BAUER

Global Dam Services

Content
Rehabilitation and Upgrade Dams
Center Hill Dam, USA ............................................... 4
Sylvenstein Dam, Germany ....................................... 6
Hinze Dam Upgrade, Australia .................................. 7
New Dams
Peribonka Hydroelectric Development, Canada ........ 8
Punatsangchhu-I Dam, Bhutan ............................... 10
New Assiut Barrage, Egypt ..................................... 11
Competences

Construction Methods ............................................ 12

Equipment and Techniques ..................................... 14
Design .................................................................... 16
Concrete................................................................. 17

Responsibility
Quality Management ............................................... 18
HSE Management System ...................................... 19

AUER Spezialtiefbau GmbH, together with its subsidiaries, has over 30 years experience in designing
and executing cut-off walls for dam rehabilitation,
upgrading of dams and new dams including their cofferdams. Our core competencies include different types of
concrete barrier walls to depths of more than 150 m
through alluvium and embedded into fresh rock as well
as grouting and ground improvement to meet the project requirements. Dam safety is our utmost priority.
Bauers technological developments and experience in

barrier wall installation facilitate the preparation of designs. Our highly professional staff is available to enhance planning in the emerging hydro energy market.
BAUER Spezialtiefbau GmbH provides excellent service,
experience and innovation in ground engineering techniques necessary for dam construction. The strength
of our company are our in-house resources facilitating
world-class solutions for projects around the globe, with
the goal to deliver safely, on time and on budget.

Center Hill Dam, USA

enter Hill Dam is located in the

State of Tennessee, just east
of Nashville. The Dam was
designed and built in the 1940s with
concrete and embankment sections
founded on karst limestone. Being responsible for the Center Hill Dam from
its Nashville District, the US Corps
of Engineers identied that seepage
through the karst limestone beneath
Center Hill Dams foundation was
sufciently severe to warrant a large
scale remediation project. This remediation requires the construction of
positive cut-off walls in the foundation
of the embankment dam section, into
the left abutment of the embankment
dam and a connection to the concrete
dam section to address the seepage
situation.
Bauer was awarded the contract as
main contractor to install a concrete
barrier wall through the earthen portion of the dam and into the rock to
depths of about 100 m.
After complex preparatory works,
including obtaining required permits
and approvals, the widening of the
embankment dam crest and the installation of a heavy-duty concrete
working platform for Bauers equipment and site-setup was built. The
platform had to provide a stable work
area for equipment with individual
weights of up to 330 tons each.
After completing the remarkable site
installation required for the works
including trafc management of the
highway along the site, the concrete
seepage cut-off wall is constructed in
two phases.
The rst phase is the installation of a
concrete encasement wall to protect
the dam embankment during the construction of the permanent barrier wall.
The encasement wall, a diaphragm

wall installed by a BAUER trench cutter

MC 50 on an MC 128 base carrier, is
set into the underlying bedrock. The
high-performance MC 50, equipped
with two powerful slurry pumps, is the
largest hydrocutter excavating an area
of 3.2 m x 2.25 m at once. The BAUER
BC 50 trench cutter excavates the
panels under slurry to allow concrete
placement using the tremie method.
The encasement wall is completed rst
with sufcient overlap between the primary and secondary panels to ensure
the continuous wall protecting the embankment in case of unexpected slurry
loss into an undetected cavity.
Inside the concrete encasement wall
the designed barrier wall is installed
into the karst foundation rock. This hybrid barrier wall consists of primary
piles installed by a BAUER BG 50
rotary drilling rig and secondary rectangular panels installed by two Bauer
trench cutters, the BC 50 and an additional BC 40, intersecting the primary
piles to form a continuous barrier wall.

Layout and section of the walls

Rehabilitation and Upgrade Dams

A part of the barrier wall towards the

left abutment is executed as a secant
pile wall with bored piles partly cased
into rock. These piles are also constructed with the BAUER BG 50 rig.
All of the elements are installed with
very tight tolerances; verticality is
required to be within 0.25 % to a
maximum deviation of 0.25 m at 100 m
depth.
Working with the hydrocutter in the
clay-silty embankment an extremely
complex slurry treatment plant and a
downstream water treatment plant are
required to protect the environment
including the Caney Fork River. The
treatment plants are constantly computer-aided and monitored to ensure
protection of the ecosystem and the
area at the project.

