THE MAGAZINE OF THE FELBERMAYR GROUP 1/2011

TEAMWORKMULTI-MODAL TRANSFORMER TRANSPORT

SUCTION INSTEAD OF SHOVELSFLAT ROOF RENOVATION WITH SUCTION EXCAVATOR

BIG BOYSGAS TANKS TRANSPORTED TO OCEAN-GOING VESSEL

BLUE GIANTCOMPOSITE STRUCTURE LIFTED INTO PLACE WITH CRAWLER CRANE

PHOTO: MARKUS LACKNER

STEP BY STEP:HIGH-SPEED TRACK FOR RAILWAY

03 NEWSLatest news from Felbermayr Holding

08 STEP BY STEPRailway embankment for high-speed track

10 GOOD VIEWFlat roof renovation with suction excavator

11 RENATURATIONExcavating for environmental protection

14 BIG BOYSLiquid gas tanks transported

15 TRANSPORTHeavy transport for largest run-of-river power plant

16 LIFTINGTECHNOLOGYBlue giant lifts bridges

18 CRANE DUETTandem lift for conveyors

20 MULTI-MODALTeamwork for transformer transport

21 SARENORebirth of a monument

22 PORTRAITFreight carrier launched

23 STAFF NEWSRetirees, construction sports stars

INFORMER 2

The signs of an upturn are there; thetruck fleet is working at full capacity, em-ployee numbers have remained steadyand even increased in some areas – sothere’s enough work to go round again.But the past two years have left theirmark, and it hasn’t been easy to makeprogress. Why? Prices are rock-bottomand showing few signs of recovery. En-ergy costs, on the other hand, are in-creasing and another tough winter hasdelayed many projects and constructionjobs. However, week by week we’re see-

ing a following wind build and the eco-nomic engine getting up and running. Andwe’re ready for it too. We always had con-fidence, and took advantage of the pasttwo years, identifying where savingscould be made, improving processes andprocedures, and making every effort toring-fence the Felbermayr company fromthe omnipresent and undesirable eco-nomic developments. Together with ourcustomers and employees, we’ve suc-ceeded in putting the group of companiesback on the road to recovery. The follow-

ing pages contain just a few examples,such as an item on Krefeld port, situatedon the Rhine, as well as other interestingitems. Combined with the heavy loadport in Linz, it now represents anotherkey building block in trimodal transporta-tion. New sites in Austria and the rest ofEurope also bring us much closer to cus-tomers in the transport and lifting tech-nology sectors, as well as in construction.But let’s not forget – it’s still only half-time. With this in mind, we wish yourcompany and ours continued success.

Dear readers,

Page 8:Railway embankment

constructedPage 14:

Gas tanks transported

Contents

Horst Felbermayr

Yours sincerely,

Horst Felbermayr, DI

Page 16: Supporting structure

lifted into place

Half time!Half time!

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KREFELDTRIMODAL INTERFACE FORRAIL, ROAD AND WATER

As the operator of the heavy and bulk cargo port in the Rhine city of Krefeld, Felbermayris expanding its potential in Germany. The 15,000 square metres of storage space and5,000 square metres of handling space guarantee customers maximum flexibility. Witha permanent cargo-handling capacity of 500 tonnes and the ability to receive and sendby rail, road and water, the harbour is ideally equipped to meet the requirements of tri-modal transport.

MOBILE ON SITEFelbermayr expands its range of mobile construction cranes

Felbermayr is enlarging its rental fleet with three new MK88s and one MK110. This is the company’s response to the regional require-ments of our customers. This will bring to nine the equipment in the fleet and cover performance categories from the MK 63 to the MK110. The new equipment was supplied to branches by Liebherr and the crews instructed and trained over a period of just six weeks. TheMK series of cranes combines the manoeuvrability of a traditional mobile crane with the functional advantages of a rotating towercrane. MK cranes have the latest undercarriage technology for maximum mobility, safety and comfort. The MKs are designed for fast,programme-based one-man installation at the press of a button and are ideal for use in the tightest of spaces. Multiple uses per day areno problem for these »taxi cranes«.

STRUCTURAL ENGINEERINGLiving by the Mühlbach

A residential building dating from1920, situated by the Mühlbach in thecentre of Wels, is currently beingbrought up to the latest standards inbuilding physiology and technology. Atotal of 1,500 square metres of livingspace is being renovated sensitivelyin order to preserve the turn-of-the-century style while creating a modernambience in keeping with the times.Only the load-bearing walls, curvingstaircases and fine vaulting will be retained. A total of 15 apartments withloggias and south-facing balconieswill be created over 4 storeys, plus 9garages and 8 parking spaces. Com-pletion is planned for the end of 2011.

INFORMER 3

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NEW SLANTFelbermayr builds Salzach pedestrian bridge

Felbermayr equipment was contracted for about a month for the transportand erection of a cable-stayed bridge over the River Salzach. Felbermayrwas able to complete the work in the Salzburg suburb by the middle ofMarch. The two Salzburg suburbs of Aigen and Josefiau were then joinedby the 96-metre long Salzach bridge. A total of seven loads up to 33 metreslong and with 32 tonne sections were needed. These parts of the bridgecame from Furth im Wald (Germany), 300 kilometres away. The sections hadto be on site before 6 am in order to prevent traffic hold-ups. An LTM 1500from Liebherr and an AC 120 from Terex Demag started the lifting operation.The AC 120 was used as a compensator crane. The actual 32-tonne loadwas borne by the LTM 1500. That is how the raising of the first pylon for an-choring the wire cables on the Josefiau side was achieved. Sections one tofour formed the footbridge itself. An island was created in the bed of theSalzach using rip-rap stones to allow the sections to be deployed. TheLTM 1500, AC 120 and an AC 80 were used to raise the sections, 5.9 metreswide, and up to 25 metres long. The five-tonne, 90-metre steel cable fortensioning the bridge was laid out using a crane. Once the pylon had goneup on the Aigen side, the precision work was carried out using a minicrawler crane and a 36 metre high telescopic platform. The cable-stayedbridge was finally completed in June. Some 10,000 locals will profit fromthe pedestrian and cyclist bridge – their trips to work or school will now beconsiderably shorter.

