Foundation Equipment in Greater Demand: Sany, Schwing Stetter & Casagrande

Demand for foundation and piling equipment is surging, following a period of stagnation during the Covid 19 pandemic shutdown of construction activities. Ongoing and upcoming metro rail, access controlled elevated roads, bridges, ports, and real estate developments across the country are driving the need for advanced ground improvement techniques. This new demand is translating into a requirement for a higher volume of equipment with state-of-the-art technology. More importantly, the industry is evolving to focus on solutions that bring significant value. Project consultants, builders and contractors are looking for innovative foundation technologies like diaphragm wall systems, CFAs, displacement piles, stone columns, and soil mixing, etc, in order to execute projects with greater quality and faster completion timelines.

Sanjay Saxena, COO, Sany India, informs that in many regions of India, soil conditions are less than ideal for standard foundation methods. “Areas with weak or highly variable soil, high water tables, or expansive clay require specialized piling and ground improvement techniques to ensure stability and performance. Managing groundwater and mitigating its impact on construction is increasingly important, especially in urban environments.”

“Techniques like jet grouting and soil mixing are used to stabilize ground affected by high groundwater levels. Advances in piling and ground improvement technologies such as CFA (Continuous Flight Auger) piles, micro piles, and single column mixing, are expanding the range of solutions available for ground improvement. These technologies offer more efficient, cost-effective, and less invasive methods for dealing with complex ground conditions.”

He adds, “At Sany India, we are well positioned to cater to the varied ground improvement jobs through our wide range of advanced products, which are backed by technical support. We have advanced solutions for diaphragm wall construction, particularly for applications involving shorter cycle times and deeper depths. In diaphragm wall construction, Kelly bars are critical for drilling and handling various soil and rock conditions. For shorter cycle times (400-800 mm) and deeper depths (40-45 meters), we have rope suspended Grab SH500 with options of 600, 800, 1000 and 1200mm width retaining wall construction and can reach 80mtr depth, while the SH700 is capable of 800,1000, 1200, 1500 and 1200mm width retaining wall construction."

To cater to the new applications, Sany has introduced several variants of Continuous Flight Augers (CFAs) designed to enhance performance and efficiency in construction, particularly in ground improvement and foundation work. The company’s models like SR185MIII, SR235MIII, SR285MIII are catering to a majority of the CFA requirements. Some of the key application areas of CFA are laying foundations, ground improvement and stabilization, etc.

Says Saxena, “CFAs play a significant role in soil displacement, particularly in ground improvement and foundation work. CFA technology, traditionally used for creating piles, can be adapted for various soil displacement applications to improve soil stability and enhance load-bearing capacities."

The CFA auger displaces soil and injects grout or concrete to create a pile that reinforces weak soil. The displaced soil is effectively replaced by a stable grout or concrete column, enhancing soil strength and load-bearing capacity. By creating a continuous column of grout or concrete, CFA piles improve the load distribution and stability of the ground, which is crucial for supporting structures like buildings and bridges.

For delivering flexibility in operations, Sany’s base machines are designed with versatility and adaptability in mind, enabling them to work with a range of attachments and kits such as Kelly bars, continuous flight augers (CFAs), and other specialized tools. This flexibility is achieved through precise engineering and integration of advanced technologies. The base machines are built with modular components that allow for easy interchangeability of different attachments. This modularity ensures that the same base machine can be configured for various applications, including piling with Kelly bars, drilling with CFA, or other specialized tasks. Standardized mounting systems and connection points facilitate the quick and secure attachment of different tools and kits. This design allows for rapid switching between different operational modes.

“Sany machines are equipped with advanced hydraulic systems that can be adjusted to accommodate different attachments. The hydraulic flow and pressure settings can be modified to match the requirements of various tools, such as Kelly bars or CFA equipment. The base machines have powerful engines that provide the necessary power for a wide range of attachments. The engine’s performance can be fine-tuned to meet the demands of specific applications, ensuring optimal efficiency and effectiveness. The load-bearing capacity of the base machines is engineered to support different attachments and operational requirements. This includes accommodating the weight and forces exerted by Kelly bars, CFA rigs, and other tools," informs Saxena.