The construction process, the quality

control and the verication of the
works is provided in real-time with
monitoring data being available online via a visualization software like
WallTracker. The clients quality inspectors as well as Bauer Quality Control Management are equipped with a
tablet computer providing data while
walking the site ensuring verication

Rehabilitation and Upgrade Dams

of the works being carried out as specied. To ensure safety on the work
site, a rigorous HSE system is implemented on the project to safeguard all
personnel and the installation during
the execution of the works.
Bauer with the experience of working
on impounded dams for decades
ensures high quality work and dam
safety throughout the project.

Sylvenstein Dam, Germany

n the course of 2012 within a

construction period of eight months
from spring to autumn BAUER
Spezialtiefbau GmbH installed a diaphragm wall with a depth of 70 m and
a thickness of 1 m. The installation
of the concrete cut-off wall was the
rst step in a three-phase measure
to retrot the dam. The client, Bayerisches Staatsministerium fr Umwelt
und Gesundheit (Bavarian Ministry for
the Environment), was represented by
the Water Management Ofce Weilheim which had the responsibility for
the execution. The Sylvenstein Dam,
built between 1954 and 1959, has
now been reinforced by the cut-off
wall and further with a state-of-theart reporting and controlling system
for leakage water after having run for
more than 50 years. Originally, the
main task of the dam was to correct
the low water level of the Isar, meanwhile the focus has turned on mitigating strong oods.
B13 to Lenggries

B307 to Tegernsee

lamellas
embedded in rock
approximately
0.3 m

This trench was sealed by several

rows of injection grouting using claycement during the construction of the
dam. The slim central sealing core
consists of a soil-concrete (gravel,
ne sand, silt with bentonite) with up
and downstream lters of moraine
gravel. Now, a two-phase diaphragm
wall was installed as new sealing element. Its position in the core is shifted
slightly downstream of the dam axis.
By executing several investigation
drillings up to a depth of 140 m into
the dam subsoil it was determined
how deep the diaphragm wall had to
be. The diaphragm wall had to reach
a depth of up to approximately 70 m
below the dam crest (suffusion stability) as there are alternating layers
of gravel and rock sediments and the
highly varying permeability of the old
underground sealing. Starting from the
180 m long dam crest Bauer Spezialtiefbau installed the concrete cut-off
wall having a total area of 10,000 m.
Preparation works were executed with
a grab in the upper part of the trench.
Then, the diaphragm wall was installed,
deploying a BAUER trench cutter BC
40 with a base carrier MC 128, up to a
depth of 70 m also embedding the wall
laterally into very hard rock.

Bernhard Lederer, Bauoberrat (Responsible Authority) from the Bayerisches

Staatsministerium fr Umwelt und
Gesundheit (Bavarian Ministry for the
Environment)

Thus, the rehabilitation was also a

precaution against the follow-up of
possible climate changes and has
proven during the oods of 2013 to
be a major key to preventing ooding
in Bad Tlz and Greater Munich. Sylvenstein Dam being 42 m of height
and 180 m of length is based on a
100 m deep erosion trench in the main
dolomite lled with detrital of the river.

Following the successful completion

of Bauers part of the project, we would
like to express our perfect satisfaction
with the means and methods in which
Bauer has performed on the project.

