BAUER FOUNDATIONS AUSTRALIA

P R O J E C T S

Hinze Dam - Cut-off Wall Project

Installation of a two phase plastic concrete Cut-off Wall of 800 mm thickness and up to 54 m wall depth. Total excavation 8,000 m²;

- Hard rock excavation: 3,300 m² (strength up to 200 MPA) - Medium rock excavation: 1,700 m² - Low strength rock excavation: 1,600 m² - Soil excavation: 1,400 m²

RESOURCESSPEZIALTIEFBAU MASCHINEN

The core company BAUER Spezialtiefbau GmbH executes foundations, excavation pits, cut-off walls and ground improvement all over the world. Our main services are all kinds of bored piles, anchors, diaphragm and cut-off walls, as well as injections and deep vibrations. The approved quality of these production methods comes from long years of experience, with qualified and continuous research.

Competent partner and sister companies and more than 50 subsidiaries add to this comprehensive range of construction services.

Specialist foundation engineering machinery from Bauer has been a byword for top performance and quality and for continuous innovation since the late 1960’s. BAUER Maschinen GmbH, which designs and manufactures rotary drilling rigs, diaphragm wall equipment and all related tools, has been operating on the market as an independent entity within the BAUER Group since 2001.

The other companies are subsidiaries of BAUER Maschinen GmbH. Together they provide the full range of specialist foundation engineering equipment and equipment for exploration, mining and safeguarding of valuable natural resources. Bauer Maschinen offers ‘more than just the machine’. Based on the company’s extensive experience, customers are provided with complete solutions from a single source.

We are focusing on products and services in the fields of water, energy, mineral resources and environmental technology.

The foundation of BAUER Resources GmbH in mid 2007 was the beginning of the new segment Resources, the third business area within the BAUER Group besides Construction and Equipment. BAUER Resources GmbH is concentrating on products and services related to water, energy, resources and environment. BAUER Resources GmbH is a holding company which consolidates three operating divisions: Materials Division, Exploration and Mining Services Division, and the Environment Division.

BAUER Foundations Australia Pty Ltd is part of the Bauer Asia Pacific Region which is in turn a subsidiary of BAUER Spezialtiefbau GmbH (BST), a world leader in advanced foundation technology.

The strength of Bauer Foundations Australia is dealing with particularly difficult sub ground conditions. We have developed techniques to enable us for instance, to successfully deal with hard rock ranging from 150 MPA to over 200 MPA for Bored Pile, Diaphragm Wall and Cut-off Wall construction.

The company can operate on projects Australia and New Zealand wide.

THE BAUER GROUP

Founded in 1790, the BAUER Group today employees some 9,500 people. Bauer Foundations Australia is part of the BAUER Spezialtiefbau GmbH (BST) Group, a world leader in advance foundataion technology. BST is a group of International geotechnical engineers and contractors with management and subsidiary offices which operate in over 50 countries throughout the world with a particularly strong focus on the Asian Pacific region.

THE WORLD IS OUR MARKET

Regional headquarters are in Malaysia, with the Region comprising of Australia, Hong Kong, Singapore, Thailand, Philippines, Indonesia, Malaysia, Vietnam, and New Zealand, completing many important and highly technical challenging projects for more than 25 Years.

The Bauer Asia Pacific Region

Global Projects and Equipment

Competant - Inspired Strong - Safe Operations

Bauer Foundations Australia have developed a strong technical and operational team for the design and construction of foundations. Our company provides all types of specialised foundation works to the industrial, commercial, civil and governmental construction projects. Including, but not limited to

- Bored Pile Foundations - Diaphragm Walls and Secant Pile Walls - Retaining and Cut-off Walls - Excavation Pits and Coffer Dams - Ground Improvement

Your company will get the most suitable construction methodology tailor made to fit the project conditions. Our highly qualified engineers will consult and support you in planning and estimating your project. Together with our skilled workers we will perform the construction works on site in a professional and cost effective manner as well as in the shortest time frame.

BAUER DESIGN AND CONSTRUCTION EXPERTISE

Bored Piles - Kempsey Project

Scope Construction of 60 no. 1,800 mm and 4 no. 1050 mm diameter bored piles

Concept and Design The bored piles are designed to carry the bridge loading through end bearing in the rock and side friction in the 2-16 m rock sockets provided. To cater for heavy impact loads and scour, the piles are designed with relatively heavy reinforcement cages.

Due to the possibility of contamination of the river with drilling fluids, the piles are installed with permanent casings extending to the rock head level.

