BAUER Maschinen GmbH

With groundbreaking machines and innovative solutions for special foundation engineering, the BAUER Maschinen Group, Schrobenhausen/Germany, once again set new industry standards at bauma 2025. Several thousand industry professionals flocked to BAUER City to experience the company’s latest developments and technologies up close. The broad range of exhibits included BAUER’s proven rotary drilling rigs, diaphragm wall technology and drilling tools, as well as innovative products from its subsidiaries KLEMM, RTG, and BAUER MAT. Eurodrill was also present, as in previous years, with its own booth showcasing drilling drives.

A key highlight was the new BCS 185 power pack cutter system (Figure 1). Featuring a modular drive concept, it offers flexible operation with either electric or diesel power. This system allows for locally emission-free use and variable positioning of the power unit to reduce the footprint on construction sites.

Another standout exhibit was the eRG 21 t hybrid from RTG Rammtechnik. The combination of a powerful 430 kW diesel engine with an additional 88 kW electric motor enables operation with up to 68 % fewer CO₂ emissions – a clear reflection of BAUER’s commitment to sustainable innovation.

KLEMM Bohrtechnik impressed with the newly developed KR 806-4E, an evolution of its electrohydraulic KR 806-3E drilling rig. The latest version offers increased motor power, improved battery capacity and an optimized electric system – delivering environmental performance without compromising the power of its diesel-hydraulic counterparts.

BAUER MAT Slurry Handling Systems presented the new CMS 50 colloidal mixer, which boasts a 10 % larger mixing volume than its predecessor, along with cutting-edge technology and a new design. In the field of injection technology, MAT unveiled the fully automatic IPA 250-E. It combines proven MAT mixing technology with Obermann pump technology, setting new benchmarks in injection processes.

A particularly noteworthy innovation showcased at the BAUER booth was the prototype of the electronic Cutter Soil Mixing (eCSM) system. As the world’s first electrified diaphragm wall method, it replaces traditional hydraulic components with a powerful electric drive architecture – reinforcing BAUER’s position as a technological leader in this field.

Peter Hingott, Member of the Executive Board of BAUER, emphasized: “We want to place even greater focus on our innovative strength and engineering expertise. BAUER is already a leader in the industry, but our goal is to be the best. We don’t just deliver products – we offer complete solutions for our customers’ challenges.”

Wulf Flos, Managing Director of BAUER Maschinen GmbH, added: “Our products are designed to inspire customers around the globe. As a premium manufacturer, we rely on strategic partnerships and outstanding service. Once again, bauma 2025 proved that we are shaping the industry with state-of-the-art technology, sustainable solutions, and low emission drive systems. The feedback on our BAUER City and the exhibits was excellent. A strong order intake speaks for itself.”

Further information:
BAUER AG
www.bauer.de

Operating large, mobile hydraulic construction equipment is a demanding task. Safe and efficient operation depends primarily on the operator’s experience – expertise that can take years to acquire. Less experienced operators often reach their limits quickly. This is precisely where the recently concluded OPAI4DNCS research project, funded by the Bavarian Research Foundation (BFS), stepped in.

Industry and science joining forces
For this project, BAUER Maschinen GmbH, HAWE Hydraulik SE and STW (Sensor- Technik Wiedemann GmbH) collaborated closely with the Chair of Automation and Information Systems as well as the Chair of Ergonomics at Munich Technical University. Over the course of three years, the project partners explored operator-centered assistance for mobile construction equipment used in specialist foundation engineering.

Needs-based assistance from AI
The aim of this project was to develop adaptive, intelligent, and self-learning control systems based on multi-agent systems (MAS). The focus was on needs-based assistance of machine operators to enable safe operation even in borderline situations.

Bauer grab used as test vehicle
The technology was demonstrated using a hydraulic grab (Figure 1), typically used in the construction of diaphragm walls. The crucial factors were dampening vibrations and stabilizing the grab. Operating the grab is particularly challenging due to its swinging bucket. Using a soft sensor to measure the pendulum movements caused by pressure fluctuations on the hydraulic actuators, a real assistance system was development and successfully implemented in test campaigns.

