Rebuilding of superlatives
June 2, 2025 | Susanne Winter
The „Paper Machine 11“ in the paper mill, which previously manufactured paper for magazines and advertising folders, was rebuilt. It is now used to produce packaging paper from recycled waste paper. Numerous construction works were necessary to complete the rebuilding. Excavators ranging from 5 to 35 tonnes, lifting platforms and forklifts - in some cases 84 at the same time - dumpers, articulated climbers, various mobile cranes as well as a building construction crane were used. Between 10 and 20 Felbermayr Construction employees were on site at any one time.
High level of reinforcement and high concrete quality
The main rebuild, which accounted for around 60 per cent of the work, took place between August 2023 and June 2024. „This was demolition and concreting work for the rebuild of paper machine 11. This was carried out in existing facilities and during operation,“ reports Christian Gugerbauer, construction engineer from Felbermayr's Building, Industrial and Power Station Construction division: „The demolition and new concrete work posed a challenge, given the high level of reinforcement and high concrete quality. The cast-in-place concrete components and precast concrete parts were characterised by high precision requirements.“
This included setting small-calibre piles, constructing foundations for a machine with dynamic behaviour, installing numerous builtin parts and performing extensive grouting work. „Extensive adaptations, combined with various dismantling works, concrete reinforcements and the construction of a new machine base including foundations, were necessary to install new parts of the paper machine and system components,“ explains Gugerbauer.
Ceilings with around 250 heavy-duty pedestals underneath
In addition to the rebuild of paper machine 11, the RCF 11 (Recycled Fibre) waste paper processing system was replaced by a new drum. The existing facilities were also rebuilt and small-calibre piles were set. The enormous weight of around 220 tonnes forced Felbermayr Construction to place the ceilings underneath the old drum before it was removed. Around 250 heavy-duty pedestals were set up in the basement area for this purpose. After removal in December 2024, the construction experts concreted new foundations, as the new drum was installed in a different position. It is also larger and heavier than the old drum.
When the new drum was installed in February 2025. Felbermayr Construction once again secured the ceilings in the basement area and also erected a temporary concrete ramp as well as two 60 metre long strip foundations to support the lifting frame. Work was completed in May 2025.