Construction Works and Special Features The piling works were completed during two visits with an overall period of six months. During the break in piling works, the rock fill platform was moved from one side of the river to the other in order to ensure that the flow of the river was never interrupted.

BORED PILE FOUNDATION

BORED PILE FOUNDATIONS

Scope The Barangaroo site is a major extension to the Central Business District of Sydney, and represents an increase of over 15 % in the size of the CBD. Construction of approximately 1,000 bored piles 1,000, 1,200, 1,500 and 2,400 mm diameters up to 35 m in depth.

Concept and Design The bored piles are designed to carry the building loadings through rock shaft friction and end bearing. Groups of piles are designed beneath the raft cores with ‘mega piles’ supporting the main tower columns carrying up to 10,000 t each. Pile settlement has been designed to be limited to just 0.3 % of the pile diameter and this has meant rock sockets of up to 8 m being required. To optimise the design two Osterberg pile load tests have been performed.

Challenges Bauer overcame a number of challenges with this site. The historic industrial nature of the site has meant that there is the presence of hazardous materials including asbestos in a number of areas. Piles in these areas were installed in designated contaminated zones.

A wide range of obstructions were present on the site, including a major seawall consisting of a sand filled concrete caisson. Due to the presence of obstructions, piles up to 1.5 m in diameter were installed using double wall segmental casing.

Bored Piles - Barangaroo

Scope Construction of 88 no. of 1,500 mm and 23 no. of 900 mm diameter soldier bored piles up to 18.2 m in depth for the Northern Wall of Western Trough.

Concept and Design Soldier pile wallings comprises 1,500 mm diameter bored piles at nominal 3.0 centres and 900 mm diameter bored piles at nominal 2.4 centres. The piles were embedded within BP4 and BP3 material to provide lateral restraint at the pile toe. Where required, permanent anchors are also utilised to provide lateral restraint.

Construction Works The piling work was executed successfully by the experienced construction team in line with the thorough and detailed plan. It was completed ahead of the client’s program by three weeks. The hardness of the encountered rock had been pre analysed and well addressed on site with various drilling tools and techniques.

BORED PILE FOUNDATIONS

Bored Piles - Legacy Way - Western Trough

Your project is our challenge.

RETAINING STRUCTURES LIKE DIAGRAGM WALLS, PILES WALLS AND CUT-OFF WALLS FOR CONTAINMENT

Cut-off Wall - Hinze Dam

Diaphragm Wall - Airport Link

Scope Installation of a two phase plastic concrete Cut-off Wall of 800 mm thickness and up to 54 m wall depth. Total excavation 8,000 m²; - Hard rock excavation: 3,300 m² (strength up to 200MPA) - Medium rock excavation: 1,700 m² - Low strength rock excavation: 1,600 m² - Soil excavation: 1,400 m²

Hard rock excavation up to 55 m. Dealing with fissures and cavities. Special Bow Mix Design required to cater for movement.

Concept and Design

The 227 m long, 800 mm wide and in parts over 50 m deep wall was excavated in sections (panels) in alternating sequence to ensure the integrity of the main dam wall at all times and the safety standards are continually met. The 47 panels of 2.8 to 7.0 m length were supported by bentonite slurry during the excavation process. Bauer designed a low strength ‘plastic’ concrete with 2 to 4 MPA strength to construct the wall.

Challenges The ground was classified as extremely weathered to very high strength rock with strength of up to 200MPa. Because of the very inhomogeneous ground conditions an assortment of different equipment was used for the excavation.

Scope Construction of approximately. 28,000 m2 of diaphragm wall and barrettes with thickness 1,000 mm and 1,200 mm up to depths of 40 m.

Concept and Design The wall involves construction of approximately 200 panels of both 1,000 mm and 1,200 mm thicknesses and with lengths varying from 2,800 mm to 7,400 mm.

Construction Works Excavation was performed using a combination of two hydraulic grabs and a Bauer BC 40 cutter. The grabs were used to excavate the soil material. Once rock was encountered excavation continued using the cutter. Upon completion of excavation full depth stop ends were installed, followed by reinforcement cages of up to 60 t per panel. High slump flowable concrete was then used to form the panel. In certain panels that form TBM breakout points Glass Fibre Reinforcement (GRP) was utilised.

Diaphragm Wall - NCIG Coal Export Terminal

Scope 24 no. diaphragm wall panels, 3,050 m², depth 27 m, width 600 mm & 800 mm. 40 no. secant piles, 10 m deep

Concept and Design The coal dumper was constructed adjacent to an operational coal dumper constructed during stage one. One external wall is shared between the two dumpers. The dumper 800 mm diaphragm walls were reinforced with a max depth of 29 m. A cut and cover tunnel was also constructed with the reinforced 600 mm wide diaphragm wall with max depth of 18 m.