Human-AI collaboration
One central result of the project was the development of a shared-control platform that enables intuitive collaboration between human operators and artificial intelligence. A retrofitting solution was established that can extend existing control systems with intelligent functions, without requiring major changes to the machine’s architecture. The assistance system offers three different control modes tailored to the operator’s experience level. Combined with a multi-agent architecture, the system delivers flexible, context-sensitive assistance for complex control tasks – improving efficiency, safety and resource conservation on construction sites.

Further information:
BAUER AG
www.bauer.de

At its most recent meeting, the Supervisory Board of BAUER AG appointed Lena Effinger as a member of the Executive Board with effect from 1st June 2025 (Figure 1).  She will take on responsibility as Chief Financial Officer of BAUER AG.

Lena Effinger has been with the BAUER Group since 2006 and has headed the Group Finance department since 2016, where she was most recently responsible for financing and treasury.

“I would like to thank the Supervisory Board and the Executive Board for their trust and look forward to working closely with the entire management team,” said Lena Effinger.

“I am delighted to continue our long-standing collaboration with Lena Effinger on the Executive Board. She is an experienced finance professional who has been responsible for coordinating with our banks for many years and has significantly developed Bauer’s treasury in recent years,” said Peter Hingott, member of the Executive Board of BAUER AG.

Following the appointment of Lena Effinger, Hartmut Beutler will step down from the Executive Board. After leaving the Executive Board at the end of 2021, Hartmut Beutler had been reappointed as interim member of the Executive Board of BAUER AG.

Further information:
BAUER AG
www.bauer.de

The BAUER Group has continued to pursue its course towards becoming a sustainably successful and profitable company. In an environment where the political and economic conditions around the world remained challenging, Bauer considerably increased total Group revenues to 2,183.4 M €. At 89.1 M €, EBIT was on a par with the previous year’s 89.0 M €.

In this context it should be noted that the execution of a major project in Hungary alone contributed roughly 318 M € to the increase in total Group revenues. The earnings figures contain provisions that were created due to the difficulty in forecasting the ongoing progress of that major project. This was owing to additional sanctions entering into force in late 2024, which worsened the conditions for this major project.

Overall, the global environment was shaped by various influencing factors, including Russia’s ongoing war against Ukraine, attacks by Israel on the Gaza strip, a persistently weak construction sector in China and an ongoing weak economic performance in other Asian countries.

“We are basically satisfied with the key figures achieved in 2024 owing to the economic and political conditions, even though our long-term goals for the earnings figures are positioned at higher levels,” emphasizes Peter Hingott, Executive Board member of BAUER AG.

The company succeeded in making further progress with the development of the balance sheet figures. Total assets remain nearly unchanged at 1,683.6 M € despite the increased revenue, and net debt further reduced to 375.3 M €. The ratio of net debt to EBITDA further improved to 1.68 and thereby achieved a new historically low value.

Development of the segments

In the Geotechnical Solutions segment, the international presence was further optimized by placing focus on subsidiaries in sustainably stable and promising markets. Successes are already evident here as a result of the reduction in fixed costs, as well as from consistent improvements in risk management. The operative implementation of projects was positive again in 2024, which meant that nearly all regions delivered solid contributions to earnings. Revenues were up on the previous year, mainly due to the execution of a major project in Hungary, while earnings after taxes were burdened by provisions.

The Equipment segment recorded a stable financial year in terms of the operative business with growth in the sales figures in Europe and the Middle East. Business was solid in Germany, while restraint among customers was evident in the USA due to the presidential elections. In contrast, China was once again unsatisfactory as a sales market due to the persistent weakness of the construction market, and restructuring measures burdened the earnings. Overall, the Asian market is proving to be increasingly challenging in part due to growing competition from local manufacturers. The cyber attack in late October 2023 influenced this segment most significantly in the previous year. This resulted in the loss of almost two months of sales and the corresponding earnings contribution in the 2023 figures, which means that the considerable increase in revenue and earnings figures needs to be put into perspective to a certain degree.

The Resources segment recorded an encouraging development once again. Good revenue and earnings performance was achieved in nearly all business divisions. In environmental services, due to the difficult market environment for construction in Germany and the increasingly competitive situation, there was a downturn. Performance was encouraging in the area of mining, which not only delivered a positive contribution to earnings once again, but was able to considerably increase its order backlog even further. This means long-term utilization of capacities in this area of business. The bottom line is that revenues in the segment decreased slightly while earnings after tax increased slightly.