Rehabilitation and Upgrade Dams

Hinze Dam Upgrade, Australia

he Hinze Dam is located on the

Nerang River, 15 km south-west
of Nerang in South East Queensland and provides the major part of
the Gold Coast regions water supply.
The Hinze Dam was built in 1975 and
raised in 1985 up to a level of 93.5 m.
During stage 3 the dam was raised
once again, this time by 15 m to 108 m,
thus doubling water capacity and
signicantly elevating ood storage
capacity. The project also provides
greater ood mitigation for properties
downstream of the dam and adjusts the
structures to current dam safety design guidelines and standards. During
the design stage of the Hinze Dam
upgrade the permeability of the dam
and the foundation were evaluated.
It was found that the increased water
pressure would have an impact on the
right abutment, due to the presence of
highly permeable chert and greenstone
with a discrete series of defects as
well as continuous defects in geological contact zones. This unfavorable
geological formation inuences the
seepage through the structure, which

Rehabilitation and Upgrade Dams

causes increased leakage through the

foundation, internal erosion and piping. The clients design team, which
was supported by Bauer, concluded
that only a plastic concrete wall which
stops seepage through the hard rock
strata (UCS up to 150 MPa) would
meet all the requirements, providing a
reliable and sustainable seepage barrier. The cut-off wall of 220 m length, a
depth of more than 50 m and a thickness of 0.8 m constructed by Bauer
begins within the existing saddle dam,
extends through the section of the
central core and nally reaches into a
5,000 m hard bedrock area below the
core where seepage is being decreased
to a minimum.

Peter Kinsella, Construction Manager

from Thiess Pty Ltd
I congratulate you and your team on
the completion of a successful and
very professionally run project.

Peribonka Hydroelectric
Development, Canada

he Peribonka dam is located in

the heart of the province of Qubec, Canada. The project involves
the construction of a main earth dam
across a main and secondary valley,
two main dykes and a hydroelectric
generating Run-Of-River station with
an estimated capacity of 385 megawatts.
Under the main dam body, the construction of an exceptionally deep
cut-off wall was required, to create a
seepage barrier in highly permeable
riverbed alluvia.
Bauer was awarded the contract on
the basis of an alternative design:
the plastic concrete cut-off wall to be
completely embedded in the bedrock,
a design which avoided any potentially hazardous areas to be sealed by
cement grouting.
The cut-off wall was exceptional by
its depth, reaching almost 116 m, and
being surrounded by complex geotechnical ground conditions.
Bauer commissioned a hydraulic
cutter, the CBS CBC 135, the biggest
ever manufactured, which included
new features and was designed specically for the construction of the
Peribonka dam cut-off wall. Beside
the extreme depth of the bed rock, the
design was further complicated by the
presence of hard rock including granite, with strengths at times in excess
of 200 MPa, quasi vertical rock cliffs,
rock overhangs, and gullies lled with
coarse alluvia, including boulders.

Fill/moraine
Boulder layers
Alluvium without boulders
Rock

New Dams

In addition to the cut-off wall construction Bauer provided a complete

construction package comprising soil
improvement of alluvium and manmade ll material by vibro densication
down to depths of 48 m rock consolidation and contact grouting as
well as construction of a grout curtain
to depths of up to 150 m by drilling
and grouting, and the installation of
permanent and temporary dewatering
systems.
The plastic cut-off wall constructed in
Peribonka has shown that this technique provides solutions for dams in
ground conditions which are beyond
the limits of other techniques such as
cement grouted cut-offs.

Richard Boudreau, Principal Director

from Production Projects,
Hydro-Qubec Equipment and SEBJ
It means a lot to me to say thank
you to the teams of Hydro-Qubec,
SNC Lavalin and Bauer. Because
of the fusion of their energy, knowhow and skills the works were completed in excellent quality within the
given time frame. After completion
of this successful phase now, we
can begin with the construction of
the dam so that the lling of the
basin can be started as planned in
autumn 2007.
Congratulations!

