REFERENCE PROJECTS – ARCHIVE

Collaboration with the world’s largest road paver Vögele

From March to December 2019, KUTTER was commissioned by the Kempten agency of the Bavaria motorway authority to renovate the A96 over a total length of 2x 5,900 m and a width of 11.5 m.

The construction site included three junctions. Collaboration from the start: with the world’s largest road paver Vögele.

We would like to thank Vögele for providing us with the impressive video featuring the road renovation project.

Built by Kutter!

The town park in Kempten was redesigned in October 2018. KUTTER was involved as the lead construction company. 2,500 m of ductwork for cables were laid with a total of 3,200 m of cabling.

The park has a new paved surface covering a total area of 6,400 m² and consisting of large granite paving from four different quarries. A border of approx. 500 m in length was also created around the meadow area.

In addition, the design of the central bus stops was optimised and permanent installations were also created for the Allgäu Festival Week. Particular highlights also include the fountains with lighting effect and underground water supply shaft.

Our teams made sure the trees were fully protected of course during all the construction work.

We are delighted that the town of Kempten has documented the construction work and made the material available to us.

TIME FOR THE NIGHT SHIFT

KUTTER beats off EU-wide competition

From a military airport to one of the most important backbones of the Free State of Bavaria: Allgäu Airport in Memmingen has been an important hub for some time now. It offers flights to Egypt, Corsica, Italy, Morocco, Spain, Portugal, Great Britain and many more destinations. With a new record flight plan of over 50 destinations, it is attracting increasing numbers of holidaymakers and business travellers. In order to be able to offer additional, varied destinations to its many air passengers in future, the airport is now being expanded – not least so it can continue to fulfil the increasingly strict international security guidelines.

After a ten-month marathon of negotiations, this challenging and exciting project was awarded to KUTTER. The costing work alone for this EU-wide tender took almost two months. This was followed by a lengthy planning process with regard to employee self-monitoring as well as a time-consuming approval process for each individual worker and each individual machine – after all, the project was for an airport, classed therefore as a high-security zone. Ultimately, KUTTER was able to complete the tender stage to the utmost satisfaction of the customer and emerged successful in face of the competitors from across the EU. Last November, the groundbreaking ceremony for the renovation project took place in the presence of Bavarian Minister President Markus Söder.

The excavators roll onto site at 9.30pm

Since March 2019, it’s been a daily occurrence for the KUTTER team: “Time for the night shift!”. As soon as the last flights have left the runway, the large construction machines start moving. First of all, cable trenches for a ductwork system were dug out along the entire runway, in which the electrics for the runway lighting will be installed at a later point. The biggest challenge: By 6am precisely when the first planes start moving, all the machinery must be returned the garage, and all the holes and trenches must be filled in until the four KUTTER crews get back to work again in the evening at 9.30pm.

Complete closure of the airport in autumn

Things will get really exciting in early autumn, when the airport will be completely closed to air traffic for the last two weeks of September. This is when the work will ramp up and be performed day and night in shifts to extend the width of the runway from 30 to 45 metres across its entire length. It will be a race against time as no delays can be afforded, considering the fact that the largest airline Ryanair will suspend all air traffic during this period.

Financed by the free state

The mammoth project is being partially financed by the Free State of Bavaria as well as the airport’s shareholders. The order value of the civil engineering work performed by KUTTER alone equates to EUR 15 million. To get an overview of the large construction project, Bavarian State Minister for Construction and Transport, Dr Hans Reichert, recently visited the site. Together with the airport’s CEO, Ralf Schmid, and Member of Bavarian State Parliament, Klaus Holetschek, KUTTER CEO, Peter Groll, and Head of Division, Andreas Binder visited the site with the politician, explaining the individual work steps and highlighting the particular challenges for both the workers and the machinery.

KUTTER in the media

Naturally, the project is being covered by the media. The press reports regularly on the progress, as do TV channels such as Allgäu-TV, which is often on site and broadcasts impressive footage of what is currently happening on the construction site.

