One of the largest modernisation and full refurbishment projects on the Main–Danube waterway has been awarded to a consortium comprising the construction companies PORR, HABAU and FELBERMAYR through an open tendering procedure. On behalf of the Waterways Construction Office in Magdeburg, the three companies will comprehensively overhaul both existing lock chambers, one at a time, over a period of 13 years, starting with the southern lock. During the six-year reconstruction of the southern lock, traffic will be routed via the northern lock, and vice versa.

Guido Zander, Head of the Waterways and Shipping Office Danube MDK (WSA) responsible for operation and maintenance: “Having been in operation for almost 100 years, the Kachlet barrage is an example of outstanding engineering. With the necessary modernisation and full refurbishment now under way, the structure will be made ‘fit’ for the next 100 years. This will make an important contribution to ensuring that the international Rhine-Main-Danube connection remains safe and reliable in the future for the environmentally friendly and energy-saving mode of transport that is shipping.”

Highly complex engineering

For the consortium, the project represents a major challenge. PORR CEO Karl-Heinz Strauss: “The refurbishment and fundamental repair of transport routes is a key area of activity for PORR. Construction work on the water using ships is always challenging. This project involves the sophisticated interplay of different activities. For example, excavators with special cutters, standing on pontoons, will cut slots into the existing lock walls. Anchors will then be drilled into these recesses and the niches will be sealed up again with concrete. Together with our partners, we are proud to be able to demonstrate the full breadth of PORR’s expertise.”

Hubert Wetschnig, CEO of the HABAU GROUP: “The general refurbishment of the Kachlet lock is a large-scale project of exceptional engineering complexity. The works require the utmost precision in both planning and execution. For this, HABAU is contributing its proven expertise in engineering and hydraulic engineering to work with its consortium partners to create a permanently safe and efficient infrastructure for the Danube.”

Bernhard Strasser, Managing Director of FELBERMAYR-Bau: “We at FELBERMAYR are delighted to be part of this once-in-a-century project with our civil engineering division and Domarin hydraulic engineering company. Specifically, we will be actively involved in the construction work with dredging, the provision of floating units, demolition and earthworks, and pipeline and road construction.”

PORR, HABAU and FELBERMAYR each bring their particular strengths to the consortium, complementing each other. PORR’s specialist civil engineering expertise, engineering and earthworks services are particularly in demand, while HABAU also contributes special engineering and earthworks expertise, and FELBERMAYR brings lifting technology and many years of experience in hydraulic engineering. 

A contract with special dimensions

This is a large-scale project whichever way you look at it: Each lock will be approximately 335 m long and 24 m wide when completed. A variety of measures will be used in the construction, from demolition and earthworks to concrete construction, pipeline construction and steel hydraulic engineering. Up to 100 staff will work on the construction site. 

The existing structures will be demolished down to the foundation and completely rebuilt. In addition to the new construction of the lock chambers in accordance with current technical standards, the project includes the installation of modern lock gate technology with new stem gates, hydraulic drives and state-of-the-art control, automation and safety technology. The aim is to increase operational safety, adapt the facility to today’s inland waterway transport requirements, and ensure its functionality for decades to come.