construction

and transport vehicles on a scale of 1:50.

A special feature are the many individual

pieces that the skilled car mechanic has

made himself by hand.

PORTRAIT

INFORMER 22

Walter Ludl from Kaprun finishes most of his individual pieces by hand.

A masterpiece that is over a metre long: a reproduction of the transport convoy used for the Limberg II pumped storage power plant (scale 1:50).

KAPRUN MUSEUM

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NEW MEMBERFelbermayr Constructionexpands services

Since early 2012, the Felbermayr Spe-cialised Civil Engineering division hasbeen working with a geotechnics de-partments. The department is being ledby Emmerich Schießling. Originallyfrom Tirol, he has been working in thearea of ground surveying for 19 yearsand thus has wide-ranging expertiserelating to geothermal and exploratorydrilling, as well as rotation core drillingin loose material and bedrock. More-over, the geotechnics department of-fers diverse borehole investigationsright through to dynamic probing usingheavy dynamic penetrometers (DPH).Most recently, Schießling worked for awell-known geotechnics company.

LIFTING TECHNOLOGYCRANE AND PLATFORMSERVICING AND REPAIRS

In April, Franz Briedl was entrusted withservicing and repairing cranes and plat-forms throughout the Transport and Lift-ing Technology department. In thisposition, Mr Briedl is technically respon-sible for servicing and repairs. Alongsidehis training as a mechanical technician,additional training as an electrical techni-cian, as well as sitting masters’ exams inmechanical and industrial engineering, MrBriedl has the necessary experiencethanks to the twelve years he has spentworking as a service technician for mo-bile and crawler cranes. By incorporatinga central service centre for cranes andplatforms, additional savings potentialand an improvement in our customerservice can be unlocked.

You can find the answer in this edition. We will draw winners of the 15 non-cash prizes from amongst the correct entries. For further information, go to www.felbermayr.cc/informer – Click to enter! Please send us the correct answer by fax to +43 7242 695-144 or e-mail informer@felbermayr.cc. The closing date forentries is 30th November 2012. There is no legal recourse.

Prize question:Which crane was used to transfer a 140-tonneautoclave in Aschach an der Donau?

1st prize:A 1:50 scale model of a MAN TGA with PalfingerPK100002 crane. This faithful reproductionmodel is a special edition from Conrad, madefrom diecast aluminium.

RETIREMENTSWell-earned retirements

Many thanks and well-deserved ap-preciation are extended to all those

who have recently retired. They havecontributed to the growth of the firm,some for decades, and thus have helpedshape the company’s history.

Gisela Cservenka – Administration, Linz ·Johann Drothler – Transport, Klagenfurt ·Rudi Franke – Cranes, Görlitz · HerbertGiger – Civil Engineering, Wels · AlfredHellmayr – Civil Engineering, Grieskirchen· Alois Hohenwarter – Civil Engineering,Wels · Miroslav Jevtic – Civil Engineering,Wels · Karl Malzer – Civil Engineering,Wels · Zivadin Petrovic – Civil Engineer-ing, Salzburg · Hubert Rathmoser – HeavyTransport, Wels · Siegmund Richter –Cranes, Schwarze Pumpe · NotburgaRosic – Administration, Wörgl · NikolausRuhland – Heavy Transport, Wels · AloisSageder – Administration, Wels · Wolf-gang Scharf – Cranes, Kamenz · FranzSchmid – Civil Engineering, Grieskirchen· Heinz Stecher – Cranes, Wörgl · LjubisaVojinovic – Cranes, Lanzendorf · JosefWieser – Civil Engineering, Wels

Competition

Media owner and publisher: Felbermayr Holding GmbH, Machstrasse 7, A-4600 Wels, Austria Tel.: +43 7242 695-0 · www.felbermayr.ccEmail: office@felbermayr.cc · Responsibility for content: Horst Felbermayr · Editing and concept: Markus Lackner · Layout: Stephanie Ebenberger · Free subscription: If you do not yet receive the »INFORMER« magazine regularly, but would like to have it deliveredto your door twice a year, absolutely free, or if you would like to order it for someone else, go to our website: www.felbermayr.cc/informer

Emmerich Schiessling Franz Briedl

INFORMER 23

PERSONNELPH

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