BAUER

B-Tronic Display
Technology
 Kelly Drilling

2 B-Tronic Display | © BAUER Maschinen GmbH 6/2017

The Kelly drilling technique is a classic bored pile system in which the torque and the crowd
force are transferred to the drilling tool by a multiple telescopic Kelly bar and the drill spoil is
removed from the borehole intermittently by the drilling tool. With each spoil removal cycle, the
drilling tool is emptied and returned into the borehole. Depending on prevailing ground condi-
tions, cased drilling may be required to ensure that the borehole does not collapse and/or is
secured against ingress of water.

– Support of the borehole wall by way of excess fluid pressure (support fluid) or drill casings
– Installation of the casing sections with the rotary drive or with attached casing oscillators
– By using a variety of different drilling tools, applications in all types of soil (including rock)
are possible
– Drilling diameter 600 - 3,000 mm
– Drilling depth 15 - 90 m

The on-screen displays, designed specifically for Kelly drilling operations, present the relevant
parameters in a clear layout. Special features, such as the Kelly visualization or the torque dis-
play related to the Kelly bar, support the rig operator in a safe operation.

Available assistance systems:

– Adaptive Kelly speed assistant – Hold-back control

– Kelly drilling assistant – Slack rope prevention
– Automatic crowd control – Crowd stroke monitoring
– One-directional spoil discharge assistant – Automatic mast alignment
– Bi-directional spoil discharge assistant – B-APS (Bauer-Assistant Positioning
– Casing extraction assistant System)
– Slew angle indicator – Control lever assistant
– Automatic swivel alignment

B-Tronic Display | © BAUER Maschinen GmbH 6/2017 3

 Kelly Drilling

Pile number
Winch

Main winch:
load and speed

Auxiliary winch:
load

Force
Crowd System

Speed

Direction

Selection: Set mast

automatically vertical
Mast

Selection of saved
mast inclinations

Input construc- Input File admi- Start recor-

tion site data production nistration ding of
process production
data

Visualisation current
mast inclination
Visualisation drilling tool

Operating radius
limitation (green area)
Slewing angle of upper
carriage/undercarriage relative

Current mast inclination

Current mast inclination (X-axis)
(Y-axis)

Current operating radius

Current operating Slewing angle of upper

radius carriage/undercarriage absolute

4 B-Tronic Display | © BAUER Maschinen GmbH 6/2017

 List of current messages

Kelly bar type

Load pressures
P1, P2, P3, P4, PKDK, Pcrowd

Rotary drive
Available torque

Prohibited torque

Speed

Kelly segment display/spring

compression

Kelly visualisation
Crowd distance upwards to
next locking recess
Status adaptive Kelly
speed assistant
Kelly locking recess
display (green)

Crowd distance downwards

to next locking recess

Storage Stop re- Open input Interrupt Main menu

space cording of casing tube input
display production menu
data

Position of the crowd sledge Casing tube (green)

Set crowd depth indicator
to zero
Last depth reached
Progress of drilling tool
(yellow)
Progress since the last
Current drilling depth
depth reached
(red)

Current depth
Set main winch depth indica-
tor to zero
Distance of drilling tool lower
edge to casing tube lower edge Minimum distance of drilling
tool lower edge to casing
tube lower edge

B-Tronic Display | © BAUER Maschinen GmbH 6/2017 5

 Cased Continuous Flight Augers Drilling (CCFA)

6 B-Tronic Display | © BAUER Maschinen GmbH 6/2017

By using long continuous flight augers (CFAs), which are drilled into the ground in one piece, the
drilling performance can be increased significantly. In contrast to the CFA technique, the CCFA
technique is carried out by drilling a casing string simultaneously with the continuous auger into
the ground.

– The soil is loosened by the tip of the auger and conveyed to the surface by the auger flights
– The continuous volume of drill spoil between the auger flights ensures that the borehole wall
is stabilized
– The application of the crowd winch enables penetration into hard soil formations
– The drilling depth can be increased by 6 - 8 m by the installation of a Kelly extension
– Concrete is placed in the pile bore through the hollow stem of the auger by a concrete pump
as the continuous flight auger is simultaneously extracted. The concrete pressure can be
measured at the tip of the auger
– Drilling diameter 500 - 1,200 mm
– Drilling depth 10 - 28 m

For cased continuous flight auger drilling (CCFA), optimal control of crowd force and speed of
rotation is essential to prevent blockages in the auger or getting stuck during drilling. This pro-
cess is automated with the automatic drilling control for single-pass processes. On the working
screen, the operator can accompany the course of the desired penetration rate and the actual
penetration rate. The rig operator can monitor on-screen the progression of the target penetra-
tion rate against the actual penetration rate and exercise control if necessary.

