Energy routes

We implement sustainability in a variety of ways in the construction of our energy lines.

Use of a walking excavator

The use of walking excavators in the short construction method (approx. 6 m long) for canal and pipeline construction and for energy line projects compared to the conventional construction method with an excavator length of approx. 20 m enables a significant reduction in Excavators and trucks. This is associated with a saving in diesel consumption of around 70 % and a CO2 reduction of 167 kg per running meter with a balanced advance rate of 9.2 m per day.

"Mudcleaner" treatment truck

The disposal of sludge resulting from the HDD drilling process in the closed construction method (e.g. for roads and railroad crossings) is becoming increasingly important due to severely limited disposal options. In the Group's own "mud-cleaner unit", which is unique in the construction industry, the drilling mud produced is fed directly to a centrifuge for mechanical dewatering on the construction site via feed pumps and an upstream vibrator. The mineral substances, reduced in mass by 70 %, are then disposed of properly. The separated liquid, enriched with bentonite, is returned to the storage tank and reused as a drilling suspension. This means that up to 90 % of the water required to produce a drilling fluid can be saved.

Material flow exchange and digital dashboard

Our material flow exchange, which will be supplemented by a self-developed digital dashboard in 2024, has the task of significantly reducing the number of transports, freight kilometers and the associated diesel consumption. This is achieved by intelligently managing and optimizing the corresponding material flows and by monitoring and documenting the equipment and trucks used on the construction site. As a result, we are already emitting 0.5 kg less CO2 per tonne of Soil transported. In combination with the digital dashboard, we will be able to further increase this value in the future.

Alternative power supply on construction sites

In addition to a conventional power supply, a construction site can also be supplied with energy via photovoltaic panels including regulation and battery storage on construction and residential containers. Photovoltaic hybrid units are used for the construction of overhead line foundations, where an additional diesel drive guarantees an uninterrupted power supply. The power supply for dewatering is of particular importance here. According to the manufacturer, the savings potential per container panel installed is an average of 2,300 kWh per year (equivalent to around 1 t CO2 ). The reduction in CO2 when operating a photovoltaic hybrid genset compared to a conventional diesel genset is around 60%, depending on the daylight yield and the connected consumers.

Road construction

At Max Bögl, we don't just carry out road construction work according to the current state of the art and contractual specifications. Wherever possible, we also implement the latest research results in order to minimize the impact on the environment:

-resource-conserving design of asphalt formulations through precise knowledge of rock properties

-exact coordination of binder content and minerals for optimum use of the energy-intensive resource bitumen

-Temperature reduction of the mix while maintaining the same properties

-Continuous further development of the recycling rate and durability of the products

-Aggregates for bituminous base and binder courses come from the company's own quarries in order to keep transportation distances as short as possible.

-Use of recycled asphalt (RC material) when building new roads or repairing existing ones. In this way, a particularly high proportion of asphalt granulate can be achieved in new asphalt layers without the need for new aggregates. The bitumen contained in the granulate can also be reused in this way.

When processing asphalt, Max Bögl achieves two central sustainability goals that go far beyond the legal requirements. The BA 4000 asphalt mixing plant from Benninghoven can process large quantities of recycled material and noticeably reduces CO2 emissions thanks to its innovative technology.

Modern vibratory rollers, which determine the optimum window for compaction by means of continuous sensor-based temperature measurement, are used to lay the mix. In addition, the rollers are digitally networked with each other so that areas are not driven over unnecessarily often. The company's own fleet of vehicles is regularly serviced in the company's own workshop and is always up to date in terms of engine technology and exhaust gas cleaning.

Modular bridges

With the modular bridge, we have developed an innovative and sustainable bridge system. Essential components are manufactured in a construction factory on the basis of parameterized and digitized planning in an industrially optimized process and assembled on site.

This reduces the construction time by up to 70 %. The high quality of the components also eliminates the need for costly maintenance cycles.

The basic building materials steel and cement for the production of the modular bridges are already mainly supplied by rail, and rail is also increasingly being used to transport the components. Optimum component weights, achieved through our material savings, ensure that the transport options are used particularly efficiently. In the production of steel, the transition from classic blast furnace steel to green electric steel is already in full swing. In addition, the environmental concretes for our modular bridges follow our 10C approach, a further development of the cement industry's 5C approach: less fossil fuels in clinker production, combined with less clinker in the concrete as well as less cement in the concrete and less concrete in the structure.

The roadway slab of the Modul Bridge Bögl consists of individual roadway slab modules that can be driven on directly. By integrating the bridge caps and dispensing with waterproofing and surfacing, not only is construction time saved, but also significant refurbishment intervals within the life cycle can be omitted compared to traditional bridge systems.