INCREASED CAPACITYLambach railway station to be enlarged

During the extension of the Westbahn track, Lambach station in UpperAustria wil l be enlarged and modif ied by employees of the Felbermayrcivi l engineering section to accommodate the future increased require-ment for shunting for companies located in the area. By the t ime the workis completed at the end of 2011, one new ki lometre of track ( incl . baseand drainage), three sets of points and some 30 ki lometres of cable wil lhave been instal led. A new bridge and retaining walls wil l have beenconstructed to cross the public road. These wil l be supported by 27dri l led pi les 90 cm in diameter and up to 11.5 m in length. Some 28 ki lo-metres of the exist ing cable wil l have to be replaced during the rebuild-ing. As the construction work wil l be carried out close to or on the tracknear the station, i t wil l have to proceed in stages and wil l require verylabour-intensive scheduling. To guarantee the work near the track issafe, sections wil l be closed at night and at weekends so that ÖBB trainservices are not affected.

BLACK GOLDTRANSPORT OF AN OIL-DRILLING RIG

Two mobile cranes and six tractorunits are currently in use east of Vi-enna looking for new oil and gas de-posits. Circumstances require thedrilling rig to be moved to the regionaround Gänserndorf. Because thedrilling modules can be up to threemetres high, additional mega-trailersand semi-low-loaders are also in use.Up to 60 transporters will be neededfor one rig because the individualcomponents can weigh as much as 40tonnes. The project started in August2010 and is scheduled to be com-pleted in July this year. It will make asignificant contribution to safeguard-ing domestic oil and natural gas pro-duction for OMV.

NEWS

INFORMER 4

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FOOTBALL TEMPLESTADIUMCONSTRUCTION INBUCHAREST

Ten mobile cranes plus platforms and lift-trucks have been in service since Aprilbuilding the canopy over the Romanian na-tional stadium in Bucharest. The cranes areunits capable of handling maximum loadsof 55 to 250 tonnes. Because the use ofworking cages is forbidden in Romania, twolifting platforms working at more than 60metres have been employed. These willhelp with the installation of the transparentroof, among other things. When it is fin-ished in August, the stadium will be able toaccommodate 55,000 sports fans. Some4,000 of these will be able to follow theleather ball from VIP seats. The footballtemple is named after discus-thrower LiaManoliu who brought the discus goldmedal back to Romania from the 1968Olympic Games in Mexico.

ENFORCED BREAKLow waterlevel delays transport

Nine nacelles for wind turbines have beentransported from Rotterdam via the Rhine-Main-Danube canal and the Danube to theheavy load port in Linz. The load included 72-tonne fibre glass and carbon compo-nents. The heavy weight stemmed from theintegration of generators and transformers.Low water in Eastern Bavaria meant theload had to be distributed over two vesselsin Regensburg. This reduced the draughtand allowed the vessels to proceed. De-spite this enforced break, the vesselsneeded just 10 days to reach the heavyload port in Linz, where gantry cranes tookover the load. The nacelles remained in theopen depot at the Felbermayr heavy loadport before continuing on to Mark-grafneusiedl in Burgenland.

FUTURE-ORIENTATEDElectric cars used at Wels expoEnergy

The stars among the other mainly powerful vehicles are two electric carswhich, together with the combustion engines in the Felbermayr waste man-

agement fleet, will be responsible for the cleaning and waste removal servicesat the Wels exhibition site. With the purchase of these two electric productioncars from Mitsubishi, Felbermayr is demonstrating its openness to future de-velopments. The i-MiEV vehicles will be used mainly for urban business trips.On the spot at the Wels exhibition grounds Felbermayr employee BarbaraDickinger will be responsible for business trips in an electric car for the Fel-bermayr waste management section. She is very pleased with the vehicle. Onlythe range is a little limited – 150 kilometres according to the company. How-ever, Ms Dickinger says that this reduces global warming considerably, al-though that is a secondary consideration at the exhibition. The mainadvantages there are the low noise emissions. And given the numbers of visi-tors expected at the exhibition, the vehicle will certainly have its admirersfrom the point of view of future mobility.

INFORMER 5

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POWER PACKSUPERHEATERBUNDLES REPLACED

Two so-called superheater bundleswere replaced in mid-March at theAVE heat recovery facility in Wels.One of the most powerful cranes inAustria was used to exchange these31-tonne components. It was anLTM 1500 with a 75-metre longboom including compensator. Thecrane was also equipped with 165tonnes of ballast. An LTM 1045 (45-tonne crane) was used to erect ascaffolding tower so the compo-nents could be stored temporarilyafter lifting. The two new super-heater bundles were also suspendedthere, waiting to be lifted into theirfuture location. These were takenfrom the low-loader and suspendedin the scaffolding tower using a thirdcrane (LTM 1090). One day wasneeded for the replacement. Felber-mayr was also contracted for thetransport of the two superheaterbundles to Wels. They started fromthe international industrial servicecompany FMT in Graz, whichwas  also Felbermayr’s client. Thepower company Energie AG reportsthat some 60,000  households canbe supplied from the heat recoveryfacility in Wels.