Available assistance systems:

– Automatic drilling and extraction – Slew angle indicator

control – single pass – Active mast support
– Hold-back control – Control lever assistant
– Fast grip change (for equipment with
Kelly extension)

B-Tronic Display | © BAUER Maschinen GmbH 6/2017 7

 Drilling in CCFA

Pile number
Winch

Main winch:
load

Auxiliary winch:
load

Force
Crowd System

Speed

Direction

Selection: display drilling

Selection: display pulling

and concreting

Input construc- Input File admi- Start recor-

tion site data production nistration ding of pro-
process duction data

Visualisation current
mast inclination

Operating radius limi-

Visualisation drilling tool
tation (green area)

Current mast inclina-

Current mast inclination (X-axis)
tion (Y-axis)

Current operating radius

Slewing angle of upper

carriage/undercarriage

8 B-Tronic Display | © BAUER Maschinen GmbH 6/2017

 List of current messages

Load pressures
P1, P2, P3, P4, PKDK, Pcrowd

Rotary Drive
Available torque

Auger speed
Prohibited torque
Casing tube speed

Correction penetration rate

Penetration rate
nominal value

Storage Stop re- Input Interrupt Main menu

space cording of production input
display production parameter
data (automatic
drilling and
extraction
control)

Current depth

Pressure (concrete/air)

Casing tube

Drilling depth reached Required crowd speed

Depth of casing tube
Current crowd speed

Penetration rate
Relative displacement actual value (drilling
progress per rotation)

B-Tronic Display | © BAUER Maschinen GmbH 6/2017 9

 Pulling in CCFA

Pile number
Winch

Main winch:
load

Auxiliary winch:
load

Force
Crowd System

Speed

Direction

Selection: display drilling

Selection: display pulling

and concreting

Input construc- Input File admi- Start recor-

tion site data production nistration ding of pro-
process duction data

Visualisation current
Visualisation drilling tool
mast inclination

Operating radius limita-

tion (green area)

Current mast inclina-

Current mast inclination (X-axis)
tion (Y-axis)

Current operating radius

Slewing angle of upper

carriage/undercarriage

10 B-Tronic Display | © BAUER Maschinen GmbH 6/2017

 List of current messages

Load pressures
P1, P2, P3, P4, PKDK, Pcrowd

Concrete pressure

Auger speed

Rotational direction auger

Correction of detection of concrete piston

pump stroke

Differential pressure peak recognition

Storage Stop Input produc- Interrupt Main menu

space recording tion parameter input
display of product- (automatic
ion data drilling and
extraction
control)

Current depth

Concrete pump stroke counter

Concrete quantity
Concrete quantity nominal value actual value

B-Tronic Display | © BAUER Maschinen GmbH 6/2017 11

 Multi-Purpose Crane

12 B-Tronic Display | © BAUER Maschinen GmbH 6/2017

The duty-cycle cranes can be used for multi-purpose applications in specialist foundation
engineering:

In crawler crane operation

– with mechanical clamshell for 2-rope clamshell grab operation
– with drop weights for Bauer dynamic compaction (BDC) in automatic mode

In liftcrane mode as base carrier

– for hydraulic diaphragm wall grabs with hydraulic hose drum system and grab rotation device
– for cased bored piles in combination with a grab and a casing oscillator
– for different types of vibratory pile drivers
– for Bauer trench cutters with different hose drum systems
– for Bauer Flydrill with the power coming from the on-board hydraulics

Depending on the machine configuration and the current operating radius, the B-Tronic shows
at a glance the current load and the percentage of the maximum allowable load. When selecting
the operating procedure LML (load moment limiter), the B-Tronic prevents any further operation
beyond the allowable range as soon as 100 % of the maximum allowable load is reached, in
order to ensure machine stability and component strength.

Available assistance systems:

– Grab assistant – HDS (Hose Drum System) control

– LML (load moment limiter) – Automated chisel control
– Slew angle limiter – Slack rope prevention
– Boom angle limiter – Synchronised winch speed control
– Slew angle indicator – Control lever assistant
– BDC automated control
(Bauer Dynamic Compaction)

B-Tronic Display | © BAUER Maschinen GmbH 6/2017 13

 Multi-Purpose Crane

Pile number

Load main winch 1/main

winch 2

Set depth to zero

Depth main winch 1/main

winch 2

Utilisation

Current hook load

Synchronous operation of main winches
synchronous stroke function activated/deactivated
Secured free-fall
activated

Input construc- Input File admi- Start recording

tion site data production nistration of produc-
process tion data

Nominal value of slew-

ing angle/boom angle Actual value of slewing angle/
boom angle

Deviation of boom angle

to nominal value Deviation of slewing angle to
nominal value

14 B-Tronic Display | © BAUER Maschinen GmbH 6/2017

 List of current messages

Load pressures P1, P2, P3, P4

Current operating radius

Current boom angle

Current roller height

Number of reevings (main winch 2/main

winch 1)
Indication of active main winches
(active green)
Counterweight at back
Undercarriage counterweight
Boom length

Storage Stop Input Interrupt Main menu

space recording free-fall input
display of produc- settings
tion data

Last depth reached

Progress since the last

depth reached

Current depth

Set current depth indi-

cator to zero

B-Tronic Display | © BAUER Maschinen GmbH 6/2017 15

 Diaphragm Wall Cutting

16 B-Tronic Display | © BAUER Maschinen GmbH 6/2017

A continuous wall is constructed by a series of independent rectangular panels. The open trench
is supported and stabilized during excavation by a thixotropic slurry. Subsequently, a reinforce-
ment cage is lowered into the open trench and concrete or self-hardening sealing material (plas-
tic concrete) is placed into the trench from the bottom up using tremie pipes.

