Technology
Nord Drivesystems in Alps
Published
4 years agoon
By
admin
Heavy duty work for industrial gear units from Nord Drivesystems in the Alps
In an extremely demanding construction project in the Swiss Alps, at an altitude of around 1700 m and almost 600 m inside a mountain, large chambers are being excavated to form the new expanded underground centre of a pumped storage hydroelectric power station that will increase its present power output from 480 mw to 1480 mw. With an extreme incline of 45 degrees and a height difference of approximately 180 m, conveyor systems in a sub-station are transporting 500 tonne of excavated material per hour, around the clock, using conveyor belts that are driven by Nord industrial gear units.
The expansion project "Linthal 2015" will upgrade three existing power station systems and increase their overall output power from 480 mw to 1480 mw. A new underground pumping station will drive water from a lower reservoir at an altitude of 1860 m into a lake reservoir which is about 600 m higher. The pumped storage power station will use this elevation difference to produce hydroelectric power on demand. The client for this project is Kraftwerke Linth-Limmern AG, a part of Axpo Holding AG.
The power requirements of a national electricity grid are subject to large fluctuations over the course of a single day. At night, power consumption is at a minimum and typically reaches a peak at midday and in the evening. In Switzerland, electric power is mainly supplied by nuclear and river-based hydroelectric power stations. Biomass and conventional thermal power stations also make a contribution. In contrast to nuclear and river-based plant, pumped storage hydroelectric power stations can rapidly respond to changes in demand. The optimum interplay between these various types of power generation technologies ensures that a reliable and economic power supply is maintained around the clock.
Pumped storage stations assure peak-time energy: Unlike pure storage power stations, pumped storage stations cannot just generate energy at peak times; they can also convert excess power, which is generated during periods of low demand, into valuable peak-time energy. The demand for peak energy is continuously increasing throughout the entire European grid network. Apart from the general increase in annual consumption, another important reason for this is the intensive development of wind energy in the coastal regions of the European Union. This factor results in an increase in the so-called stochastic energy, which depends on random wind conditions and therefore cannot be reliably planned. If power from wind energy is generated in times of low demand, the excess can be used to pump back water into the higher reservoirs of pumped storage power stations. If there is no wind during the day, pumped storage power stations can then cover this power deficit. A further reason for the increasing demand for peak energy is the opening of the electricity market. As power can be purchased by consumers from anywhere on the free market, power distribution networks must increasingly be regulated by system services, which ensure a reliable supply.
Pure hydroelectric power stations have an upstream reservoir. In contrast, pumped storage plants have an additional lower reservoir. If power is generated, water from the upper reservoir flows into the pressure system. The water drives turbines, which in turn power the motor generator. The electrical power which is produced is fed into the grid. After leaving the turbine, the water flows into the lower reservoir. If too much electricity is produced, the water can be pumped back from the reservoir into the higher altitude lake, from where it can be used at a later time to generate electricity. Pumped storage power stations can therefore store energy in the form of water in reservoirs. Pumped storage is a well-established method of compensating for fluctuations of supply and demand in the grid network, in an environmentally friendly and economic manner.
The scope of the project "Linthal 2015" includes excavation and construction work for the underground central station of the pumped storage power station and the tunnel system for the water that provides the power. Construction of a new heavyweight dam for the higher lake will increase its storage volume from the present 9 to 25 million m³. Expansion work for the existing compensating reservoir is also included. Construction work on Switzerland’s largest hydroelectric project is being carried out at considerably different altitudes and inside of the mountain. The compensation reservoir at an altitude of about 800 m is the lowest point. One thousand metres above this is the upper reservoir Limmernboden with a capacity of 92 million m³. At an altitude of about 1700 m and some 600 m inside the mountain, the heart of this gigantic expansion project is being created with huge excavated chambers that will house underground stations for the four groups of machinery used in the new pumped storage power facility Limmern. The underground station consists of a 150 m long, 30 m wide machinery chamber with a maximum height of 53 m, as well as a separate transformer vault which is about 130 m long, 20 m wide and 25 m high. This central station creates the link between the two lakes via a system of upper and lower water delivery tunnels, parallel pressure shafts and other service tunnels. Personnel, materials and machines are transported to the construction site using a cable railway with a load bearing capacity of 25 tons.
The excavation work for the two chambers is completed. The work has been proceeding rapidly in an intensive 24/7, 3-shift operation. The chambers have been excavated from above and below; every day about 800 m³ of rock has been removed from the mountain and in total almost 2,445,000 m³ have been excavated to form both chambers.