A BIG’UNDemolition excavator for site clearance

With a boom that can be extended up to 31 metres, the new demolition excavatorweighs in at more than 64 tonnes. Fitted with an electrical working area limitingsystem, rear and jib cameras, and a safety windscreen, the high-tech machineleaves nothing to be desired when it come to safety, either. A breaking tool/ham-mer and sorting grappler come as standard on this special machine. It also starswhen it comes to digging ditches, thanks to an adjustable jib and a three-cubicmetre bucket.

BAUTRANSFLEET PART ENLARGED

Six new tractors were recently deliv-ered to the Felbermayr subsidiary Bau-Trans. The new machines represent areplacement investment for retiredequipment. Five of the machines arebeing sent out from BauTrans Hungary,based in Budapest. One of them is as-signed to BauTrans in Lauterach (Aus-tria). The Scania tractors, with up to560 HP, will be used for transportingexceptionally wide or heavy loadsacross borders.

STRUCTURAL ENGINEERINGFramework agreement for service station shops

By the end of 2011, the structural en-gineering section will have con-

verted around 30 service station shopsowned by the Doppler Group into new»SPAR express« outlets. The work tobe carried out will range from com-pletely new designs, starting withclearing the site, to the external designand construction of washrooms. How-ever some service stations will only re-quire modifications to their internallayout. The new SPAR express servicestation shop concept will also allowDoppler customers to buy from theservice station at supermarket prices.

NEWS

INFORMER 6

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MANUAL WORKElectric motorinstalled using strand jack

Installing an electric motor canbe a heavy job, especially whenthe rotor and stator weigh in at69 tonnes. That’s the way it wasfor the Felbermayr insertion teamfrom Linz, but they showed it wasa piece of cake in the Polish cap-ital of Warsaw at the end of Feb-ruary. The 4.8-metre diameterstator was lowered to the precisemillimetre using lifting gear andstrand jacks into a 3.5-metredeep opening and attached to an-chors. The 32-tonne rotor was3.6 metres in diameter and 3.7metres high. After it had beenbrought into exact position abovethe stator using delay tracks, itwas lowered gradually with thestrand jacks. Thanks to advancecalculations and manual assis-tance, it was lowered into thestator in a just a few hours.When you consider that there isonly two millimetres clearancebetween rotor and stator, the re-sult was really in the »luxuryclass manual labour« category.The lifting gear used has a maxi-mum lifting capacity of125 tonnes per piston. When allfour pistons are used, that meansa 500-tonne stroke.

SPECIALISED CIVIL ENGINEERINGSHOTCRETE WALL FOR FESTIVAL HALL

The work involved in securing a 1,500 m2 rock face lasted from January toMarch. It was needed for the construction of the new Tirol Festival Hall in Erl.Some 2,500 lineal metres of rock anchor, 15 tonnes of reinforcement and 800tonnes of concrete were needed to shore up the rock face which was up to 20metres high and 80 metres long. Rock slabs with a total area of 150 m2 cameloose during routine blasting because of a geological fault. The dril l truck and32-metre carriage were used because the digger was unable to reach the 10-metre away location. The truck was able to dril l the holes for the anchors andmake the site safe.

AWESOMEContainer village moved by self-drives

At 45 metres long and 7 or 10 metres high and wide, the BG80 from voestalpine Stahlcan certainly be described as »impressive«. Thanks to thorough preparation by theclient, BIS Gerätetechnik, transport was a snip. Four mobile cranes lifted 32 contain-ers of different designs and placed them on the 24-axle self-drive. The mobile officeswere then driven to the new location 800 metres or so away and placed on theirfoundations.

On behalf of the partner company BIS Gerätetechnik, Felbermayr transported a mobilecontainer system at 600m² of office space in mid June. The assignment was carried out tothe highest satisfaction of the end customer voestalpine.

INFORMER 7

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In August last year, the Felbermayr civil engineering section began work on straightening the four-kilometre section

between Lambach and Breitenschützing. By 2013, trains here should be capable of up to 230 km/h and thus make

a considerable contributions to increased mobility of the Westbahn railway.

Railway embankmentfor high-speed track

CIVIL ENGINEERING

INFORMER 8

Even today, the future high-speedstretch of the ÖBB is steamingahead. Up to seven dump trucks

are making their way up and down thethree-kilometre construction site. Theyare filled continuously by two bulldozersso there’s no time for the excavator op-erators to get bored. Site managerThomas Wallenstorfer from Felbermayrconstruction operations is also hard at it:»The main earthwork activity consists ofcreating a 2.5-kilometre long railway em-bankment including installing vibration-compacted columns to reinforce the sub-soil and the creation of a drainage sys-tem including retention basins, plus atrain station,« he explains. The figuresbehind this bland project summary aretruly impressive. For example, the totalamount of rubble processed for con-struction of the embankment comes to

some 16,000 dumper loads. This is theequivalent of 160 kilometres of vehiclesend to end. Equally remarkable is the in-stallation of more than 7,000 vibration-compacted columns and the laying ofaround 2,500 lineal metres of drainageand sewage pipes.

Embankmentconstruction with obstacles

Because the existing soil was not strongenough to support the embankment, thesoil had first to be replaced. »That in-volved removing 25,000 m3 of material,«says Wallenstorfer. Vibration-compactedcolumns were inserted where the stablesoil couldn’t be made deep enough: »Theequipment forces a steel rod in to adepth of up to eight metres, just like aram. After that, a funnel at the top feedsin washed gravel to a particular specifi-cation and compresses it using com-pressed air,« says Wallenstorfer,explaining the method that had to beused every three metres along the em-bankment and every metre in the stationarea. In this way, a total of 7,100 columnswere inserted. 35,000 m2 of geocom-posites were laid on the prepared baseto act as a granular sub-base. This is theequivalent size of five football fields.After the addition of around 30 centime-tres of drainage gravel and the laying of2,000 running metres of drains, plus an-other geotextile layer, the »foundation«was ready for the actual embankment.

