Looking back at the eBG33 success

In recent years, the construction industry has increasingly focused on implementing more sustainable solutions throughout the entire lifespan of projects, as carbon reduction has become a primary priority.

This drive for greener solutions could be because of compliance with regulations, government polices/certifications or corporate social responsibility. Consequently, piling contractors are looking to utilise alternative fuel solutions to meet these sustainable targets. 

The eBG33 does just that, it represents a significant advancement in deep foundation equipment technology. This rig has been designed to replace traditional diesel engines with a powerful electric drive, offering numerous benefits for both environmental sustainability and operational efficiency.

• 405kW Electric Motor 
• High energy efficiency due to modern three-phase asynchronous motor
• Supply Voltage: 690V and Rig Swing Arm for Cable Management 
• No tail pipe- No emissions 
• Integrated walkway system for safe working at height but reduced swing radius
• UW100 undercarriage with 800mm tracks 
• 340 Kw KDK Rotary Drive 
• Multi Remote Control
• Prepared for Kelly drilling and several single pass methods; CFA, CSM, FDP, & Rigid Inclusions

The eBG33 was most recently utilised at the HS2 S1 Euston approach tunnels project for Cementation Skanska and SCS. This project showcased the eBG33 and the steps BAUER Maschinen GmbH have taken to meet the decarbonisation challenge, which demands that all construction plant and equipment are working to net zero by 2050 in the UK and Europe.

As this was the first outing within the UK, there was hesitancy to set up the necessary electric infrastructure to operate from a mains supply. The equipment performance and feasibility were unknown, and consequently, it was powered using diesel generators. Despite initial reservations, the eBG33 installed 1650mm slip casing alongside its diesel-powered BG30 counterpart. The JV found it had the same capabilities, but with greener credentials. 

Following the works at Birmingham, the rig was mobilised to and operated on mains power, a first in the world for this class of machine. Arriving on site, the rig was unloaded utilising the dedicated auxiliary power pack and multi remote control. This power pack is only used to drive the crawlers and get the rig in position on the job site, during mobilisation across the site.  

The rig demand on the project was 800amp peak and standard working operations were measured at ~200amps per phase . A step up transformer was required as the machine ran at 690V, rather than 415V 3 phase supplied from the mains. 

The job was not always smooth sailing, several weeks into the project, following the rigs first use, harmonic issues were identified; A pure linear electrical wave will have a pure sine wave, but non-linear loads can distort the wave. It was identified that they weren’t drawing a linear load, and the number of distortions was occasionally exceeding the specified limit. Cementation Skanska worked with BAUER to mitigate the issue, and built a specialist set of harmonic filters, to correct the distortions during operations. 

In terms of Carbon savings, the end client (SCS) provided a 100% renewable sourced energy tariff, therefore Cementation Skanska were operating carbon free when utilising the rig on mains power. The estimated saving of embodied C0₂ per shift was calculated at 1.3t, when compared to an equivalent diesel driven rig, which over the project duration equated to ~149.t, thus highlighting the incredible benefits of utilising an emission free piling rig. In addition to being carbon free when operational, the rig operated with ~50% noise reduction, as the base carrier is 50% quieter than a diesel engine. As a result, this led to significant cost savings for the client, as local residents did not need to be temporarily relocated during the construction work as noise limits weren’t breached.  

On completion of the works, we received feedback from Andrew Entwistle, Managing Director of Cementation Skanska. 

“The emission-free capability of this rig is an exciting step forward in our net zero ambitions. This type of innovation sits at the heart of our carbon reduction strategy and supports HS2 with its ambition for all its construction sites to be diesel-free by 2029. Not only has it been valuable for us to work with the eBG33 firsthand on a live project under full mains power, a first in the UK, but it has provided an excellent opportunity to demonstrate the potential of an all-electric heavy duty piling rig to the wider UK construction industry. Cementation and Bauer Equipment UK have closely collaborated and maintained exceptionally strong relations, demonstrating outstanding teamwork and dedication to bring this concept to reality. We look forward to continuing this successful partnership and working together on future projects.” 

The rig is currently available in the UK and can be made available immediately for rental. Should you want to know more information about alternative fuel solutions please contact Julia Nicholson.