The renovation works are scheduled to be completed in 2020. Besides expanding the runway and replacing the instrument landing system, the luggage halls are also being extended, the apron areas are being widened and a rainwater retention basin is being built.

KUTTER is proud to play a leading role in shaping such an important, regional project and wishes all of the employees involved every success!

CHALLENGE ON THE A96

Extremely high flows of traffic

Besides the A8, the A96 is an important East-West transport connection in Southern Germany. It connects the arterial roads from Salzburg and Nuremberg via Munich heading towards Austria and Switzerland. Last year, KUTTER completed the renovation of the asphalt surface between Windach and Eching tunnel on the A96. The direction of traffic towards Munich was a particular challenge in the mornings due to heavy volumes of traffic.

The special contractual terms demonstrated how important the motorway is for the smooth flow of traffic. The timetable of just 14 days per direction of traffic was very ambitious. The construction work was carried out while maintaining the flow of traffic. During the day, the traffic was managed using 3 lanes + 1 lane on the construction site side. This meant there were 2 lanes available in each direction of traffic. During this time, the teams worked in operating mode 2: “Daytime construction site making use of daylight”. For work carried out at night (construction of the asphalt layers), the traffic was managed using 3 lanes + 0 lanes on the construction site side, in operating mode 3: “Execution of work at night”. The Kempten agency of the Bavaria motorway authority awarded the contract worth EUR 4.2 million to KUTTER. The planned renovation work included replacing the asphalt binding and top layers over a length of 4.5 km in each direction of traffic. During the planned construction period between July and September, we had just 14 days per direction of traffic to complete the milling and asphalt work (on the night shift). All of this requires precise planning, a great deal of flexibility and expert staff.

Despite the rigid timetable, KUTTER met all deadlines. Work is also planned this year for an additional section of the A96 between Eching tunnel and Etterschlag tunnel. We hope to win this contract too. We have the experience!

Extensive milling and asphalt work

Working day and night on the B17

In July 2019, commissioned by the state building authority of Augsburg, KUTTER carried out road renovations on two sections of the B17 between the junctions for Messe and Eichleitnerstrasse.

Working day and night, the milling department successfully completed the work within 20 days. After expanding the upper road shoulder, the milling machines were put to work. This involved removing the damaged areas as well as the subsequent reconstruction of the road shoulder.

Almost EUR 1.25 million of funding was available for the entire construction work.

LIGHT AT THE END OF THE TUNNEL

The overall process

Swiss company Marti AG was awarded the contract to build Oberau tunnel.

The tunnel is essentially constructed using underground excavation with blasting. Once the rough removal of the tunnel cross-section was complete, our specially adapted mining milling machines were deployed to profile the tunnel invert to the exact height level required.

Our machine operators were guided by defined survey points and transferred the data by means of a laser controller which engages directly with the machine controller.

The milled material is loaded directly onto the transport vehicle on site via the integrated loading conveyor. The steep belt conveyors are reinforced with solid steel inserts to prevent damage caused by sharp-edged stone.

Our machines and their performance capacity

The performance capacity of our machines is generally based on the type of stone. This project involved dolomite stone and limestone with associated single-axial compressive strength values.

A further indicator for performance capacity is the fissurisation of the material to be removed, which can be naturally inherent or due to damage caused by stone blasting.

The special task

Another key area of this project was the creation of utility trenches within the tunnel invert. To complete this special task, we used the W 2200 milling machine with lateral milling device, which we had modified in-house and has a milling width of around 65 cm. This way we were able to create trenches that were approximately 70 cm deep.

The benefit of this technique is the fact that the milling machine with an entire operational weight of more than 40 tonnes is positioned centrally above the milling drum.

Quality thanks to years of experience

We have many years of experience in both surface and profile milling and can produce cost-effective results through optimised applications, even in extreme conditions.

The tunnel builders in Central Europe are familiar with the opportunities presented by milling technology, and are already incorporating our technology in the planning and costing phases of their projects.