Outlook

Overall, Bauer wants to place a stronger focus on performance and also increasingly highlight innovation and technology. “Over the past years, we have laid all the foundations for being sustainably successful once again. The reinforced balance sheet gives us options for beneficial investments in the future. The economic and political environment in the world has weakened further in the past year, and we are preparing ourselves for this. We are working on reducing costs in all areas in order to remain successful in the coming years even in a difficult market environment. We have laid all the foundations for making 2025 a successful year,” remarks Peter Hingott, Executive Board member of BAUER AG.

Further information:
BAUER AG
www.bauer.de

On October 16, 2023, the headquarter of BAUER Maschinen GmbH in Schrobenhausen, Bavaria/Germany hosted the kick-off event for a research project with the potential to catapult the carbon footprint of specialist foundation equipment to a whole new level. The goal: climate-neutral operation based on a fuel cell system. The consortium partners are BAUER Maschinen GmbH along with the Professorship for Fluid Systems Technology and the Chair for Fluid Mechanics at the Friedrich-Alexander University of Erlangen-Nuremberg.

A machine from Bauer as a basis

Over the next three years, the project partners will work together to develop a concept for operating construction equipment in specialist foundation with zero CO2 emissions. The plan is to integrate a drive system comprising a hydrogen fuel cell, along with all necessary peripheral components (“balance of plant”), into a special foundation machine from BAUER Maschinen GmbH. The fuel cell system along with other required components such as H2 storage unit and cooling unit are designed as a plug-in module for universal use.

Reducing noise emissions

Within the project, operating strategies for fuel cells and backup batteries are evaluated with regard to the technical requirements. Another focus of research is the targeted influencing of noise emissions, which negatively impact both equipment operators and the environment during the operation of construction equipment. With the aid of aeroacoustics simulations and resulting measures to reduce noise, the aim is to significantly reduce emissions compared to conventional, diesel-powered equipment. At the end of the project, the plug-in module will be installed on a Bauer machine and tested in practical application.

Logical further development

The research project planned for three years, with its official title “Modular drive system with fuel cells for applications in specialist foundation engineering” (MABAS), has received funding from the Federal Ministry for Economic and Climate Action as part of the 7th Energy Research Program, a grant of approximately 2.5 million euros. The project represents another logical step towards the goal of sustainability: Following Bauer’s previous contributions to sustainable construction with the cable-bound eBG 33 and battery-powered eBG 33 H all electric, the use of hydrogen technology in the form of a fuel cell is a logical enhancement. A hydrogen-powered machine can be used anywhere a cable connection is impossible or specific services are required that cannot be provided to the necessary extent using only batteries.

Further information:
BAUER AG
www.bauer.de

High throughput, fast assembly, digital operation with remote maintenance: that’s the new BE 600-C desanding plant from BAUER MAT Slurry Handling Systems. The Allgäu branch of BAUER Maschinen GmbH recently brought it on the market as a successor of the established BE 550 that truly keeps it all together: This two-stage plant with double cyclone design is installed within a container frame, and includes a reservoir tank, solids discharge, hose guide, all-round access platform and upstream coarse screen. It delivers 174 kW of power and a considerable throughput capacity of 600 m³/h. This means that the plant can process up to 120 t of solids per hour – setting new standards in the field of desanding.

Two become one

There’s a whole lot of established technology in the BE 600-C, since strictly speaking it’s comprised of two standard Type BE 300-C desanding plants. However, the optimized separation is new: After being fully treated in a first step, the slurry is pumped through the second tank inside (rather than outside) the plant toward the desilter unit. Another feature is the comparatively low space requirement, as pumps and desilters are located within the container frame and not outside, as would be the case for standard double cyclone plants. The BE 600-C thus achieves a base area of just 6.1 x 5.9 m.

But that’s not all: Because all components are installed within the container frame, it is possible to carry out transport, assembly and commissioning on site, quickly and easily – for example for cutting, tunneling, grabbing or drilling projects. What makes it unique: As needed, the BE 600-C can be divided back into two individual BE 300-C units, and the upstream coarse screen can also feed just a single unit. “This makes our plant as flexible as our customers’ projects,” summarizes Tim Eberwein, Sales Manager at BAUER MAT Slurry Handling Systems.