New Dams

Punatsangchhu-I Dam, Bhutan

he Punatsangchhu-I Hydroelectric
Powerplant project is located in
the Southern Himalayas, about
80 km east of Bhutans capital Thimphu. The new dam reaches across
the Punatsangchhu River, delimited
by steep hills on both sides. For the
excavation of the pit for the main
dam construction, two temporary
cofferdams were required upstream
and downstream of the pit across the
Punatsangchhu River bed, to seal off
ground and river water ingress. The
V-shaped river gorge is lled with heterogeneous river deposits, predominantly consisting of highly permeable
sand-gravel packages, intercalated by
cohesive layers. Boulders in sizes up
to few meters also frequently occur.
Bedrock reaches from exposed surface down to as deep as 93 m below
actual working platform elevation, with
a UCS strength of occasionally more
than 100 MPa. These highly permeable non-cohesive soil layers needed to
be sealed for the purpose of creating
a seepage barrier underneath the
upstream cofferdam. After evaluation
of different sealing methods, a twophase cutter excavated cut-off wall
(COW) was selected as the most
appropriate and reliable methodology
for the construction of the sealing element. Pretreatment works were carried
out by means of gravity grouting and
tube--manchette grouting, to temporarily seal the open void soil layers and
to x boulders and big cobbles, thus
mitigating the risk of localised collapses
of excavated COW trenches, and to minimize material overconsumption. Pretreatment reached down to as deep
as 96 m below working platform. The
cut-off wall was constructed using one
BAUER DHG-C hydraulic grab, and
two BAUER BC 40 trench cutter units.

The nominal width of the COW is

1.2 m with panel length of 2.8 m
and depth down to a maximum of
93 m, always embedding a minimum
of 0.6 m into the solid bedrock. The
biggest challenges hereby were cutting through the numerous boulders,
and the embedment of the COW into
the steeply inclined, partially vertically
dipping bedrock contour. Amongst
the technical challenges for constructing a COW under such difcult
geotechnical conditions, the site logistics were one of the most signicant
issues: All machineries, equipment
and tools had to be shipped to Kolkata/
India, and then by road to the site,
over narrow mountainous roads into
a quite remote area. Despite all the
challenges, Bauer managed to complete the project on time and to the
full satisfaction of the client.

10

New Dams

V. Mahadevan, Project Manager

from Larsen & Toubro Limited
The project has been completed
as per subcontract agreement with
good safety and quality standards.

New Assiut Barrage, Egypt

he Assiut Barrage is a damming

structure across the river Nile in
the vicinity of the city of Assiut in
Upper Egypt (400 km south of Cairo).
The Assiut Barrage was constructed
between 1898 and 1903 across the
Nile, about 560 km downstream of the
Aswan Dam. Its purpose was to divert
the river ow during low water levels
into Egypts largest irrigation canal,
the Ibrahimiya Canal.
Along with the old Aswan Dam, the
Assiut Barrage today remains in service as the oldest barrier on the Nile in
Upper Egypt. Naga Hammadi (with the
contribution of Bauer) and Isna Dams
were already replaced with new dam
structures in the 1990s. Between 2000
and 2005, the Egyptian government
commissioned an extended feasibility
study nanced by the German government to investigate the options of rehabilitation or upgrade of the existing
Assiut Dam and the Ibrahimiya Canal.
The study evaluated the practicality
of rehabilitation in comparison to a
replacement with a new hydropower
barrier. German consultants nanced
by the Kreditanstalt fr Wiederaufbau
(KfW) conducted the study and concluded that a new barrier with power
generating capabilities would be the
most economic solution. This new
retaining structure would provide an
increase in the allowed pool levels,
permitting more water to discharge
into the Ibrahimiya Canal and improve
navigation conditions. The new barrage
will also include a low head hydropower plant.
Based on the results of the feasibility
study the decision was made to proceed with the project of constructing
a new dam structure approximately
200-300 m downstream of the existing

dam. The main works for the project

were awarded to the Egyptian French
New Assiut Barrage Joint Venture
which consisted of the three international companies Vinci, Arab Contractor
and Orascom. Due to the vast experience in both, cut-off wall construction
and previous dam projects on the Nile,
Bauer was awarded the sub-contract
for specialist foundation engineering
works, comprising of different work
packages ranging from cut-off walls
for temporary purposes to the construction of dewatering wells, as well
as the foundation barrettes and permanent cut-off wall works. The specialist foundation engineering works
were designed by the German design
company Lahmayer International with
strong input from Bauer on the design
properties of the cut-off wall and the
cut-off wall material. In a rst step
Bauer constructed 60,000 m of temporary single-phase cut-off wall for the
ring dam with 38.2 m in depth and
0.8 m thickness, using state-of-the-art
BC 40 cutter equipment. Within the dry
excavation pit of the temporary ring
dam Bauer then constructed about
12,000 m of permanent double-phase
cut-off wall with varying depths between 20 and 30 m and a thickness of

New Dams

0.8 m to create a cut-off under the future barrage.