Drive systems for conveyors
Industrial gear units are used in the conveyor systems which are located in the central area of the construction project "Linthal 2015". Two "S-conveyors" convey 500 t of material per hour over a distance of about 260 metres with an extreme incline of 45 degrees and a height difference of around 180 m. The excavated material is conveyed down to a crushing plant. This conveyor belt is driven by a NORD industrial gear unit with brake control, which simultaneously generates electricity. On the second conveyor belt, the crushed material is conveyed up to the gravel plant, where it is stored until it is needed for further processing as construction aggregate for the dams or as concrete for walls and ceilings. This conveyor has a belt speed of 2.2 m/s and is driven by two NORD industrial gear units, located at the right and left of the conveyor system and connected by a common shaft. With a protection class of IP55, these industrial gear units each have a drive power of 250 kw.
The industrial gear units for this massive construction project were developed according to the tried-and-tested UNICASE principle. The UNICASE is a one-piece housing block, into which all the bearing seats are integrated, with production carried out in a single stage using state-of-the-art CNC machines. The concept features extreme precision, rigidity and strength with no joints between the output side and the gear unit which are subject to radial forces or torque. The UNICASE principle enables a more compact design due to the staggered arrangement of the shafts and also allows the use of larger roller bearings that guarantee a long operating life. Industrial gear units can be right or left mounted.
Customer-oriented drive solution
The supplier of this complete drive solution was Getriebebau NORD AG, Switzerland – a member of the NORD DRIVESYSTEMS Group. Customer orientation and closeness to customers are particularly important for the drive specialists from Arnegg, near St. Gallo. Guido Eigenmann, Manager of Getriebebau NORD AG, Switzerland explains: "We sell customer benefits – not just products. As well as this we offer a comprehensive service package. In addition to commissioning, we also provide maintenance training, so that the customer knows what to look out for. It is particularly important for us to supply complete systems which are highly efficient and economical. Many users require not just drive components, but rather complete and functioning system solutions. We tailor our drive solutions to each individual customer." The plant constructor and customer of Getriebebau NORD is Marti Technik AG, which was founded in 2002 and is one of the many subsidiaries of the Swiss Marti Holding AG. Marti Technik AG is a provider of individual tailor-made solutions, principally focussed on underground construction work. Building on its many years of experience gained on large construction sites and third party projects, the company predominantly specialises in the field of tunnel boring systems, conveyor technology, switchgear construction, as well as electrical engineering. Ernst Kuster, head of maintenance and responsible for the conveyor systems is very satisfied with NORD products and services. "The very good cooperation with Getriebebau NORD Switzerland is particularly positive for me. All of our requirements were catered for. What is also remarkable is the high ability to supply. It only took about ten weeks from ordering to delivery. With other suppliers, four or five months are not unusual. All-in-all we are very satisfied – a very good cost-benefit ratio, excellent advice and support, on-schedule delivery and last-but-not-least, NORD products deliver a very high performance and are of very good quality.
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Economy & Market
RAHSTA Roundtable Sets Agenda for Smarter, Safer Highways
Published
1 week agoon
March 16, 2026By
admin
Roundtable discussions focus on innovation for safer highways.
Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the RAHSTA Roundtable brought together stakeholders from across the highways and infrastructure ecosystem to shape the agenda for the 16th RAHSTA 2026, scheduled for 8–9 July 2026 at the Jio Convention Centre, Mumbai. The session focused on key industry themes including road construction, technology, safety and long-term sustainability.
Opening the discussion, Pratap Padode, Founder, FIRST Construction Council, said the roundtable marked the beginning of a broader consultative process leading up to the July event. The aim, he noted, is to bring together industry stakeholders to refine the agenda for discussions on the future of roads, bridges, tunnels and allied infrastructure.
Padode noted that while central road project awards have slowed in recent years, states are increasingly driving the next phase of infrastructure growth. Maharashtra, with its long-term road development plans and agencies such as MSRDC and MSIDC, is expected to play a significant role in this expansion.
RAHSTA Expo 2026 as a specialised platform dedicated to road infrastructure, covering highways, tunnels, bridges and flyovers along with construction technologies, safety systems and maintenance solutions. He also highlighted the growing importance of rural connectivity and said the organisers are engaging with government bodies to highlight rural road development initiatives.
Tanveer Padode, CIO, ASAPP Info Group, presented insights from IMPACCT, the group’s infrastructure intelligence platform. He pointed to a strong project pipeline despite slower highway awards earlier in the year, noting that states such as Maharashtra, Odisha and Arunachal Pradesh are emerging as key drivers of new projects. The data also revealed that only a small group of contractors participates in large-value infrastructure bids.