Technology insupport of earth movement

When it is finished, the embankment willbe 20 metres wide and 4.5 metres high.Accounting for why the embankment iscurrently seven metres high, Wallenstro-

fer says, »For maximum compaction, a2.5 metre high top layer of fill was alsoadded.« Once settlement is complete,this layer will be removed. The geologistswill decide on the timing. The materialwas compacted using a 12-tonne rollerequipped with a surface compactionchecker. This keeps the operator contin-uously informed of the degree of com-paction of the embankment area beingrolled. »Even the bulldozers are soft-ware-controlled and so help the operatorby creating the correct level for the rail-way embankment,« Wallenstorfer contin-ues. The result is that time-consuminglevelling using a surveyor's staff andlaser are a thing of the past in the case ofmajor earthmoving projects. The earth-works will be followed by installation ofthe railway equipment. As Wallenstorfer

explains: »During that phase, we’ll be in-stalling about 100 pylon foundations andnumerous cable troughs for the railwayelectrics.« The change-over from the ex-isting to the new track is scheduled forsummer 2012. After that, the old em-bankment will be taken down and theconstruction site recultivated. Sectionsof the old embankment will be includedin the creation of ponds and ecologicalbuffer areas.

New addition to the fleet: The automaticlevelling controller kept the 22-tonnebulldozer used to construct the railwayembankment on a flat footing.

The material needed to build the embank-ment came from close to the site. Afterproject completion, the 26,000 m2 area willthe carefully renatured.

Five railway and two road bridges wereconstructed in the course of the project.This required laying an 80-metre sectionof road.

INFORMER 9

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The high-rises south of Linz are52  metres high. Their flat roofshave also done their duty for

decades. But it was now time for the flatroof to be recovered to prevent damageto the building. However, the first stepwas to remove the gravel holding downthe sheeting. Removal in the standardway, using wheelbarrows and chutes,was not possible owing to the differentlevels of the roof and the 13-storeyheight. »By using the suction excavator,we were able to provide an economi-cally-viable solution,« comments area di-rector Reinhold Reisenbichler fromFelbermayr Waste Management.

Time- and money-saving solution

A lot of skill was required to set up the 100-metre suction hose. One workerthought it would not be easy to lay thepipe from the suction excavator to aheight of 52 metres. However, this wasachieved in just a few hours thanks tothe practical experience of the Felbermayr employees and some dedi-cated scaffolding. »Two dayswere needed to suction-clearthe 800 m2 area,« re-ports Reisenbichler.

This included the prepara-tion and removal by truckof 40  tonnes of material.Felbermayr will be calledon again oncethe roof

renovation is complete. This won’t be forsuction but to transport the new gravelusing a crane – also a time- and money-saving solution. It also minimises the

potential risks for the workers onthe site.

CIVIL ENGINEERING

INFORMER 10

Suction instead of shovels is the motto of the Felbermayr waste management section. This refers to the suction

excavator introduced successfully several years ago. The advantages of this easily used device became clear

during some flat roof renovation in Linz.

Across the roofs of Linz

The suction excavator also providessterling service when it comes to flatroof renovation: costs are saved thanksto its flexibility when removing gravel fill.

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The Traun, originally a branchingsystem of waterways, has be-come a narrow river bed as a re-

sult of well-intentioned regulations overpast decades. The result has beenwashed-out bank protection and flooding,frequently threatening communities.Now, efforts are being made in numerousplaces to again liberate the Traun from itsdeep river bed and thereby reduce the riskof flooding. One example is the 1.2-kilo-metre stretch of the Traun at Fischlham inUpper Austria. »We’re widening the Traunand recreating the natural drainage sys-tem,« explains Hans Wolfsteiner from Fel-bermayr hydraulic engineering. Almost60,000 m3 of material will be excavatedto widen the river bed. Because of re-strictions by the water authorities, it is not

possible to move the material to thenearby banks, explains Wolfsteiner butthere is a solution: »To transport the ma-terial to the opposite side, we created anisland in the middle of the river. That’swhere we located a crawler crane. Fittedwith a double-shell type grab, it transportsthe material to the opposite bank. Fromthere, it’s taken away by truck« The craneuses a jib length of up to 45 metres tospan the 70 metre wide river bed. Thecrane will take about three months totransfer the material. After that the artifi-cial island will be removed.

Granite gently guides river

»To shore up the flat banks, we’ll bedumping some 20,000 tonnes of ar-

mourstone in so-called groynes,« ex-plains Wolfsteiner. This should subtlyguide the flow of the Traun. The granitewill come from the Felbermayr gravelpits four kilometres away in order tokeep the logistical costs under control.»Once the work is finished, we’ll re-store the access road needed to trans-port the crane,« says Wolfsteiner,looking to the future. A huge effort,then, for 1,200 metres of river, but onewhich is justified if we consider thelong-term improvement in living condi-tions for the animals in the woodlandsand the minimal maintenance of theTraun banks that will be required in thefuture. There will obviously be a signifi-cant benefit in protecting nearby com-munities from flooding as well.

Construction machinery weighing many tonnes was used until March in the Traun meadows near Fischlham in

Upper Austria. Its task was careful renaturation and a potential increase in drain-off in a flood event. This

federal/state initiative is aimed at protecting low-lying communities from flooding and preventing the woodlands

from drying out.

Traunau sensitively renatured

INFORMER 11

CIVIL ENGINEERING

The combination of construction and liftingequipment made possible the renaturationof Traun near Fischlham in Upper Austria.