In addition to these cut-off wall works
for the dam, Bauer also installed
18,000 m foundation barrettes with
0.8 m thickness and depths up to
23 m to allow a construction of the
barrage piers with low settlement.

11

Sheet pile wall

Diaphragm wall
Permanent cut-off wall
Temporary slurry wall

Construction Methods
Diaphragm Wall Concrete
The classical type of positive cut-off
wall for deep barriers in all types of
geology is excavated by grab and hydro cutter to reach depths of 150 m and
more and is embedded in bed rock as
designed. The walls are constructed
using primary and secondary elements
with element length depending on

safety, trench stability of the slurry

supported excavations and given geology. The continuous walls are formed
by overcut of primaries while constructing the secondary elements. The
limited number of joints are serrated
and cleaned as required for optimum
interlocking.

Secant Pile Wall Concrete

Positive cut-off walls constructed
by overlapping/interlocking circular
primary and secondary elements are
being executed by drilling rigs. The
open boreholes are supported by
either special segmental steel casings
or by slurry. The number of joints is to

be considered for these generally economical types of walls. The relatively

small size of equipment is predestined
for smaller working platforms. The
continuous walls are being installed in
all types of geology including embedment into rock.

Hybrid Wall Concrete

These types of concrete cut-off walls
are executed by drilling rigs and hydro
cutter primary elements are bored
piles with large diameter whereas
secondaries are relatively slim rectangular elements. Put together these
elements form a continuous wall still

limiting the number of joints compared

to the secant pile wall. Wall depths
reached are up to 100 m with special
high precision pile installation. Execution of the individual element type will
take place as explained above.

Grout Curtains Grout

Grout curtains are intended to reduce
the seepage through discontinuities
in the foundation rock (ICOLD Bulletin 1192000). Different techniques
of grouting are provided and chosen
by experienced engineers to provide

Mixed-in-Place (MIP) Wall Cement-Bentonite

Mixed-in-Place (MIP) walls are formed
by mixing the existent soils with cement or cement-bentonite slurry to
form a durable continuous cut-off
wall. Available techniques are tripleauger Mixed-in-Place and CutterSoil-Mixing. Depths reached by these
techniques depend on the base carrier

size and range between 20 m to 30 m.

Execution sequence with primary
elements and overcutting secondary
elements are typical and similar to
diaphragm wall. The very economic
Mixed-in-Place walls are typically used
to improve existing levees and dykes.

12

Competences

seepage mitigation in the foundation.

Whether jet grouting or permeation low
pressure grouting is used depends on
a number of factors to be discussed for
the individual project based on specied tasks and the existent geology.

New Dams - Greeneld Projects

Bauer cut-off walls provide new opportunities for investors and designers
involved in Water Resource Development projects. When planning a new
Water Resource Development project,
one of the major obstacles is nding a
location with suitable geological and
hydrological formations for the project
which also has appropriate environmental and social aspects. Bauer cutoff walls can be installed in any type of
ground condition to provide a reliable,
durable and impermeable (approximately 1x10-8 m/sec.) system which
ensures efciency, durability, stability
and safety for your project. Thus, the
Bauer cut-off wall makes selection of
the project site that bit easier. Bauer
cut-off walls convert the existing
ground conditions to meet your design
requirements, at a location of your
choice. The ability to install the walls
in remote areas enables you to meet
the environmental and social requirements of dams.