The secant bored piles were constructed hard/hard using the CFA cased method of construction.

Challenges Secant bored piles were constructed within 30 mm of an existing operational rail bridge structure.

Scope 16,500 m² Diaphragm Wall with width 1,000 mm and up to 27 m depth and 3,200 m² (60 no.s.) Barrettes with width 1,000 m and 19 m depth.

Concept and Design For construction of the tunnel two 400 m Diaphragm Walls were designed; one wall for the northern side of the carriage way and one for the southern side. In the centre line of the tunnel 60 no.s. Barrettes were installed using the Diaphragm Wall method.

Challenges Special equipment was necessary to comply with the headroom restriction near the airport. Bauer Foundations Australia could provide a low headroom grab, a special Bauer CBS 25 cutter as well as other low headroom equipment.

Reinforcement cages were installed in 3 (19 m) or 4 (27 m) sections. In order to connect the roof and base slab to the Diaphragm Walls at a later date coupler boxes were mounted onto the cages. The environment around the Tugun Bypass Project is highly sensitive. Flora and fauna and also the adjacent Cobaki Broadwater area needed special attention. The area is also rich in cultural heritage of local indigenous people.

Diaphragm Wall - Tugan Bypass

Scope One inlet and one outlet shaft with a diameter of 12 m and a depth of approximately 35 m were embedded in sandstone formation.

Concept and Design The thickness of the wall panels was designed to be 1,000 m so that no additional anchoring or bracing was needed. Due to the techniques of the Diagragm Wall method, the shafts had to be constructed as a hexagon. Each leg of the hexagon was 7 m long and consisted of three bites. Due to the shape and size of the hexagon sections the reinforcment cages had to be constructed on site.

Challenges Verticality requirements were strict therefore during the process of panel excavation the verticality was constantly controlled and monitored.

Diaphragm Wall - Gold Coast Desalination Plant

Diaphragm Wall - Gold Coast Desalination Plant

SECANT PILE WALLS

Secant Pile Wall - Legacy Way - Eastern Portal

Secant Pile Wall - Vision

Scope Construction of approximately 590 no.s of secant piles, soldier piles and bored piles with 900 and 1,200 mm diameters up to 28.5 m in depth for Eastern Cut and Cover and Open Transition Structure.

Concept and Design Bauer Foundations Australia was awarded the piling works for the Eastern Cut and Cover Structure. The eastern buried structure will be constructed as a series of anchored secant pile walls. A ‘hard-firm’ wall configuration has been adopted.

Challenges The main challenge of the site was to overcome the unexpected extreme high strength rock. Various rock tools were utilised to drill and core the hard rock out of the bored hole.

Scope 1,000 m2 Secant Pile Wall with pile diameter 880 mm up to 22 m depth and 3,500 m2 Diaphragm Wall with width 600 mm and up to 19 m depth.

Concept and Design The below ground car park required a 80 m × 70 m excavation to a depth of 21 m and due to the close proximity of existing buildings on the boundary line a retaining wall was required for this structure.

Challenges Diaphragm wall panels were constructed adjacent to the site boundary line on Mary and Margaret Streets and adjacent to the low and high rise buildings on the boundary.

Barrette Piles

Stone Columns

Cutter-Soil-Mixing (CSM)

Mixed-in-Place Techniques

GROUND IMPROVEMENT - PRINCIPLE SYSTEMS

Safe work practices, quality workmanship, technical knowledge, strength in hard

rock excavation and the willingness to be the most reliable partner in the foundation market are forming the foundation of our company. We can develop and execute

cost effective and quality solutions, tailor made for any project size.

health safety environment

BAUER Foundations Australia Pty Ltd recognises the importance of constantly maintaining Health Safety and Environmental consciousness at all levels of organisation with the aim of creating and maintaining a safe and friendly workplace environment for everyone.

WE VALUE AND CARE FOR HEALTH, SAFETY & THE ENVIRONMENT

Bauer Foundations Australia has always prided itself on it’s commitment to it’s number one asset, our people. We are made up of a diverse range of professionals project managers, engineers, operators, site and office staff working in various locations with one common goal; to combine the quest for technical excellence with outstanding client service and results.

OUR PEOPLE

BAUER Foundations Australia Pty LtdGround Floor, 154 Enoggera RdNewmarket, Queensland 4051Ph: 07 3352 7444 Fax: 07 3352 7244info@baueraustralia.com.auwww.baueraustralia.com.au