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Self-propelled vehicles also make difficult roll-on/roll off activities possiblewhen unloading ships.

TRANSPORT

INFORMER 14

The sky-blue self-propelled modulartrailers (SPMT) have already car-ried lots of heavy weights on their

backs. However, they demonstrated un-precedented strength last Decemberwhen transporting the two liquid-gastanks. »At 540 tonnes, the larger of thetanks was our major headache,« saysDaniel Costea from the Felbermayr branchin Bucharest contracted for the job. It wasa very impressive sight at 40 metres longand 18 metres wide. And if that wasn’tenough, it was 12.2 metres high! To get anidea of the size, just think of the 10-metretower in your local swimming pool. Yet theheight played a minor role in the transportof the two tanks. The core issues weretheir transport on the Danube and unload-ing at the dock.

Locks as obstacles

The steel colossuses travelled on a sea-going vessel from Shanghai to the BlackSea port of Constanza, according toCostea, taking some three weeks via theSuez Canal. Once they were there, a float-

ing crane was used to transfer the larger,double tank to a flat-deck pontoon. Thesmaller of the two was stored temporarilyat the port. Some 650 kilometres of theDanube now separated the tanks from theshipyard in Turnu Severin. »A transit timeof about a week is normally enough,« ex-plains Costea. However, flooding threwout the schedule for the Felbermayr crew.There were considerable delays passingthrough a dozen locks and, because offlooding, the last damn 30 kilometres fromthe destination denied the pontoon and itsexpensive freight a smooth passage. Avery low bridge over the lock was causingdelays. »We managed it in the end,« sayCostea, »with just 1.2 metres clearance«.That may be generous for heavy trans-ports on the roads, but a close call forshipping which can involve waiting a weekand incurring additional costs.

Unloading

»Road transport of the SPMTs took aboutthree days from Wels to Turnu Severin,«says Costea of the 900+ HP self-pro-

pelled vehicles. Six trucks were neededfor the modular transport vehicle, whichweight around 60 tonnes. The six under-carriages and two drive units were as-sembled using the harbour crane at thedestination. Unloading was planned to be»RORO«. »This stands for Roll-on/Roll-off,« explains Costea, »meaning unload-ing from the vessel via a ramp.« And thatwas another problem: there was noramp. »We built a temporary ramp usinggravel and reinforced concrete to solvethe problem,« say Costea. After unload-ing, the tank was lowered into the dock-yard. The second tank was transported inthe same way. At »only« 29 metres longand 12 metres wide, it was not quite sospectacular. The grand final was a su-perlative highlight: Working together, twocrawler cranes from Liebherr lifted thetanks into the hull of a gas tanker. Thevessel’s owner and builder was Hart-mann-Reederei from the East Friesiantown of Leer. Impressive though the liftwas, the big boys soon disappeared forgood into the hull of the 115 metre longand 17 metre wide »Gaschem Werra«.

Towards then end of last year, Felbermayr moved two gas tanks for the transport of LPG from the Romanian Black

Sea port of Constanza along the Danube to Turnu Severin in Southwest Romania. The Romanian specialist shipyard

of Severnav was the unloading point for the 820 tonnes of megacontainers.

Big boys

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The teams worked togethertremendously,« says a happy Gün-ther Trauner, manager since 2007

of the heavy transport section in Wels. Theconvoy left on its 950-kilometre journeyfrom the Andritz-Division für Generatoren-bau in Weiz (Styria). From there, it followedthe A2 southern motorway to Eisenstadt,then on via the A1 past Amstetten to theheavy load port in Linz.

On the limit

»Thanks to the very cooperative authoritiesat Asfinag, approval was given for the traf-fic procedures needed,« says Trauner,whose team, together with transport es-cort service Trummer from Graz, carriedout advance route studies and surveys.The result was a minutely detailed sched-ule. The dome, 7.76 metres long and7.51 metres wide, was followed by the sta-tor and rotor, the largest components tobe transported. The first 25 kilometres tothe motorway were a challenge: »The loadwas half a metre wider than the road, soall the roadside posts had to be removed,«explains Trauner. It was also necessary to

dismantle numerous roundabouts in theconvoy’s path, plus traffic lights and roadsigns. Some of the narrow bottlenecks inthe towns were even more of a problem.The convoy’s progress was decided by justa few centimetres. »We really were on thelimit,« says Trauner, full of enthusiasm thatthe convoy was finally successful. A num-ber of traffic routing measures also had tobe scheduled for the motorway. For ex-ample, a construction site on the A2 be-tween Pinggau and Zöbern could not becleared. This meant that the oncominglanes had to be blocked temporarily for

10  kilometres to allow the heavy trans-ports to pass, making the convoy a kind ofwrong-way driver. Some 350 kilometresand two nights’ driving later, the convoyreached the Felbermayr heavy load port inLinz. »When is came to the actual imple-mentation, you really had to take your hatoff to the drivers,« says Trauner about theperfect teamwork. »They did a great job allthe way!«

River trip

The three components were subsequentlytransferred to an inland waterway vesseland transported via the Danube and Rhine-Main-Danube canal to their destination inIffezheim some 600 kilometres away.There, bearings, rotor and stator shouldguarantee the problem-free operation ofthe fifth generator and contribute to theproduction of a further 122 million kWhpower per year. This will allow around75,000 people to be provided with hydro-electric power. The five generators willproduce a total of 870 million kWh per yearand supply electricity to residents in theequivalent of a city the size of Bonn.

INFORMER 15

TRANSPORT

In early April, a convoy from Felbermayr transported three heavy components for the Iffezheim power station on the

Upper Rhine. The starting point was the Andritz Hydro GmbH plant in Weiz.