Cofferdams for New Embankment

Dam founded on alluvium

Cofferdams for excavation pits for

New Concrete Dam founded on rock

temporary diversion

temporary diversion

new dam
temporary
cofferdam

upstream
temporary
cofferdam

downstream

temporary
cofferdam

temporary
cofferdam

if required

if required
proposed permanent
cut-off wall

proposed
cut-off wall

Design and Construction

Stage 1

proposed
cut-off wall

Design and Construction

Stage 1

new dam
temporary
cofferdam

temporary
cofferdam

foundation treatment
if required

permanent
cut-off wall

Cut-off wall in operation

Stage 2

Excavation in operation
Stage 2

Existing Dams - Upgrade, Rehabilitation and Repair Projects

Upgrade of Existing Dam
(heightening)

proposed permanent
cut-off wall

Upgrade Design and Construction

Stage 1

permanent
cut-off wall

Upgrade in operation
Increased dam safety and storage capacity
Stage 2

Mitigate Seepages by
durable Concrete Barriers

proposed permanent
cut-off wall

Rehabilitation Design and Construction

Stage 1

As part of dam safety programme,

dam owners, municipal and state authorities and private parties conduct
regular reviews of all their dams. Although the condition of a dam has not
changed since it was built, reviews of
the purpose or the design identify a
need for upgrades to increase capacity
or to enhance life span and dam safety
which may be compromised due to
hydraulic conditions or during major
earthquakes.
Other existing barrier systems, for
example those constructed with conventional grouting methods, often fail
to meet the degree of efciency and
durability, as well as other performance
specications over the life of the structure as required by the design.

permanent
cut-off wall

Rehabilitation in operation
Increased dam safety and storage capacity
Stage 2

Competences

13

Equipment and Techniques

Cutter and Grab
Bauer trench cutters and Bauer hydraulic grabs are typically the lead
equipment for the panel excavation for
the execution of concrete cut-off walls.
The centrepiece of the Bauer trench
cutter system consists of a steel frame
with two gearboxes attached at its
base, which rotate in opposite direction around a horizontal axis.
Cutter wheels suitable for the prevailing ground conditions are mounted
on the gearboxes. Selecting the most
suitable type of cutter wheels (standard
cutter wheel, round shank chiselcutter wheel or roller bit-cutter wheel)
is essential for cutter progress which
mainly depends on the soil conditions
(particle size, density, abrasiveness,
compressive strength, etc.). The accurate determination on the trench
cutter for your project depends on
ground conditions, the required trench
width and wall depth. The ideal base
machines for Bauer trench cutter and
mechanical or hydraulic grab equipment are BAUER foundation cranes
MC 64, MC 96 and MC 128. The entire
hydraulic power supply of the attached
cutter/hydraulic grab is provided by
the hydraulic systems of the MC crawler cranes which have been specially
designed for those applications.

Rotary Drilling Rig

Bauer rotary drilling rigs on large
dams are used to construct a secant
pile wall or in combination with diaphragm wall elements a hybrid wall.
The BG drilling rigs like BG 28 or
BG 40 are ideally suited for drilling
cased or slurry-supported boreholes

14

Competences

with the kelly-system and special

drilling tools as demanded by the individual geology on the project. The
segmental steel casings for cased
boreholes are installed by rotary drive
or optionally by hydraulic oscillator
powered by the drilling rig.

Small Diameter Drilling Rig

The main equipment for the drilling &
grouting method on large dams are
the Bauer hydraulic drilling rigs of the
KLEMM KR 800-series. These modern
and extremely compact rigs are particularly suitable for the different drilling
applications:
Rotary-,
Rotary drilling with down-the-hole
hammer,
Rotary percussion-,
Overburden-,
Double head drilling rotary/rotary
and

Double head drilling rotary/rotary

percussion
The drilling rigs will be tted with
hydraulic drifters of the Eurodrill HDseries, with different types of drill
rods and drill tools to suit the geology
and depth required for the individual
project. After state-of-the-art controls
over borehole deviation the grouting
process will be executed. The accurate determination on grouting equipment (pump-type, mixer, packer type,
etc.) depends on soil conditions and
the required grouting material.

Mixed-in-Place
Bauer Mixed-in-Place (MIP) is developed specically for use in the overburden (granular, slightly cohesive soils).
The entire hydraulic power for the rotary drives of the attached triple augers
is provided by the hydraulic system of
the base carrier which have been specially modied for those applications.
Base carriers like BAUER RG 18, RG 22,
RG 25 or BG 40 are chosen as per the
nal depth to be reached.

