Gulf Construction Online - Bauer takes silent route to success

German Expertise

Bauer BG 15 H ... one of the quietest rigs available.

Bauer takes silent route to success

Bauer, recognised worldwide for its foundation engineering expertise, is now focusing on producing high-performance equipment that boasts noise reduction properties.

01 March 2021

From drilling rigs to cutters, Bauer Maschinen has set new standards in recent years when it comes to noise reduction at specialist foundation engineering sites.

“Reducing noise is an extremely important topic in the new development and ongoing development of our equipment,” says Christian Heinecker, Head of Business Unit Drilling Equipment at Bauer Maschinen. “Thanks to our Energy Efficiency Package (EEP), Bauer equipment is now significantly quieter than their predecessor models.”

For example, Bauer’s smart eco mode relies on dynamic regulation of the engine speed based on the respective action being carried out. This not only reduces cumulative noise emissions but also reduces diesel consumption. This is assisted by an automatic motor stop function that automatically switches off the equipment if it is not used for a certain period of time. Optional add-on modules, such as inflatable noise control cladding for the power head or the upper carriage, also have a positive effect and can even be retrofitted to existing equipment.

The silent mode is used for Bauer equipment featuring standard technology without EEP.

“This operating mode makes the new Bauer BG 15 H and BG 20 some of the quietest drilling rigs available in their class,” reports Heinecker. The silent mode reduces the maximum engine speed and slows down the hydraulic consumers. The result: The equipment’s noise level decreases by -2 dB(A). Compared with its predecessor model, the new BG 20 manages to reduce cumulative noise emissions by 9 dB(A). In some cases, individual measurements recorded values of just 100 dB(A). This is an extremely significant reduction in noise pollution – a decrease of just 3 dB(A) means cutting the noise intensity in half, while a decrease of 6 dB(A) actually reduces the noise intensity by 75 per cent!

Apart from the equipment, the drilling method also influences noise emissions. A differentiation is made between intermittent (for example, Kelly drilling) and continuous methods (for example, drilling with an auger using the displacement pile or double-head drilling method). The latter method combines pulling and concreting into a single process, and for this reason produces lower emissions during excavation than a method such as Kelly drilling.

However, this method is limited with respect to drilling depth and drilling diameter. For Kelly drilling, Bauer’s adaptive Kelly retraction assistant reduces the speed during the retraction process at the joints of the Kelly bar, which has a positive effect on the noise level generated. Various assistants help during drilling and discharge, for example by preventing the drilling tool from overfilling (over-drilling) and thereby facilitating the subsequent discharge process. The optimal filling level of the drilling tool is displayed for the operator in the B-tronic. During discharge – an activity that used to be carried out manually – a one-directional or bi-directional spoil discharge assistant helps the operator.

In addition, a one-directional spoil discharge assistant can be used to optimise the intensity when shaking out the auger. “Whether EEP, silent mode or assistance systems, many individual components result in a noise-optimised package at the end,” summarises Heinecker. “We continually optimise our equipment and conduct our own foundation research as well as participating in publicly subsidised research projects.”

EEP is also firmly established as the state-of-the-art technology for Bauer’s cutter carrier equipment, the MC duty-cycle cranes. The cutter itself produces very low levels of noise and cutting is ultimately a low-vibration and thus low-noise method. The principal noise sources, apart from the motor of the support frame, are the cooler and the hydraulic system.

Bauer has developed a compact series of cutters with low noise emissions for such uses: the CBC Silent Cutter.

The Silent Cutter – available as CBC 30 for cutting depths of a maximum of 80 m and as CBC 45 for cutting depths of up to 120 m – features an innovative concept: The hydraulic power pack, which ensures particularly silent operation, is not permanently attached to the rear of the support frame as is usual, but can be positioned on the side or even separately next to the support frame and connected via hydraulic lines. “This modular system, which is also available as a low headroom variant, offers maximum flexibility even in very tight spaces,” explains Leonhard Weixler, Head of Business Unit Diaphragm Wall Technique at Bauer Maschinen.

The power pack is housed in a container with a length of 6 m, width of 2.5 m and height of 2.5 m. Compared with the standard MC duty-cycle crane from Bauer, the Silent Cutter produces noise emissions that are 3 dB(A) lower, which corresponds to approximately half of the perceived noise.

This is possible because the separate power pack provides extra volume for noise insulation.