Lt Gen Rajeev Chaudhary, former Director General, Border Roads Organisation and Chairman of the RAHSTA Expo Committee, emphasised the need for stronger collaboration across the ecosystem, including policymakers, contractors, technology providers and financiers. He also called for addressing systemic issues within the sector and encouraged greater participation of women in infrastructure leadership.
The discussion also explored the evolving economics of road development. Phani Prasad Mandalaparthy, Associate Director, CRISIL Intelligence, noted that the slowdown in project awards reflects a shift towards higher-value logistics corridors rather than simple road widening projects. However, private participation through BOT and TOT models remains limited.
From the contractors’ perspective, Sudhir Hoshing, Whole-Time Director, Ceigall, said companies are becoming more selective in bidding, favouring projects with clearer payment mechanisms and efficient processes. While NHAI continues to offer greater operational clarity, states such as Uttar Pradesh and Bihar were cited as relatively supportive environments for project execution.
Durability and sustainability also emerged as key themes. Himanshu Agarwal, COO – Road & Infrastructure, Zydex Group India, highlighted the need to prioritise lifecycle performance and resilient pavements, while participants discussed the potential of alternative materials such as plastic waste, steel slag and industrial by-products in road construction.
Dr LR Manjunatha, Vice President, JSW Cement, emphasised that India has abundant fly ash, slag and other industrial materials that can improve durability and sustainability if integrated into specifications and policy frameworks.
Technology and equipment challenges were also discussed. Dr Lakshmana Rao Mantri, Dy General Manager, Afcons Infrastructure, highlighted the shortage of tunnel boring machines (TBMs), which is delaying several underground infrastructure projects. Participants agreed that developing domestic TBM manufacturing capabilities will be critical for future infrastructure expansion.
The future of concrete pavements was another area of discussion. Dr V Ramachandra, President, Indian Concrete Institute, stressed that the debate should focus on lifecycle performance rather than material choice alone, noting that evolving design standards are improving the feasibility of concrete roads.
Prof Dharamveer Singh of IIT Bombay added that while India has made significant progress in infrastructure development, stronger capacity building and better execution practices are essential to ensure consistent road quality.
The discussion also touched upon technology adoption in the sector. Rushabh Mamania, Partner & CBO, Roadvision, highlighted the growing role of AI in road infrastructure, noting that AI-driven monitoring systems are already being deployed across large stretches of national highways.
Overall, the roundtable underscored that the future of highway infrastructure will depend not only on the pace of construction but also on durability, safety, technology integration and sustainable materials. The discussions offered valuable insights that will help shape the agenda for RAHSTA 2026 and guide future collaboration within the industry.
Economy & Market
CTS Roundtable Charts Tech-Led Roadmap for Construction
Published
1 week agoon
March 16, 2026By
admin
CTS Roundtable Maps Technology Roadmap for Construction
Ahead of the Construction Technology Show (Con Tech Show) 2026, industry leaders, technology innovators and academia came together in Mumbai to deliberate on how digitalisation, automation and industrialised construction can reshape the sector. The discussion made one thing clear: construction can no longer afford to treat technology as optional.
Held on 12 March 2026 at Courtyard by Marriott, Mumbai, alongside the Infrastructure Today Airport Conclave, the CTS Roundtable served as a precursor to the Construction Technology Show 2026, scheduled for 19–20 August 2026 at NESCO, Mumbai.
A platform to move from discussion to deployment
Opening the session, Pratap Padode, Founder and Editor-in-Chief, ASAPP Info Global Group, said construction technology has long remained close to his heart, especially given the sector’s traditionally slow pace of technology adoption. He noted that over the years, the Construction Technology Summit had steadily built interest, and the next step was now to expand it into a larger, more meaningful platform that could bring together technology providers, users, startups and innovators under one roof.
Padode said the vision for CTS is not limited to software alone. The platform aims to embrace all forms of technology that can improve construction efficiency, quality and execution—from digital tools and project management systems to lean construction, off-site fabrication and startup-led innovation. He also highlighted plans to deepen startup participation and create space for young companies to showcase emerging construction solutions.
Industry at a turning point
Moderating the roundtable, Naushad Panjwani, Chairman, Mandarus Partners, set the context by pointing out that the global construction industry, despite being a multi-trillion-dollar sector, continues to lag in productivity. He noted that while manufacturing has consistently improved efficiency, construction has remained slow to modernise.