Mixing and Desanding Unit

The open trenches of diaphragm wall
elements are supported by slurry. During the preparation of bentonite slurry,
the bentonite powder has to be mixed
intensively with water. This can be
achieved by pump mixers or colloidal
mixers of the SCW/SK-series. Singlephase slurry mixes for cut-off walls
consisting of multiple components,
such as rock powder, cement, bentonite and water, are produced by Bauer
mixers as well.
Bauer desanding plants are developed
specically for the use with trench cutters to separate the cuttings from the
slurry used to support the open trench
and to transport the cuttings.
The plants are characterized by the
following features: modular construction throughout the entire plant unit
and, therefore, the ability to match
treatment capacity to soil type and
cutter output capacity.
Advantages: secondary circulation with
desilter or centrifuge possible, short
setting up and dismantling times and
containerized transport dimensions.

Competences

15

Design

auer Spezialtiefbau supports the

designer in different stages of
project development regarding
relevant foundation engineering techniques. State-of-the-art foundation

engineering methods together with reliable software is used by experienced

in-house designers to support clients
and their engineers during preliminary
stages and for the execution design.

Execution and Final Design

To carry out special foundation works,
complete designs with all details are
needed to ensure safe and smooth
execution. Not only specic design
calculations such as trench stability
designs are provided, but also complete geotechnical project designs to

establish the execution parameters

of the various foundation engineering
techniques in accordance with the
clients requirements. For dam rehabilitation projects the safety of the existing structure is considered to be of
utmost importance for such designs.

Computation
In addition to the standard design
calculations such as the stability of
the open trench during construction
of a cut-off wall or slope stability con-

sidering the working loads during the

execution of works on existing dams,
special tasks are also performed regularly.

3D model of open trench,

contour plot of total displacement

An actual example of such a task is

the Sylvenstein Dam project (page 6)
where a trench was cut next to a recently completed panel. The required
initial concrete strength in the panel
was analyzed using the 3D-FEM tool
PLAXIS. Both Fellenius Method and
the computed settlements method
were used to assess the safety level
of the system refer to gures.
Model in plan view, contour plot of settlements

Documentation
Accuracy of workmanship and the
verication of the special foundation
works executed are vital to us. The
as-built survey of each structural element is documented to be transferred
into a structural as-built drawing as
per project requirements. By entering
all the measurement data into
an illustrative quality
system the exact properties

and alignments of the diaphragm wall

and the achievement of the minimum
panel overlap can be conrmed refer to gure
below.

Primary panel
Secondary panel

As-built drawing of a
completed cut-off wall

16

Competences

Concrete

auer Concrete Competency has

been established and has been
constantly progressing due to:

In-house scientic research supported through academic cooperation with partner universities, investigating and assessing materials
inuence on the installation process
and their inuence on the nal, integral quality of the wall or pile.
Cooperating in Standardization
BAUER Spezialtiefbau GmbH cooperates worldwide with various organisations to specify standards and
regulations. Amongst others we participate in the following groups: We

are a member of the concrete task

group, which was established by TC
288 (= the Technical Committee of
CEN in charge of European Standards for Execution of special geotechnical works, Diaphragm Walls).
We are also a member of the tremie
concrete task group of the Concrete
Institute of Australia (which compiled the Guideline on Tremie Concrete for Deep Foundations published in 2012). Furthermore, we act
as chairman of the Concrete Task
Group of the EFFC, the European
Foundation Contractors, established
in January 2014. Its aim is to adjust
the composition, placement and
quality control of concrete to latest
developments and to introduce the
results to the European and international market.
Consulting in operational works,
hence giving project-specic
advice in concrete design, raw
materials and concrete testing as
well as quality assessment, in all
construction phases from planning,
calculating or nally executing the
dam rehabilitation project.
Bauer aims to support own projects in
all matters and steps of materials use
for deep foundation works. Regarding
concrete for dam rehabilitation principal demands have to be specied in
order to proof both sufcient fresh and
hardened concrete properties:
Permeability and erodibility,
both must, within dened ranges,

Competences

ensure the demanded serviceability of the wall.