The individual deck modules can be separated and repaired if necessary, an important factor in a sustainable circular economy in which the components of a product are reused, redistributed, repaired or recycled. Due to the shortened construction time and the elimination of essential maintenance work - such as the regular replacement of pavement and cycle path caps and the renewal of waterproofing and surfacing - the traffic flow is less disrupted during the life cycle of a Modul Bridge Bögl. This results in a significant improvement in the CO2 footprint compared to traditional construction methods.

Soil freezing technology: Soil and groundwater-friendly construction method - everything from a single source!

Due to increasing urbanization, construction work under or directly next to existing buildings is not uncommon. Existing underground structures have to be supplemented or extended under cramped conditions and in the immediate vicinity of public transportation. With ground freezing technology, the Max Bögl Group offers a proven and safe method for the construction of structures in difficult subsoil conditions and complex boundary conditions. By temporarily freezing the Soil, watertight and load-bearing structures are created. The process is chemically neutral and environmentally friendly. After thawing, no disruptive installations remain in the Soil. Soil and groundwater are not affected or altered.

As a leading construction company, Max Bögl has an extensive portfolio of its own machines and equipment. These have been specially developed and tested for the application of ground freezing technology. Standardized components, temperature-controlled nitrogen dosing, reusable line systems as well as measurement and control technology are continuously developed and form the foundation for progress. The modular line segments for nitrogen and brine processes enable standardized planning, calculation and installation. In addition, the high-quality elements can be reused and therefore conserve resources. In this way, the company avoids the usual disposable systems on the market.

The central components of brine freezing are the freezing units. Based on our many years of expertise, these are specially designed and adapted for Ground freezing technology. They have a much more favorable EER value (Energy Efficiency Ratio) than conventional units on the market. The natural refrigerants ammonia (R717) and carbon dioxide (R744) are used in the freezing units to freeze the Soil. With a GWP of 0 (ammonia) and 1 (carbon dioxide), these have a significantly lower value than the refrigerant R507A (GWP: 3,985), for example.

Sustainability in steep curve construction (SMB)

In 20XX, the joint company SMB Construction International emerged from the many years of trusting and successful cooperation between STRABAG and Max Bögl in the construction of proving grounds for automotive development. In this special segment of road construction, sophisticated construction techniques and innovative equipment are used to meet the high demands of car manufacturers.

The superstructure of steep bends involves a number of risks for employees. We have therefore set ourselves the most important common goal of occupational safety for everyone involved. However, sustainability also plays a major role in the implementation. Natural resources are needed to build the steep curves. With every new project, we face the challenge of using as little material as possible.

Major savings in resources are possible as early as the planning stage of a proving ground with the associated steep curves. To this end, we actively advise potential test site operators and their planning engineering offices in advance. For example, the height of the proving ground has an impact on the earthworks. With forward-looking planning, we make it possible to compensate for excavation and application soils so that missing material does not have to be brought in from outside and excess Soil does not have to be removed from the construction site.

Thanks to our technical skills, we can build steep bends with a transverse gradient of 49° (approx. 115% gradient). These have smaller radii than curves with a lower gradient, which means that less space and therefore less material is required for the test site.

For many years, we have achieved the greatest potential for saving resources in the production of our high-quality track. By using the best materials and our optimized paving method, the roadway can be used over a long period of more than 20 years without any restrictions. For example, the layers are produced in one width across the entire cross-section of the steep curve (up to 18 m), which means that the paving is carried out seamlessly without longitudinal seams. This type of paving prevents the typical weak points of any road construction: the formation of seams through which water and frost can penetrate. The surface course, which is the uppermost and most vulnerable layer of asphalt, is regularly laid in a 24-hour process, which also reduces the need for transverse seams.

Traffic sign gantries

e currently process over 40,000 tons of steel per year for our traffic sign gantries. Thanks to our high degree of pre-assembly, we deliver them to the construction site just-in-time and fully pre-assembled. This reduces the duration of freeway closures during installation to a minimum, which has a positive effect on already heavily congested traffic. At the customer's request, we can also install the display boards in advance.

Our traffic sign gantries impress with their very high quality. They are particularly durable thanks to the use of duplex systems. Our steel components are hot-dip galvanized in advance and then coated several times. This allows us to virtually eliminate the risk of corrosion, which increases the service life of the traffic sign gantries. Our in-house expertise in steel and plant construction leads to sophisticated solutions that improve planning and execution processes.

In brief, our traffic sign gantries offer

■ Versatility: use on freeways and multi-lane urban roads

■ Flexibility: customizable with sensor technology, additional equipment, maintenance walkways and more

■ Quality: compliant with ZTV-ING and high quality standard

■ Fast installation: short assembly times

■ Complete solution: planning, pre-assembly, Quality control, transport and assembly from a single source

■ Sustainability: contribution to sustainable Mobility through the combination of concrete and steel construction in our products

"Reduce highway closures, downtimes and associated emissions to a minimum!"