Referring to both global and Indian trends, Panjwani underlined that the industry is now at a decisive moment. India, he said, is entering a major build cycle, and delivering the next phase of infrastructure and real estate growth through traditional methods alone is no longer viable. The goal of the roundtable, therefore, was not to debate technology in isolation, but to identify the most critical conversations that would bridge the gap between innovation and implementation.
His central message was clear: CTS 2026 must be shaped around themes that make CEOs, CIOs and CTOs feel they cannot afford to miss the event.
From BIM to AI, data to governance
A major theme that emerged through the discussion was the need for better data, better visibility and better decision-making. Dr Venkata Santosh Kumar of IIT Bombay echoed this, saying that the underlying data infrastructure itself needs attention. Construction projects, particularly remote ones, often face issues around connectivity, data collection and data use. Without this foundation, more advanced technologies cannot deliver their full value.
Chandra Vasireddy, CEO & Co-founder, Inncircles, expanded the discussion to governance, arguing that technology must help connect the many moving parts of a construction business. For him, the real value of digital transformation lies in creating better governance, clearer visibility and stronger business outcomes.
Tejas Vara of Inncircles stressed the importance of timely site data for leadership teams, especially in large and remote projects where decisions on materials, machinery and manpower often get delayed because information does not reach headquarters in time.
The role of AI also featured prominently. Rushabh Mamania, Partner and CBO, Roadvision said that while AI and machine learning are now common terms, vision intelligence and language intelligence have still not deeply penetrated the construction sector. He emphasised that startups in India are building relevant AI-led solutions and are already attracting international interest, showing that innovation need not be imported—it can be built locally and scaled globally.
Industrialised construction gains ground
The roundtable also placed strong emphasis on industrialised construction methods. Kalyan Vaidyanathan, CTO – Construction & R&D, Tvasta, called for greater focus on off-site fabrication and the broader industrialisation of construction. Bhargav Jog, General Manager, Dextra, highlighted precast technology and alternative sustainable materials as areas with immediate relevance.
Several participants agreed that modular, precast and pre-engineered approaches are no longer niche ideas. They are increasingly becoming practical responses to the sector’s challenges around labour shortage, timelines, quality control and predictability.
Anup Mathew, Sr VP & Business Head, Godrej, argued that the industry needs a fully integrated approach—from design and procurement to execution and asset management. Unless these are connected, technology adoption will remain fragmented and sub-optimal. He pointed to pre-engineered and modular systems as examples of how industrial thinking can compress timelines, improve quality and reduce dependence on difficult on-site conditions.
Adoption remains the biggest hurdle
While there was broad agreement on the promise of technology, the discussion repeatedly returned to one fundamental challenge: adoption.
Abhishek Kumar, COO, LivSYT, observed that the market is crowded with solutions, but many buyers still struggle to evaluate which technology suits which use case. According to him, the industry needs clearer frameworks to help users select, compare and adopt solutions, rather than expecting a single platform to solve every problem.
Dr Tenepalli JaiSai, Associate Professor, School of Construction(SoC), NICMAR University, noted that isolated technologies will not solve the productivity problem by themselves. What is required is an integrated Construction 4.0 approach, where digital, physical and cyber-physical systems work together rather than in silos.
That concern around silos was reinforced by Subodh Dixit, former Director, Shapoorji Pallonji, who said the issue is not just that technologies are disconnected, but that stakeholders are as well. Clients, consultants, contractors and partners often operate with different priorities. Unless these silos are broken, technology will struggle to percolate across the full project value chain.
Harleen Oberoi, Project Management, Tata Realty shared a practical perspective from the client side, saying that successful BIM implementation requires investment across the ecosystem, not just within one organisation. Trade partners, vendors and other stakeholders must also be trained and aligned if the technology is to deliver its intended results.
Beyond buzzwords
A notable takeaway from the session was that the industry is moving past the phase of treating technology as a buzzword. Participants repeatedly stressed that the real question is not whether technology should be used, but where it creates measurable value and how that value can be scaled.
The conversation also expanded beyond mainstream themes to include repairs and rehabilitation, construction and demolition waste, sustainability, circular economy, green sourcing, carbon measurement, design interoperability, generative design, robotics, and the role of horticulture and greener built environments.
Setting the agenda for CTS 2026
By the close of the session, the roundtable had surfaced a strong set of themes for the upcoming show: BIM and digital twins, AI and data platforms, industrialised construction, startup innovation, governance-led technology adoption, robotics, sustainable materials, and integrated project delivery.
More importantly, the session established CTS 2026 as more than an exhibition. It is shaping up to be a serious industry platform where users, technology providers, researchers and policymakers can collectively define the future of construction.