According to Bauers experiences
gathered in own research, standards and consulting works the
concrete, prior to its application
in a project, must be properly designed, specically tested and optimized. For placing concrete in deep
excavations, the fresh concrete
behavior must be understood and
required properties must consequently be controlled throughout
the concreting process.
It is Bauers experience that the
cut-off wall construction safety,
in terms of its function as a water
barrier, should not be based on
the ultimate limit state thus on
the strength of the plastic concrete
used but on its deformation capacity, as it is a common practice for
the service limit state.

17

Quality Management
Veried Quality is our most successful product.
It is the key to success, today and tomorrow.
Compile accurate records of test
results, certications and other
required documentation which conform to the project specic contractual requirements and standards;
Notifying the clients representative
of deciencies in quality and proposed corrective action, and ensuring
that agreed corrective action is properly implemented;
Construction Quality Control (CQC)
System Commitment
Bauer is committed to deliver high
quality products for all our projects.
For each project we implement a
project specic Construction Quality
Control (CQC) System which aims
to ensure a consistent, high quality
standard of workmanship throughout
all phases of the works. Our CQC System intended to control and verify the
works executed, is based on, amongst
others, the following core fundamental
quality principles:
Ensuring the highest quality of
works by establishing, monitoring,
maintaining and updating quality
control procedures. This is achieved
by providing written instructions to
govern quality control procedures
and practices to clearly establish
dened responsibilities and authorities early in the project to ensure
quality compliance;

Quality Strategy for Cut-off Walls

Proper continuity of the entire wall
Integrity of the cut-off wall concrete
material placed
Proper embedment of the wall into
the dened strata

Providing qualied individuals who

will be responsible for the management and implementation of an
agreed CQC program; and
Providing high quality workmanship and project administration by
implementing agreed transparent
documentation procedures.
Quality is the basis for the BAUER
Groups worldwide success and therefore it is part of the key-focuses of
the company. The condence in the
quality of our products, services and
equipment gained throughout many
years will be preserved and expanded
to its optimum.

Quality Control Areas for Cut-off

Walls
Trench stability
Slurry mixing and recycling
Monitoring of supporting slurry
Monitoring abnormalities, soil
conditions and wear & tear
Panel verticality and overcut
verication

System
Our quality management system is
based on ISO 9001 and the relevant
legal and industrial norms.
All relevant processes of our company
are methodically analyzed and documented. The processes are aimed at
increasing the product quality for the
continuous improvement process and
thus help to improve the customers
and employees satisfaction levels.
We use key gures to regularly check
if the planned quality objectives have
been achieved. Deviations are analyzed and rectied in due time.

18

Responsibility

As-built visualization
Proper concrete mix design with
quality products
Concrete batching and testing
Production analysis
In-time documentation

HSE Management System

he required Health, Safety and

Environmental performance is
achieved through the:

Reduced costs associated with

accidents and illness

Bauer Spezialtiefbau HSE System

Compliance with the HSE policy,

system and standards are mandatory
and subject to periodic audit. In partnership projects, Bauer Spezialtiefbau
subsidiaries are required to encourage
the partner to work to Bauer HSE
standards and to implement an appropriate HSE management system that
will achieve the following goals:

National and international standards and guidelines

Reduced work-related accidents

and illness

Improved company image by demonstrating a commitment to manage and minimize risks to employees,
stakeholders and customers

BAUER AG Health, Safety and

Environmental Management statement and guidelines

Improved performance through

policies and procedures
Compliance to the latest legislation
Reduced risk of citations/penalties

The Bauer Spezialtiefbau HSE Management System allows for a common approach to be adopted across
all businesses. The key elements are
outlined below and are supported by
the fundamental requirement:
Leadership
Commitment
Involvement

Responsibility

19

BAUER Spezialtiefbau GmbH

BAUER - Strasse 1
86529 Schrobenhausen, Germany
Tel.: + 49 8252 97- 0
Fax: + 49 8252 97-1496
BST@bauer.de
www.bauer.de

http://www.bauerdamrehabilitation.com

905.019.2

3/2014

http://www.bauerdamcontractors.com