The rising concrete displaces the lighter support slurry, which is pumped out from the top of the
trench, cleaned and then recycled for reuse in a new trench excavation. After hardening of the
concrete, the secondary panel between the previously constructed primary panels is excavated
and concreted. To achieve the best possible watertight joints between primary and secondary
panels, the joints must be formed by suitable joint elements when using diaphragm wall grabs.

The visualization of the actual position of trench cutters (rotational direction and inclination) and
the deviations in x- and y-axis enable the rig operator to take corrective action by activating the
steering plates.

Available assistance systems:

– Surcharge control - cutter

– HDS (Hose Drum System) control

B-Tronic Display | © BAUER Maschinen GmbH 6/2017 17

 Diaphragm Wall Cutting

Panel number

Cutter wheel: hydraulic oil pressure left/right

Mud pump: hydraulic oil pressure
Mud pump: flow rate

Mud pump: speed

Cutter wheel: speed left/right

Ambient pressure

Gear oil pressure left/right

Gear oil temperature left/right

Crowd speed/imposed load/leak oil pressure

Cutter depth/weight on cutter rope

Input construc- Input File admi-

tion site data production nistration
process

Current position
of cutter
Starting position
of cutter

Deviation of cutter in Deviation of cutter in

Y-direction X-direction

18 B-Tronic Display | © BAUER Maschinen GmbH 6/2017

 List of current messages

Deviation of cutter in
X-direction

Deviation of cutter in
Y-direction

Deviation of cutter in X- and

Y-direction

Activate steering flap control panels

Activate cutting progress display

Activate gyroscope control panels

Storage Interrupt Main menu

space input
display

Rotation of cutter clockwise/

counter-clockwise

Current inclination in
X-direction

Current inclination in
Y-direction

Recording cutting
procedure

B-Tronic Display | © BAUER Maschinen GmbH 6/2017 19

 Vibratory Pile Driving

20 B-Tronic Display | © BAUER Maschinen GmbH 6/2017

The principle of vibratory pile driving is to overcome the skin friction and point resistance be-
tween the pile element and the surrounding soil. A high-frequency vibrator generates vibrations
which are transferred to the pile element. The vibrating pile section generates vibrations in the
immediate vicinity of the surrounding soil. These lead to a rearrangement of the soil particles
and thus to the reduction in the skin friction and point resistance. This effect is used to drive the
pile section into the ground. When the pile section is driven into the ground by a vibrator mount-
ed on a leader rig, an additional crowd force can be applied. This can significantly accelerate
the pile driving process. A further advantage of the vibratory technique is the ability to both
drive the pile element and extract it with the same equipment. By using high-frequency reso-
nance-free starting and stopping vibratory pile drivers, start up and shutdown peaks or vibration
velocity peaks can be avoided.

Advantages of Bauer vibratory equipment:

– Relatively quiet
– Adapting the vibration parameters to prevailing soil conditions
– No start-up peaks when adjusting the static moment
– Wide range of applications by taking additional measures (water-jetting, pre-drilling)
– Lower vibrations resulting from high frequency technology (> 38 Hz)

Available assistance systems:

– Automatic crowd control

– Active vibrator management (AVM)
– Automatic mast alignment

B-Tronic Display | © BAUER Maschinen GmbH 6/2017 21

 Vibratory Pile Driving

Pile number
Winch

Main winch:
load

Auxiliary winch:
load

Force
Crowd System

Speed

Direction

Functions left control lever

(left/right)

Functions left control lever

(forward/backwards)

Input construc- Input File admi- Start recor-

tion site data production nistration ding of pro-
process duction data

Current mast inclina-

tion (Y-axis)

Current mast inclina-

tion (X-axis)

Visualisation current
mast inclination

Current operating radius

22 B-Tronic Display | © BAUER Maschinen GmbH 6/2017

 List of current messages

Type of vibrator

Load pressures, temperature

P1, P2, P3, Pclamp, Tlubricating oil

Available static moment

Vibrator
Prohibited static moment

Rpm limit value

Speed

Selection vibrator mode

(standard- amplitude- speed)

Functions right control lever

(left/right)

Functions right control lever

(forward/backwards)

Storage Stop Interrupt Main menu

space recording of input
display production
data
Amplitude

Current depth

Slurry pressure

Slurry flow rate

slurry quantity Vibrator speed ( orange),

vibrator pressure (blue)

B-Tronic Display | © BAUER Maschinen GmbH 6/2017 23

 Technology

BAUER Maschinen GmbH

BAUER-Straße 1
86529 Schrobenhausen
Germany
Tel. +49 8252 97-0
[email protected]
www.bauer.de

Design developments and process improvements may require the specification and materials to be updated and changed without prior
notice or liability. Illustrations may include optional equipment and not show all possible configurations. These and the technical data are
provided as indicative information only, with any errors and misprints reserved.

905.759.2 6/2017