Focus on digitalization and automation

The BE 600-C also excels when it comes to digitalization with several new features, explains Yilmaz Ipeksoy, Technical Manager at BAUER MAT Slurry Handling Systems: For example, each of the two individual plants features a 12-inch display with touch screen. The complete plant can also be operated from a single screen in master-slave mode. The operator can see at a glance which parts of the equipment (conveyor belt, flow meter, accessories etc.) are running and which are not; other information such as pressures, operating hours or power consumption is also displayed. An EWON router establishes a connection with the Internet, which allows all data to be called up via remote access, along with error messages. “In this way, our service specialists can connect to the equipment quickly and easily and perform a remote diagnosis if necessary. This saves lots of time as well as costs, since our customers don’t have to wait for service technicians to arrive on site.”

Anywhere bentonite or cement slurry needs to be mixed, this MAT equipment can be used. “Whether for mixing, pumping, stockpiling or separating, our products are a key element of the complete cycle,” explains Kurt Ostermeier, Head of Product Management Mixing and Separation Technology at Bauer Maschinen. More than 30 years of expertise in mixing and separation technology contribute to the process when equipment or components are newly developed or enhanced at BAUER MAT Slurry Handling Systems. But new trends such as digitalization and automation are also in focus. Kurt Ostermeier asserts: “Digitalization as well as automation are ongoing processes that will continue to play a major role in the future. Our goal is to fully and permanently integrate our equipment into the cycle of a digital site.” And with the new BE 600-C, BAUER MAT Slurry Handling Systems has taken a major step towards that goal.

Further information:
BAUER AG
www.bauer.de

Bauer brought its first cutter to the market almost 40 years ago, thereby starting a success story that has now introduced a new chapter: In April, the company presented its new BCS 185 cutter system, which has really struck a chord with customers. “Our multi-functional MC duty-cycle cranes are used for a wide range of applications, first off as base carriers for our cutters and grabs, but also for lifting work or dynamic soil compaction,” explains Leonhard Weixler, Head of the Diaphragm Wall Division at Bauer Maschinen. “For anyone who doesn’t require this multi-functionality but needs equipment that is specially optimized for trench cutting, we have extended our BCS portfolio with the newly developed BCS 185. And the feedback from our customers is excellent.” This latest model of BAUER Cutter Systems (BCS) can cut trenches up to a depth of 90 m. In addition, the special design of our BCS systems combines proven technology with a vast variety of other useful features as well as the necessary modularity for today’s ever stricter transport requirements.

Solide base
The base carrier is a Bauer MT 185. The solid design offers high stability and comprehensive HSE features, including a rear view camera, integrated service platforms and ergonomic, highly comfortable cab layout. Operators used to our Bauer MC models are sure to feel at home quickly, since the inner workings of the cab are identical to the Bauer duty-cycle cranes. A variety of electronic assistance systems (integrated into the latest version of the BAUER B-Tronic system) supports the operator effectively and increase productivity at the same time. The MT 185 is equipped with a fuel-efficient, powerful Volvo engine, which complies to all different emissions standards worldwide.

Continuously adjustable cutter position
The BCS 185 is of course also available with the Bauer Turning Device, which allows this cutter to work in extremely confined construction sites and will still be able to ‘cut the corners’. “This is making the difference in today’s cutter operations,” remarks Leonhard Weixler. It allows the cutter to be twisted within a range of -50 to +95 degrees from its normal position to reach every corner in the excavation pit without a problem. Together with the overall compact dimensions of the BCS 185, the range of efficient cutter applications under restricted space conditions is further enhanced.

Streamlined special equipment for mid-sized applications
Attentive observers will also notice the arrangement of the hose drums in the boom, thanks to which the cutter system delivers a highly streamlined impression overall. The 30 t winch was specifically designed for use in the mid-sized range. With the maximum hook load of 43 t, the BCS 185 can be equipped with a wide range of Bauer cutters allowing trench widths of up to 1,500 mm. This makes the system as a whole even more attractive: The Bauer cutter system is not subject to crane permit regulations, hence any requirements for the operators are eliminated.