Based on emerging complexities in ground improvement works, and projects that require a combination of technologies such as piling and diaphragm walls, Sany has been enhancing its presales support to better meet the needs of its clients. The company provides tailored engineering solutions that integrate various technologies like piling and diaphragm wall systems. This includes designing customized configurations that address the specific challenges of a project before its initiation.

Says Saxena, "We undertake feasibility studies to assess the suitability of different technologies and equipment combinations for the site conditions and project requirements. Our technical experts can provide in-depth consultation on the use of combined technologies, and guidance on optimal equipment configurations and operational strategies. We can prepare customized proposals that outline the recommended combination of technologies and equipment for a project, and include technical specifications, operational plans, and expected outcomes."

We also have training programs for operators and project teams on the usage of combined technologies, besides hands-on training on piling rigs and diaphragm wall systems. Our technical team is available to provide detailed information about the equipment, its performance capabilities, and technology integration. The team also addresses any questions or concerns before a sale is finalized.

With its population of foundation equipment growing, the company is enhancing its post-sales support, its parts supply, and maintenance. It has a network of strategically located parts distribution centres around the world that ensure timely delivery of parts for different models and types of equipment.

The company’s scheduled preventive maintenance programs help clients avoid unexpected breakdowns and extend the lifespan of their equipment. These programs include regular inspections, servicing, and parts replacement. All Sany machines are equipped with telematics systems that allow for remote monitoring and diagnostics, and provide real-time data on equipment performance, usage, and potential issues.

“As part of our sales support, we actively seek customer feedback on post-sales support services to identify areas for improvement and ensure high levels of customer satisfaction. Based on feedback and performance data, we continuously enhance our maintenance support to better meet client needs," says Saxena.

Schwing Stetter India has also introduced a new range of continuous flight augers (CFA) that offer enhanced performance, greater drilling depth, and improved soil extraction capabilities, informs V.G. Sakthikumar, MD, Schwing Stetter India. “These new variants are designed for urban infrastructure projects, large-scale residential developments, and industrial foundation tasks in challenging soil conditions. These CFAs are optimized for faster drilling speeds and reduced downtime, providing a cost-effective solution for contractors facing tight project timelines."

He adds, "Increasing urbanization and the push for smart cities will drive demand for specialized solutions, particularly in construction of high-rise building foundations, urban infrastructure, and renewable energy projects. As the landscape of construction evolves, areas such as underground parking structures, water treatment plants, and coastal protection projects will also become significant demand drivers for foundation and piling equipment.”

“We are fully geared to cater to the new demand order with our specialized products that include CFAs for high-density housing projects, bridge foundations, and retaining walls in hilly terrains. Our soil displacement technologies are integral to our portfolio. We see them as essential tools for meeting the demands of modern construction projects that prioritize environmental considerations."

Schwing Stetter’s Kelly bars are engineered to perform efficiently in shorter cycles of 400-800 mm, ensuring precise and consistent performance. For rope-suspended grabs operating at depths beyond 40-45 meters, the company offers solutions that guarantee operational stability and safety at greater depths.

"Our solutions are designed to enhance productivity and minimize cycle times, making them ideal for complex and deep foundation projects. Our Kelly bars are crafted with superior materials and advanced engineering to meet the stringent demands of modern construction sites," says Sakthikumar.

He informs that Schwing Stetter is promoting its soil displacement solutions and non-vibration stone columns for use in urban areas where minimizing vibration and noise is crucial. Soil displacement techniques help in enhancing soil stability without the need for extensive excavation, while non-vibration stone columns offer an effective method for improving load-bearing capacities in soft soils.

To enable the foundation contractor have operations flexibility in projects, requiring varied components, the company's base machines are engineered keeping in mind their versatility and adaptability. They can work seamlessly with a variety of attachments, including Kelly bars, continuous flight augers (CFA), and other specialized kits.

"Our machines are equipped with advanced hydraulic systems and robust frames that ensure compatibility and optimal performance across different applications. To further enhance operational flexibility, our base machines come with preloaded software designed to accommodate the specific requirements of various attachments. This software is user-friendly and enables operators to switch between different applications with minimal setup time, ensuring that the equipment can adapt quickly to the needs of any projects."

