For a major hydraulic engineering project in a protected nature reserve, Buitink Technology developed a comprehensive concept for the assembly, launching, floating transport and controlled sinking of a massive steel structure weighing approximately 200 tonnes.

The project combined three technical disciplines:

1. Construction site protection in a sensitive area.
2. Crane-free launching of heavy steel structures.
3. Controlled positioning underwater.

By using a mobile floor with inflatable edge seals and custom-made floats/lifting cushions, a fully self-supporting floating transport system was created.

Technical challenge: building, launching and positioning without heavy equipment

The challenge consisted of three parts:

1. The steel structure had to be erected on the riverbank within a protected nature reserve.
2. There was no room for heavy cranes, pontoons or large construction equipment.
3. The element had to be transported afloat and lowered in a controlled manner to its final installation position.

Conventional hydraulic engineering methods were not suitable for this project. Consequently, a completely new concept was developed based on inflatable technology and modular buoys.

Challenge 1. Site protection in a nature reserve

The installation took place in a riparian zone within a protected nature reserve. Strict requirements apply in such environments: grinding and welding work, flying sparks, and oil and metal residues must not enter the soil or surface water.

Buitink Technology installed a mobile work floor with inflatable edge seals. This technology is also used in mobile car washes and containment floors for industrial applications.

Effects of this solution:

• All dirt and construction debris is completely contained.
• The subfloor remains intact and is not subjected to mechanical stress.
• The floor can support heavy point loads from heavy steelwork.
• The work area becomes a sealed and controllable construction environment.

The mobile floor serves both as a supporting structure and as an environmental containment solution.

Challenge 2: Launching 200 tonnes without a crane or pontoon

Once fully assembled, the steel structure on the mobile deck was fitted with custom-made floats. These float elements were developed in accordance with the same principles that Buitink Technology applies to:

• large pontoon barges,
• salvage lifts,
• industrial lifting bags for heavy loads.

The launch procedure consisted of three steps

• The inflatable perimeter seal around the floor was inflated.
• The floor basin was filled with water in a controlled manner.
• The whole structure began to float and came away from the ground.

This enabled an object weighing approximately 200 tonnes to be launched without the use of cranes.

Challenge 3. Floating transport and controlled sinking

After being launched, the structure was towed across the lake to its installation position by a small tugboat. During transport, the structure was supported and stabilised by custom-made floats supplied by Buitink Technology.

What the pioneers made possible:

• Sufficient buoyancy to safely support the structure
• Stability in both longitudinal and transverse directions during towing and manoeuvring
• Fine-tuning via separate air chambers for precise trim and balance

This compartmentalisation allows for controlled ballast adjustment during both transport and installation.

Result: a sustainable and controlled hydraulic engineering installation

Thanks to Buitink Technology’s bespoke approach, it was possible to:

• the entire steel structure can be safely erected in a nature reserve.
• the element can be launched into the water without a crane or pontoon.
• the structure can be transported over longer distances whilst afloat.
• the structure can be lowered and positioned in a controlled and precise manner.

This project demonstrates how inflatable technology can be used for complex hydraulic engineering projects, particularly in locations where conventional methods are not feasible. It also highlights the flexibility of our engineering capabilities and the scalability of floating transport systems based on custom-made floats and lifting bags.

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