Heavy transport for largestrun-of-river power plant

At 100.5 tonnes, the stator was the heavi-est component. Its weight was distributedover 12 axles.

The power station components werearound eight metres wide. That called fornumerous traffic routing measures.

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A sky-blue giant crane moved into

position shortly before Easter at

the Ötztaler Ache. It was there to

raise a 510-tonne steel composite

section for the construction of a

new railway bridge. The weighty

task was completed at the begin-

ning of May.

Blue giantlifts bridges

LIFTING TECHNOLOGY

INFORMER 16

Currently, trains can only travel overthe Ache at 40 km/h. The newbridge close to Roppen will in fu-

ture permit speeds of 80 kmh. Accordingto the ÖBB, that will mean more punctualtrains and less railway noise. The newbridge is being constructed next to the ex-isting bridge. With a length of 145 metres,the pre-assembled steel section weighed510 tonnes. »Six sections in all had to belifted for the bridge,« says Günther Wim-mer from the project section in Wels.

Crane logistics with obstacles

Even the approach to the site called for ex-tensive preparations. A total of 42 heavytransporters were required to bring in theLR 1600 with its maximum lifting capacityof 600 tonnes. »The crane brings to 45 thenumber of individual components that haveto be assembled on site,« explains Wim-mer. And that’s not counting 30 ballaststones weighing 565 tonnes. However, that

was not the problem. The first difficultycame from access to the site only beingpossible along an unsurfaced woodlandlane. »The one-kilometre long lane had tobe considerably upgraded for the transport,but up to 22 percent of the curves, treesand slopes were retained,« reports Wim-mer, adding that curve simulations werecarried out in advance »to make sure wedidn’t get stuck«. The six transporters withtheir up to 130 tonne bridge sectionsalso had to use this road. In addition, thesections had to come 500 kilometres fromwhere they were manufactured at St Paulin the Lavanttal. »The slope had to beclimbed to remove the crane,« says Wim-mer, so a 650 HP 4-wheel tractor wascalled on to help.

Giant crane raises bridge section

Once it was assembled, the dimensions ofthe LR 1600 became clear. You just can’thide 628.5 tonnes of steel. It made the 250

and 120 tonners needed to assemble thecrawler crane look almost tiny, even thoughthey are among the heavy-weights on thedomestic crane scene. »The largest load

was 88.8 metres long and weighed45 tonnes,« says Wimmer. Nevertheless,350 tonnes of suspended ballast,150  tonnes of superstructure ballast and65  tonnes of central ballast meant thecrane and its 102-metre lattice jib was ableto stand firmly by the Ötztaler Ache and liftthe bridge section to an accuracy of severalcentimetres. With the help of a guide, thecrane operator was able to lift all the othersections accurately into position. Between12 and 34 metres long, the premade steelsections were welded together and con-nected to the bridge pylons. The lifting workwas completed in early May. The newbridge should be finished and ready for railtraffic in August.

Six sections weighing up to 130 tonneswere lifted into place for the new Achbridge in the Tirol. An LR 1600 cranewith a 102-metre lattice jib was used forthe job.

The bridge elements were transported to the site »just in time«. They were manu-factured by NCA Container- und Anlagen-bau GmbH in St Paul, Lavanttal

The LR1600 needed up to565 tonnes of ballast forthe lifting.

INFORMER 17

LIFTING TECHNOLOGYPH

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LIFTING TECHNOLOGY

INFORMER 18

This year, Linz AG will start up a new thermal power station using waste material. Lifting technology from Fel-

bermayr was employed in the construction of a 460-metre conveyor system from the treatment plant to the

power station.

Crane duet for conveyor system

INFORMER 19

LIFTING TECHNOLOGY

Just about a year ago, cranes andplatforms from Felbermayr ap-peared at the site for the first time

for the construction of the conveyor. Thegap closed at the beginning of April. Thelast part to be lifted weighed in at50 tonnes, and was 35 metres long andfive metres wide. The whole project wasspectacular, but first some local history.

»The pipe bridge section had to be broughtin for assembly at a height of 68 metres,«reports head of operations Gottfried Hrastfrom the Felbermayr subsidiary in Linz. Ajib length of 40 metres made lifting extradifficult. That was why an LTM 1500 with500 tonnes maximum lifting capacity wasused as the main crane. This crane fromLiebherr had back-up in the form of anLTM 1200 with 200  tonnes maximumlifting capacity. »The LTM 1500 was fittedwith 165 tonnes of ballast and an 84-metrelong jib,« says Hrast, explaining themain crane’s configuration. Additionalpower for the LTM 1500 came from a so-called Y-anchor.

Millimetre-accurate assembly

The back-up crane made do with72 tonnes of ballast and a 72-metre tele-scopic jib. Only a few hours passed be-tween fastening the load and reaching theassembly position to an accuracy of sev-eral millimetres. »That’s where webrought a successful end to the last majorpart in the construction of the power sta-tion,« says a pleased Hrast referring tothe gap closure.

Efficient waste utilisation

There was also cause for celebration atLinz AG. The commissioning of this high-efficiency waste recovery facility meansthat some 200,000 tonnes of waste canbe processed annually. It will allow ap-proximately 37,000 households to besupplied with electricity and some11,000 with environmentally-friendly dis-trict heating.

The telescopic jib on the mobile cranereached up 84 metres to »fill the gap« inthe overhead pipe conveyor. A truckplatform with a 61-metre working heightwas used for assembly.

The lifting LTM 1500 was fitted with a Y-an-chor and 160 tonnes of ballast. Only 72tonnes were needed for the back-up crane.

The plant is designed to recoverapproximately 150,000 tonnes ofprocessed waste and some50,000 tonnes of sewage sludge. Thewaste material can be delivered bytruck or ship.

