with Christoph Mauderli from Mauderli AG
Introduction
The company Mauderli, led by Christoph Mauderli, has established itself as a pioneer in the field of innovative building materials in recent years. In particular, the use of Ultra High Performance Fiber Reinforced Compound (UHPFRC) has given the company a significant competitive advantage. This success story was recognized with the Innovation Award from the Central Switzerland Chamber of Industry and Commerce (IHZ). The following provides an in-depth look at the development of this innovative approach as well as the challenges and opportunities associated with it.
Company Background and Development
Mauderli was founded as a manufacturer of plastic pipes and molded parts and has evolved over the years into a system supplier for drainage and cable protection systems. The second generation, represented by Christoph and Philipp Mauderli, has led the company into a new era of innovation.
A central challenge was overcoming skepticism about plastic manholes in Switzerland. This led to the development of manhole bases made of concrete with integrated plastic channels and ultimately to the complete production of inspection chambers, cable manholes, and sediment collectors made of concrete. Despite strong competition in the field of precast concrete components, Mauderli focused on customer proximity and innovative solutions to establish itself in the market.
The Path to Using UHPFRC
The initial ideas for using UHPFRC arose through close customer contacts in tunnel construction. Each tunnel is unique and requires individual solutions. Customers increasingly provided feedback that an alternative to polymer concrete was needed, particularly for highway tunnel slot drains, curbstones, and siphon manholes.
UHPFRC was identified as a promising material due to its high abrasion resistance, chemical resistance, and waterproof properties combined with relatively thin wall thickness. A key role was played by consultation with building materials expert Eugen Drühwiller, who supported Mauderli in developing UHPFRC components. Despite initial challenges, particularly in adapting formwork systems and production processes, the first prototypes were successfully developed.
Breakthrough and Standards Adjustment
A crucial milestone was the inclusion of UHPFRC in the technical manual of the Swiss Federal Roads Office (ASTRA) in 2018. This enabled UHPFRC to be approved as a material alternative for infrastructure components in Switzerland. As a result, the material could be used in major highway and tunnel projects.
The first major test was the application of UHPFRC in the Schwamendingen enclosure, an innovative infrastructure project in Zurich. Here, extremely thin-walled cable manholes were realized using UHPFRC, enabling a space-saving construction method without compromising the existing sealing. Further projects followed, including the renovation of tunnels along Lake Brienz and the use of UHPFRC in the Gotthard and Brenner Base Tunnels.
Challenges and Learning Processes
The introduction of UHPFRC brought numerous challenges. In addition to the technical development of mixing plants and formwork systems, financing was also a hurdle. However, as a family business, Mauderli was able to make flexible decisions and take entrepreneurial risks.
The COVID-19 pandemic posed an additional challenge. Despite difficult conditions and constant uncertainty regarding potential production shutdowns, the company was able to fulfill its orders. This was only possible through close collaboration with customers and continuous optimization of production processes.
Competition and the Future
Through the innovative use of UHPFRC, Mauderli has gained a market advantage over competitors. However, it is expected that other companies will follow suit. Christoph Mauderli sees this as a positive development: competition drives innovation.
Today, the company is able to develop customized system solutions tailored to the specific requirements of clients. Through the modular approach with various building materials such as UHPFRC, plastic, and composites, the optimal solution can be found for each application.
Conclusion
The story of Mauderli impressively demonstrates how customer proximity, innovative thinking, and entrepreneurial courage can successfully establish new materials in the market. The application of UHPFRC not only provides economic benefits but also contributes to sustainability in the construction industry. With further major projects in the pipeline, the company will continue to play a leading role in the construction sector in the future.