The construction industry is expected to make significant investments in cleaner machinery at construction sites in the coming years. This is outlined in the Clean and Emission-Free Construction (SEB) roadmap. But what possibilities exist for more sustainable construction machinery? A recent story from the field, documented by ING.
In collaboration with Hillcon in Beilen, Vroom Funderingstechnieken took a significant step towards zero-emission construction sites last year by introducing the HSCX1500GLS-E: a battery-electric foundation machine. How did this adventure come about, unfold, and where does it go from here? Let’s head to Oosthuizen, on the edge of the Markermeer, where the company’s headquarters are located.
At Vroom Funderingstechnieken, Alex Brouwer is responsible for equipment procurement. Also present is operational director Niels Bakker, from the three-person management team of the foundation division. They are naturally proud of their new machine and are keen to talk about it, as well as the necessity of their sustainability plan.
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Converting a standard machine
The story begins with Vroom Funderingstechnieken’s investment in a large electrically powered foundation machine. “The basis of the machine is a standard machine from the Japanese brand HSC,” says Alex Brouwer. “In the Netherlands, we have been assembling it into a foundation machine for many years, with the machine being completely disassembled; the mainframe is adjusted and reinforced.”
And now, an additional step was taken, from the standard diesel equipment provided by the Japanese to the new battery-electric machine. This makes the formidable powerhouse ready for deployment on zero-emission construction sites. Why did Vroom Funderingstechnieken make this transition now, while it is scheduled for the ‘specials’, to which these machines belong, somewhere around 2035-2040? And why is the company ahead of requirements that are still uncertain?
Spreading replacement for financial reasons
Brouwer provides the answer: “You have to consider that these types of large machines – the largest foundation machines in Europe – are not fully depreciated in operational terms in ten years. The lifespan is much longer. We have foundation machines running for 20 years, which is quite normal. So, you have to plan with such a machine beyond near-term regulations. Given Vroom’s reputation in the foundation world, we decided to get ahead and start making the machine modular electric now.
Niels Bakker adds: “2035 or maybe even 2040. Yes, that’s still quite a long time.” But that’s not a reason not to embark on a sustainability plan. “To give you an idea: Vroom has more than 30 foundation machines running daily. Financially, you can’t convert 30 machines in just a year. The machine builders can’t handle such an order at all. Moreover, you have to start somewhere. That’s why we chose to start with this extra-large machine now. They call this the Next Generation: it incorporates all kinds of new developments that are different from existing machines. So, if you have the newest, largest, redesigned machine, let’s make it electric right away.”
Replacing or expanding at the right time to sustain
“The work we have to do is getting heavier,” says Niels Bakker. “The piles are getting heavier and longer, so you need more powerful machines. The machine we used before was the Hitachi CX1100GLS, just a bit lighter. But the questions we received exceeded the capacity of that machine more and more often.” So, heavier equipment was needed. “That’s when the HSCX1500GLS-E came into play. This immediately raised the question: should we make it electric with an eye to the future?”
Comparing SEB roadmap with own machines
Then it was also the right time to look further ahead. First, by mapping out the entire equipment potential. “We have about 35 foundation machines, around 25 shovels, 15 concrete mixers, 10 mini-excavators, and 15 concrete pumps. If you have to electrify all of that, it’s a considerable challenge. We looked at the SEB roadmap and compared it with our machines. Ultimately, this resulted in an expansion of our sustainability project, which we have been working on for about 10 years. One very large total project, of which this HSCX1500GLS-E is now one of the pioneers.”
Anticipating the demand for sero emission in the near future
With this investment, Vroom Funderingstechnieken is clearly anticipating the expected demand for zero emission in the near future. “At the moment, the specific demand for our type of work is not fully electric yet. At least: we don’t have the experience that it’s happening a lot. I can remember one or two requests recently,” says Alex Brouwer. “You’re not only dealing with the machine, but also with peripherals. And to be honest, we just can’t offer all of that sustainably yet.”
He continues: “For example, what we do have now for a project is that we use a foundation machine with a Stage V drilling rig and a concrete pump with a Stage V engine. And then we think along with our customer by, for example, renting an electric excavator. So, it’s still a puzzle with the solutions that are already available.”
Remotoring or electrifying
Back to the company’s sustainability journey. Alex Brouwer says: “Initially, in our sustainability plan, we looked a lot at retrofitting existing machines. This means you don’t dispose of existing machines but instead refurbish them – it’s called life-extending maintenance. For example, you remotorize. Not the same type of motor, but a cleaner one. We were very clear about it, that we wanted to remove the pre-stage motors and the stage II and III motors.”
During that time, it was often a case of necessity being the mother of invention. “Especially when it came to nitrogen. Then we would hear from the client that it had to be cleaner, even though it wasn’t mentioned in the quotation process. Otherwise, they simply wouldn’t get a permit. That whole nitrogen discussion was a turning point. Now it’s about more than that: nitrogen, health, and climate. That’s all combined in the SEB now,” says Brouwer. “You can see that the entire market is moving towards remotoring, and at the moment, the transition is mostly towards Stage V. It’s hardly a debate anymore.” Niels Bakker adds: “And for cranes or mini-excavators, it’s about electrification, because it’s simpler to electrify here.”
Remarkably smooth development process of battery-electric foundation machine
According to Brouwer and Bakker, the electrification process of their foundation machine has been remarkably smooth. “We clearly outlined what we wanted beforehand, and once it was in place, it worked smoothly. It was plug and play. So, that wasn’t the issue. But, as Brouwer points out, “then you come to the chicken-or-egg story: who provides the electricity at the construction site? We said: we have to be self-sufficient. And that’s quite painful because then you end up with a generator in most cases. Because whether you have a battery or a battery pack: you have to charge it. And a hybrid generator is also not a solution because then you’re still dealing with batteries.” So, the middle ground for now is a diesel generator. “Then you have a kind of hybrid machine.”
However, they are optimistic about the future, especially when they look at the developments and possibilities since they started with the new machine. Bakker says: “Back then, two and a half years ago, the charging systems were not yet at the level they are now. Look, for this machine, we need at least a 125 Amp connection at the construction site. That’s not available everywhere yet, and you have to request it in time.” He refers to a recent project near Antwerp. “There was power, but it was 500 meters away. Those are the practical problems you still encounter now. This type of machine is used, for example, in newly developed industrial estates or wind turbine projects, very large plants. The power is often not yet arranged there, but we are already there. Actually, you should plan the construction the other way around: first the infrastructure and then onwards. But in practice, it usually happens the other way around.”
Teething Problems? “Yes. We deliberately chose to look to the future with this machine. Because however you turn it, we’re heading in this direction anyway. And if you invest in a new machine now that has to last 20, 25 years, you have to make the right decision now. And definitely not go for the short-term vision. Because this step is coming,” concludes Niels Bakker.
After this interview, Vroom continued its sustainability strategy by investing in two PVE EHPU systems. This system is a hybrid solution for diesel-powered foundation machines. An EHPU system allows working with a Woltman 90DR foundation machine and the electric-hydraulic power unit both emission-free and with diesel fuel.
Source: ING