What kinds of waste are recycled?

• Prepared communal waste• Household waste• Bulk waste• Trade and industrial waste• Sewerage sludge• Other non-hazardous

special waste

The fuel from the treatment plant is transported to the power station via a460 metre long conveyor.

HIGH-EFFICIENCY WASTE MATERIAL RECOVERY PLANT

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INFORMER 20

This was a brilliantly, minutely planned co-operation« says Felbermayr managerChristoph Nüßler about the successful

completion of the transport which was primarilyco-ordinated by Felbermayr Switzerland as thecontractor of ABB. The Felbermayr site Hilden (D)was operative in the assignment, for the trans-port to the RoRo system (from the English Rollon/Roll off) and the Felbermayr sector ITB wassignificantly involved in the preparation of the car-rier and the Felbermayr subsidiary company Bau-Trans, for the final road transport. The transformerwas taken on at the ABB work Bad Honnef. Itwas then transported to a RoRo system aroundtwo kilometres away on a twelve axle special lowloader. »This enabled the heavy goods to be un-loaded from the road vehicle to a pontoon«, saysNüßler. The transformer was then transportedaround 120 kilometres North West on the Rhine,to the Felbermayr heavy goods port in Krefeld.When it arrived there the heavy weight wastransferred to an inland navigation vessel andtransported to Basel on the Rhine and unloaded.For the further transport of the twelve metre longand 4.4 metre high and 3.67 metre wide trans-

former two traction machines and a pushing ma-chine were used. The second traction machinewas incidentally provided by a further Swiss trans-port company, as well as a third traction machinewhich was to serve as a reserve for wet road con-ditions. Regarding the section of the route carriedout by BauTrans, Nüßler says: »On the 105 kilo-metre route between Basel and Zurich there aremany hills and hairpin bends, which could lead toinadequate grip on the tyres in the case of rain«.

Seventy metre longtransport combination

The transformer was transported on atwenty axle carrier combination. The totallength of the transport including the threemachines was 77 metres and weighed atotal of 475 tonnes. In order not to impedetraffic the road transports were only carriedout at night. The first stage led to Wettingen;whereby a bridge had to be crossed over theMöhlinbach halfway through the route. Asthe load bearing capacity of the bridge wasnot sufficient, a special bridge crossing sys-tem was used. »Thereby the weight was dis-tributed onto the bridge head and thereforeno strain was put on the self supporting partof the bridge«, explains Nüßler about thefunction. The second night the remainingthirty kilometres to the destination in the vil-lage of Fällanden with 8,000 inhabitants wascovered. The assignment was completedwith the laying of the foundations in the elec-tricity works. Here the transformer will en-sure the energy supply for Zurich.

At the beginning of May the Felbermayr subsidiary company BauTrans completed the ten day transport of a trans-

former with the laying of the foundations. Previously the 265 tonne voltage transformer was transported from ABB

works Bad Honnef near Bonn to the village of Fällanden not far from Zurich. In future it will help to ensure the power

supply for the city of Zurich.

Teamwork fortransformer transport

In Möhlin (CH) the Möhlinbach wascrossed using a special bridgecrossing system, due to insufficientload bearing capacity of the bridge.Two truck trailers were required totransport this. However the systemwas able to be constructed in justtwo hours.

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The transformer was changed over in theFelbermayr heavy goods port in Krefeld.

TRANSPORT

INFORMER 21

INSULATION

Mayor Karl Seitz would havebeen very pleased. Built dur-ing his term of office in 1923,

the Hanusch-Hof was like new again afterits thorough refurbishment. In the early1920s, it was regarded as a prime exam-ple of urban housing. Unlike the bedsits intenement blocks, with toilets and wateravailable in the corridors, the apartmentsin the Hanusch-Hof had toilets and wash-rooms in the apartments themselves, aswell as a number of shared facilities. Thearchitect was Robert Orley (1876 – 1945),

a member of the Hagenbund and Seces-sion groups of artists. He belonged to theavant garde of his time and is often men-

tioned in the same breath as Adolf Loosand Josef Hoffmann. His other works in-cluded the plan for the Zeiss plants in Pen-zing (Vienna), but his main achievementwas the 1908 Luithlen sanatorium (laterAuersperg sanatorium). From 1927 to1932, he contributed to the plan for theTurkish city of Ankara.

Renovation was inevitable

Over the years, the splendid Hanusch-Hofhad become unsightly, and renovationwas inevitable. The contract for thoroughrefurbishment from Stadt Wien – WienerWohnen went to ARGE Leyrer+Graf/Sareno. The task of local supervision wentto ARGE Gemeinnützige Wohnungs- und

Siedlungsgen. »Siedlungs Union« reg.Gen.m.b.H – A. & G. Galli Gesellschaftm.b.H. Over a three-year period, the prop-erty was renovated from the ground up,connected to the district heating, andgiven a Capatect WDVS (exterior insula-tion finishing system) over a total26,200  m2, bringing it up to modern energy standards. A series of new apartments was also created under thenew roof of the top floor. Approx. 11.5 mil-lion euros was the investment made byWiener Wohnen for the renovation andrestoration of the building which today isagain a district showpiece.

After installation of new insulation by Sareno, the Hanusch-Hof in Vienna

again showed its better side.

Rebirthof a monument

The Hanusch-Hof on Ludwig-Koeßler-Platzin the 3rd district of Vienna after renovationConstructed in 1923, the property wasnamed after the social-democrat politicianFerdinand Hanusch, a founder of modernlabour law.

After: Renovated from the ground up andwith modern Capatect insulation installed,the property now offers a considerably higher quality of accommodation.

The energy-saving EIFS façade growsunder the netting.