First operations in China and Europe
Just on display at Bauer’s In-House Exhibition in Schrobenhausen as well as in a product launch event in Tianjin in China, the new cutter system already started its operation in the South of China. It had been shipped to the construction site beginning of June and was assembled in a record time of only 22 hours. The first unit in Europe will soon travel to the French city of Toulouse. This BCS 185 will be used on a cutter project together with other Bauer cutters. “The BCS series, our MC-based cutter systems as well as our world novelty, the BAUER Cube System complement one another fantastically,” Leonhard Weixler remarks confidently. “And with that, Bauer once again demonstrates why we are the leading manufacturer of the worldwide most productive cutter systems!”

Further information:
BAUER AG
www.bauer.de

Cementation Skanska and BAUER Maschinen GmbH have jointly brought the world’s first electric, large rotary drilling rig to the High Speed 2 (HS2) project in London. Instead of a diesel engine, the BAUER eBG33 has a powerful electric drive. Thanks to a dedicated on-site sub-station, Cementation Skanska can operate the machine with zero local emissions.

This innovative rig proves that heavy-duty, electrically powered construction equipment can perform the same tasks as conventional equipment and is a further step towards diesel-free construction sites in the future. The eBG 33 has been operational for almost 500 hours on this project which means a considerable CO₂ saving. Additionally, the noise reductions are significant, with base carrier noise levels of 50% less, compared to a conventional rig.

Andrew Entwistle, Operations Director at Cementation Skanska, emphasizes: “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 eBG 33 first hand on a live project, but it has provided an important opportunity to demonstrate the potential of all-electric heavy plant to the wider industry.”

Warren Arnold, General Manager of BAUER Equipment UK Ltd, says: “We are delighted to be working with Cementation on this project to deliver this world first use of a fully local emission free, high-capacity drilling rig. We are all incredibly proud of this unique rig which is setting standards. All the data recorded during operation will help Bauer in the further development of our environmentally friendly rigs and in our ambition to be the leading supplier of sustainable equipment for specialist foundation engineering. This really is a great opportunity to showcase what the eBG 33 can deliver in real terms and the benefits to the local community and environment.”

This deployment run is a continuation of work carried out as part of the HS2 project in Birmingham, where the rig was powered by a generator. There, the cable handling was tested for the very first time in a live environment. With the ability to connect the unit to the local power grid in London, Bauer and Cementation were able to put the eBG 33 through its paces and gather valuable data on power consumption throughout the piling operation. This data will be used in the further development of the battery-powered eBG 33 H all electric recently introduced by BAUER Maschinen GmbH.

Further information:
BAUER AG
www.bauer.de

Sankhuwasabha District, Nepal – The Arun River in Nepal flows from Tibet through the Himalayas into China. Of all Nepalese river basins, it has the largest area covered in snow and ice. A new hydroelectric power plant is currently being constructed on this river, and it is expected to produce up to 900 MW of electricity.

BAUER Engineering India Pvt. Ltd., a subsidiary of BAUER Spezialtiefbau GmbH, was tasked by the Indian company Jaiprakash Associates Limited with the construction of a cut-off wall as part of the project Arun III HEP. The goal is to achieve a seal and reduce seepage water below the upstream cofferdam and in the left and right abutments.

The scope of service provided by Bauer includes the execution of 3,500 running meters of drilling and injection work on the cofferdam. In the granular construction soil, composed of sand, gravel, rubble and boulders, the pore injections are executed by means of tube-à-manchette and annular grouting.

“Using the pore injections, we are able to fill the pores in the very loose soil with cement slurry and thereby reduce its permeability”, explains Project Manager Satish Kumar. He continues: “Injections require a high degree of quality assurance and quality control. We are able to meet the strict demands thanks to our many years of experience.” In addition to the pore injections, Bauer will also carry out rock grouting in order to fill gaps, fractures and cavities in the rock.

Due to the remote location in the Himalayas, not only the construction soil poses a challenge, but also logistics. On top of that, the schedule is very tight: this is because snow starts to melt in March, causing the water level in the river to rise and making work more difficult.

A KLEMM KR 909 is being used for the drilling and injection work. The work executed by Bauer started in December 2021 and is expected to be completed by May 2022.