As Padode noted in his closing remarks, the conversation will continue through further consultations and possibly webinars in the run-up to the show. If the roundtable is any indication, CTS 2026 will aim not merely to showcase technology, but to push the industry towards meaningful adoption at scale.
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, discusses the role of skilled operators as the decisive link between advanced additives, digital control and world-class mill performance.
The industry always tries to reduce the number of operators in the Centre Control Room. (CCR) Though the concept was succeeded to certain extent, still we need a skilled person in the CCR.
In an era where artificial intelligence (AI) grinding aids, performance enhancers, and digital optimisation tools are becoming increasingly sophisticated, it’s tempting to believe that chemistry alone can solve the challenges of mill efficiency. Yet plants that consistently outperform their peers share one common trait: highly skilled operators who understand the mill as a living system, not just a machine.
Additives can improve flowability, reduce agglomeration, and enhance separator efficiency, but they cannot replace the nuanced judgement that comes from experience. Grinding is a dynamic process influenced by raw material variability, moisture, liner wear, ball charge distribution, ventilation, and separator loading. No additive can fully compensate for poor control of these fundamentals.
Operators see what additives cannot
When I joined the cement industry in 1981, not much modernisation was available then. Mostly the equipment was run from the local panel. Once I was visiting the cement mills section. The cement mills were water sprayed over the shell to reduce the temperature to avoid the gypsum disintegration.
The operator stopped the feeding for one of the mills. When I asked the reason, he replied that mill was getting jammed, and he added that he could understand the mill condition by its sound. I also learned that and it was useful throughout my career. In another plant I saw the ‘Electronic Ear,’ which checked the sound of the mill and the signal was looped with feed control!
Whatever modernisation we achieve, it is from the human factor that the development starts.
Additives respond to conditions; operators interpret them.
A skilled operator can detect subtle shifts, like a change in mill sound, a slight variation in circulating load, or a drift in separator cut point. It’s long before instrumentation flags a problem. These micro-observations often prevent major efficiency losses.
Additives work best when the process is stable
I would like to share one real time incident. The mill was running on auto mode looped with the mill outlet bucket elevator kilowatt. (KW)There was a decrease in the KW, and the mill feed was increased by the auto control (PID). After a while, the operator stopped both the feed and the mill. He asked the local operator to check the airslide between mill outlet and the elevator. They found the airslide was jammed and no material flow to the elevator!
The operator deduced the abnormality by his experience by seeing the conditions and the rate of increase of the feed by the auto control.
It’s always the human factor that adds value to the optimisation.
Grinding aids are multipliers,
not magicians.
They deliver maximum benefit only when:
• Mill ventilation is correct
• Ball charge is balanced
• Feed moisture is controlled
• Separator speed and loading are improved
• Blaine targets are realistic
Without these fundamentals, even advanced additives may become costly investments. The operator is responsible for ensuring process stability, whether using a ball mill or a vertical mill. After ensuring the system is stable, the operator observes it briefly before transitioning to automatic control. If there is any anomaly in the system the operator at once takes control of the system, stabilises and bring back to auto control.
Skilled operators adapt in real time
It will be interesting to note that the operators who operate from local panel start to operate from DCS also. They have the experience and the ability to adapt the changes. Operator checks each parameter deeply. Any meagre change in the parameters is also visible to him.
Raw materials change. Weather changes. Wear patterns change.
A skilled operator adjusts:
• Feed rate
• Water injection
• Separator speed
• Grinding pressure (in VRMs)
• Mill load distribution.
These adjustments require intuition built from years of experience, something no additive can replicate.
Human insight prevents over reliance on additives
Plants sometimes increase additive dosage to mask deeper issues like:
• Poor clinker quality
• Inadequate drying capacity
• Incorrect ball gradation
• High residue due to worn separator internals.
A knowledgeable operator finds root causes instead of chasing temporary chemical fixes.
The real optimisation sweet spot is reached when:
• Operators understand how additives interact with their specific mill.
• Additive suppliers collaborate with plant teams.
• Process data is interpreted by humans who know the mill’s behaviour.
This constructive collaboration consistently delivers:
• Lower kWh/t
• Higher throughput
• Better product consistency
• Optimum standard deviation.
Advanced additives are powerful tools, but they are not substitutes for human ability. Grinding optimisation is ultimately a human driven discipline, where skilled operators make the difference between average performance and world class efficiency. Additives enhance the process but operators
control it.
About the author:
Ponnusamy Sampathkumar, Consultant – Process Optimisation and Training, is a seasoned cement process consultant with 43+ years of global experience in plant operations, process optimisation, refractory management, safety systems and training multicultural teams across international cement plants.