After renovation: The residential buildingconstructed under Mayor Karl Seitz on theErdberger Lände is today a model for therevitalisation of urban residences from theend of the 19th century.

Before: The Hanusch-Hof was showing itsage. Some of the plasterwork had fallenaway. Renovation was unavoidable.

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Some 200 tonnes of steel wereused in the conversion of the ves-sel from dry freighter to heavy

goods transporter. Work started in Sep-tember 2010, after the vessel entered theÖSWAG dry dock in Linz. The superstruc-ture over the main deck was modified bythe experienced maritime engineers, andthe loading area, with its wear-resistantHardox plates, rebuilt. »That also providesideal conditions for heavy goods,« notesHorst Felbermayr who had the vessel re-

named »Horst Felix«. It is also worth men-tioning that the wheelhouse was equippedwith a scissors lift. »That gives you a goodview of higher loads,« the senior directorpoints out. »Other highlights for futureheavy goods transport include external re-inforcement of the bow and the creationof a 1,200 m3 ballast hold,« adds Horst Felbermayr. »The bow now allows loadingand unloading using a RORO ramp.And the ballast hold can be floodedwith water if required to vary thedraught of the vessel when passingunder bridges, for example.« The85.6-metre vessel can also be heldsteady in the current by two hy-draulic stilts.

Conversion completed

Most of the conversion work wascompleted by the end of Januaryand the vessel could be launchedafter the five-month job using theÖSWAG dock’s own slipway. The in-terior fit-out and installation of nau-

tical equipment followed. The final trialsand commissioning of the »Horst Felix«took place in March.

The hull was fitted with trim tanks. Thevessel’s draught can be varied by floodingthe tanks.

PORTRAIT

INFORMER 22

With the planned commissioning of this new vessel, the Felbermayr fleet substantially strengthens in presence

in water transport. The conversion of this jewel of the inland waterways began in autumn 2010. It was completed

this March.

Heavy goods vessel takes to the water

With a length and width of 85.8 and 10.4 metres, respectively, the »Horst Felix« is the idealsize for heavy goods transport and can also be used for hydraulic engineering projects. This delights its namesake and grandson of the senior director, Horst Felix. Its role as adredger is captured in a painting by the six-year-old.

Most of the work was complete after fivemonths of conversion at the Linz dock. Thevessel was launched in January from theÖSWAG dock’s own slipway in Linz. PH

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INFORMER 23

STAFF

Media owner and publisher: Felbermayr Holding GmbH · Machstrasse 7 · A-4600 Wels, Austria · Tel.: +43 7242 695-0 · www.felbermayr.ccE-Mail: office@felbermayr.cc · Responsible for the content: Horst Felbermayr · Concept and editing: Markus Lackner · Layout: StephanieEbenberger · Free subscription: If you do not yet receive the »INFORMER« magazine regularly, but would like to have it delivered to yourdoor twice a year, absolutely free, or if you would like to order it for someone else, please visit our website: www.felbermayr.cc/informer

RETIREMENTSWell-earned retirements

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

who have recently retired.They have contributed tothe growth of the firm,

some for decades, and thus have helpedshape the company’s history.

Engelbert Bachner – Waste managementWels · Sandor Bajusz – Heavy transportLauterach · Anton Paul Benndorf – Trans-port Lanzendorf · Franz Brendle – CraneWels · Ladislav Broco – Crane Bratislava ·Rasim Cavkic – Workshops Wels · VahidHodzic – Structural engineering Wels ·Nedeljko Jeftic – Civil engineering Wels ·Ostoja Kovacevic – Civil engineeringSalzburg · Neydharta Krondorfer – Adminis-tration Wels · Sefidin Krueziu – Civil engi-neering Salzburg · Velibor Mejancic – Civilengineering Salzburg · Hubert Rathmoser –Project section Wels · Ratomir Momcilovic–Civil engineering Wels · Franz Nimpf–Work-shops Wörgl · Franz Seidl – Crane Wels · Jo-hann Sperz – Civil engineering Grieskirchen· Richard Tarbuk – Transport and lifting tech-nology Slovakia · Milo Trivkovic – Crane Linz· Paul Walter – Transport Lauterach · AloisZach – Crane Lanzendorf

You can find the answer in this booklet. We willdraw winners of the 15 non-cash prizes fromamongst the correct entries. For further infor-mation, please see www.felbermayr.cc/informer – Click to enter! Please send us thecorrect answer by fax +43 7242 695-144 or e-mailinformer@felbermayr.cc. The closing date forentries is 30 September 2011. No legal recourse.

Prize question:On what river did Felbermayr lift a 510-tonnecomposite section just before Easter?

1st prize:A 1:50 scale model of an MK 110 mobile crane.This faithful reproduction model is a speciallimited edition from Conrad, made from die-cast aluminium.

WELS HALF-MARATHONCONSTRUCTION ATHLETES ON THE GO

Construction section managers Horst Felbermayr and Johann Gangl were joined by eight other staff members in March to exert themselves inthe Wels marathon. While the two managers demonstrated with their respectable averages over the half-marathon distance that the companyis more important than excessive training, Robert Stürzlinger, closely followed over the 7.1 kilometres by Andreas Hüttmayr, was able to comeout the Construction winner. A tendon inflammation got the better of Barbara Weiß, who limped home at the rear of the 252 participants in the7.1 kilometre event. However, one this was certain for her and all the others on the Felbermayr team: »We’ll be there again next year!«

L to R: Robert Stürzlinger, Johann Gangl, Andreas Hüttmayr, Ulrike Vorhauer, Horst Felbermayr, Barbara Weiß, Rosa Adamsmair, MarkusGodina, Robert Grundner, Josef Stroissnigg

Competition

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