Further information:
BAUER AG
www.bauer.de

Since the mid-1980s, hardly any other method has changed specialist foundation engineering as markedly as the development of diaphragm wall equipment. One milestone in this process was the introduction of the first Bauer trench cutter, which was used in 1984/85 to seal the Brombach Reservoir in Franconia (Figure 1). In just four months, this innovation conceived by Bauer engineers was designed, constructed and brought to the site – with resounding success: Despite some initial difficulties, the prototype was used to construct a wall 60 cm thick and 40 m deep. “This ‘technical adventure’ marked the start of a true success story, which has repeatedly gone beyond the limits of what was previously feasible and that is far from over,” says Leonhard Weixler, head of the Diaphragm Wall Equipment division at BAUER Maschinen GmbH. Since 1985, he has overseen the development of Bauer cutter technology in various roles.

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Special applications for Bauer cutters

In the following years, cutter technology at Bauer advanced in great strides – “always highly pragmatic, but also at times very bold and creative,” recalls Leonhard Weixler. The first cutters were sold to Japan and Turkey. In collaboration with a French partner, the maneuverable City-Cutter BC 15 was created for work in tight spaces and with working heights of just 5 m. New applications were later opened up with the Low Headroom machine that Bauer introduced on the market at the end of the 1990s. This was used to execute the encompassment of a subway station in Singapore underneath an existing airport building. Another machine of this type was used in China a few years later, in the Yeleh Dam project, to construct the sealing wall for a reservoir dam in a narrow tunnel.

Then in 2014, the CBC 40 Silent Cutter ushered in a new generation of equipment for projects in urban environments. The equipment performed impressively when it was used for a subway project in Singapore, particularly due to its low noise emissions, but also thanks to its compact dimensions, which were possible because of measures such as attaching the hydraulic power pack on the side. Next in summer 2019, an impressive depth record was set by a BAUER BC 50 cutter on an MC 128 duty-cycle crane: During a mining project in Canada, cutter excavation was for the first time carried out up to a depth of 251.4 m (Figure 2).

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Standard equipment in specialist foundation engineering

“In addition to all these special applications – some of them in difficult geological conditions – our cutters have also become established as reliable standard equipment in specialist foundation engineering, for example in the construction of diaphragm walls that can serve as retaining structures, for cut-off wall construction or as a foundation element,” emphasizes Leonhard Weixler. In addition, cutters also play an important role in soil mixing techniques such as Cutter Soil Mixing (CSM): Cutting wheels loosen the soil and mix it with a slurry to form a homogeneous soil-bentonite mortar. The method can be used to construct cut-off walls and retaining structures in various soil types, including hard soils.

Over the decades, Bauer has built and sold hundreds of cutter and CSM units. “The reliability of our equipment is largely also based on our decades of experience,” says Leonhard Weixler. “And our customers can also depend on that.” In recent years, however, the orientation for new developments and enhancements in Bauer cutter technology has been provided not only by customer requirements, but also by two major trends. “The topics of urbanization and sustainability are becoming increasingly important. They require proactive solutions, such as our first electrically powered cutter unit based on a BAUER MC 96 duty-cycle crane, which we presented in 2019 at the Bauma in Munich,” continues Leonhard Weixler.

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New applications

Finally, Bauer presented an innovation last year that opens up entirely new applications for the future of diaphragm wall construction: the electrically powered BAUER Cube System (Figure 3). This was developed precisely in the dimensions of a container. As a result, it can be easily used in tunnels with a diameter of just 3 x 3 m, a major advantage for cutter projects in densely populated large cities, for example. “The BAUER Cube System can be used precisely where the diaphragm wall needs to be constructed: underground,” summarizes Leonhard Weixler. This means that large-scale closures of urban areas could potentially be a thing of the past. The impact of construction sites on traffic, businesses, and residents (in particular) are minimized, even during daytime use. Another advantage is that the electric drive system considerably reduces the ecological disturbance of a cutter site. When it comes to logistics, the system’s compact dimensions are another major advantage. Instead of expensive heavy haulage, individual elements of the system can be easily transported to their place of deployment as conventional containers. “All in all, the BAUER Cube System sets new standards when it comes to sustainability in cutter technology,” concludes Leonhard Weixler.

Further information:
BAUER AG
www.bauer.de