Schwing Stetter is promoting its specialized equipment through presales technical support. Says Sakthikumar, "We have tailored our presales support to provide comprehensive solutions to meet the specific needs of each project. We offer detailed site assessments, customized equipment recommendations, and expert consultations to ensure that our clients are equipped with the right combination of technologies like piling and diaphragm walls."

Presales support includes technical feasibility studies, cost-benefit analyses, and simulation models that help clients visualize the potential outcomes of various approaches. "By combining our deep expertise with cutting-edge tools, we ensure that our clients receive the most efficient and effective solutions for their complex ground improvement tasks," avers Sakthikumar.

The company is also strengthening is post-sales support as the population of its XCMG foundation equipment grows. It has expanded its parts distribution network for faster delivery and increased availability of critical components. It has introduced a proactive maintenance program, which leverages IoT and predictive analytics to monitor equipment performance in real-time for pre-emptive maintenance solutions. "Our customer service teams are also equipped with advanced tools and training to provide rapid and accurate technical support, ensuring that our clients can maintain peak operational efficiency at all times," says Sakthikumar.

Says Rakesh Raina, Country Head, Casagrande India, "It is interesting to see emerging applications for foundation equipment in India, led by newer technologies and processes. The aim is to attain higher productivity with lower cost by the equipment deployed in the challenging infrastructure construction projects. At Casagrande, we have wide range of civil foundation solutions to meet specific project requirement which is compatible to given soil strata and other related project requirements. Casagrande technology department is continuously evaluating the advances in civil engineering industry and working on economical mechanical solutions which are environment friendly, safe, reliable and having faster execution time lines and accordingly develop high-end technology application solutions.

He informs that the state of Gujarat has made mandatory the use of diaphragm walls in the construction of car parking basements in residential and commercial buildings which entails safe and faster execution timelines.
The consultants and contractors prefer Kelly guided hydraulic grabs for top-down construction methodology for construction of basements. Casagrande grabs are contractors preferred and first choice and we have supplied more than 60 nos of our diaphragm wall equipments in the state of Gujarat during last five years which is witnessing a huge infrastructure and real estate development. The municipal authorities have made it mandatory for builders to construct underground parking to avoid road congestion and thereby we see a consistent demand for Casagrande grabs. We are observing a similar demand trend in the National Capital Region having favorable soil strata for adopting diaphragm wall excavation methodology.

Foundation equipment specialist Casagrande is having wide range of diaphragm wall equipment and in particular its proven Kelly guided grabs having faster cycle time are a preferred choice for economical excavation with stringent verticality control for 2-5 level basements. These machine can accomplish Dwall panels from 300mm upto 1500mm thickness and upto an excavation depth upto 46.0 m. Casagrande also has rope suspended grabs for deep Dwall excavation.

Raina informs that their equipment is finding newer applications in the construction of Retaining wall for River front projects, Jetties , underpasses besides underground metro rail station buildings.

Casagrande is also promoting its continuous flight augers (CFA) and non-vibratory stone columns application kits. "Our solutions with proven technologies are finding usage in urban construction, for instance, our vibratory stone columns application kit was used for ground improvement of Dedicated Freight Corridor rail project. Casagrande has also successfully supplied application kit for executing CFA piles and it was able to show case that for a suitable soil strata, CFA piles were more economical and faster ground improvement methodology compared to bore pile. We are also keen to introduce our other green foundation technologies in India like Soil displacement and Soil mixing which anyways are well established in Europe and other developed countries. As per the new technologies, one can achieve ground improvement without extracting the soil from the ground and is environment friendly.

"Casagrande machines find favor with specialized civil foundation contractor due to their flexibility in operation for multiple foundation applications, higher productivity, greater reliability and their lower life cycle cost. The machines can facilitate easy fitment and integration of the separate application kits for a variety of civil foundation solutions. Our customers do have to pay higher initial capital cost to acquire our machines, but are able to get better RoI,” avers Raina.

Casagrande India has a fleet of 450+ units working across India. The company has a parts warehouse in Delhi, Chennai and in Ahmedabad to support our customers. Casagrande India which is a 100% subsidiary of Casagrande Spa has factory trained service team to support our customers at a very short notice.