Building the ‘world’s first’ fully electric large foundation rig

The F4800E is based on Fundex Equipment’s diesel-powered F4800 foundation rig (Photo: Danfoss Editron)

The rig was tested in September 2023, where it completed its first commercial project for the real estate and construction services business Heijmans in Rotterdam, the Netherlands.

During the project in Rotterdam, the Canvas Living residential building project, the F4800E was able to install over 250 foundation piles.

To compare the electric rig’s performance, a conventional F3500 foundation rig was also used on the same project. Powered by Hydrauvision’s electric powertrain system and DC-generator set with a diesel engine, the company says that “the F4800E proved to be a strong, robust, and reliable machine that can match the performance of conventional rigs”.

The F4800E was said to have also demonstrated additional benefits of reduced energy consumption and noise pollution.

When Hydrauvision, a company specialising in hydraulic and electrical drive and control solutions and parent company of foundation rig specialist Fundex Equipment, decided it wanted to help drive the construction industry’s sustainable transition, it decided to electrify a foundation rig in a ‘world-first project’.

Prioritising design

The F4800E is based on Fundex Equipment’s diesel-powered F4800 foundation rig, which has a 500 kNm full-length drilling torque and a daily energy consumption of up to 2,000 kWh. 

To make the machine compatible with most construction sites, Fundex decided to prioritise flexible design and give the new F4800E the ability to switch between different energy sources. As a result, the basic machine, including winches and hydraulic pump units, is entirely electrically driven by permanent magnet machines and drive converters supplied by Danfoss.

The F4800E also features a 150 kWh integrated battery pack for peak shaving during regular operation. In addition, the battery is used to store regenerated energy from the winches. This means the machine can operate emissions-free when connected to a power source.

However, power sources are not yet available on every construction site. Therefore, Hydrauvision developed a new DC-generator set with a diesel engine to supplement the battery pack on the basic F4800E machine and prevent inefficient peak loads, with peak shaving as a power backup.

Reducing energy consumption

Danfoss Editron says that this configuration maintains the machine’s sustainability benefits by reducing energy consumption by 25% to 40%, depending on the foundation process.

Commenting on the success of the F4800E so far, Michiel Wondergem, R&D Engineer at Hydrauvision, said, “The successful performance of the F4800E on Heijmans’ Rotterdam project is a big step towards the future and an example of the opportunities that innovative design can open up in the construction industry.

“The development of the F4800E results from a deliberate choice to push boundaries by a group of enthusiastic innovators who are not afraid to deviate from existing paths and proof that sustainability and high performance can go hand-in-hand in construction.”

Antti Väyrynen, Off-Highway director at Danfoss’ Editron division, added, “Being so large and powerful, pile driving rigs were once considered one of the final frontiers in the electrification of the construction industry. With the success of this project, we have crossed that frontier, showing that the electric transition in the construction industry is unstoppable.”