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The SWIETELSKY Magyarország road builders are ready to jump at the new opportunities
As an expression of his optimistic outlook, Zoltán Hegyi described the investment in Székesfehérvár by SWIETELSKY Magyarország Kft. investment in Székesfehérvár, which, despite the current unfavourable economic conditions, inaugurated a new asphalt mixing plant on 3 October.
In addition to the strategic background of the decision, the Managing Director also looked at the history and core values of the company's road business in an interview with him, while at the same time delivering important messages to the entire road industry.
Both mobility and recycling are met
In this development, the company, which has been operating in Hungary since 1991, has built a new mixing plant on its existing site. The managing director's main criterion for the investment was that the mixing machine should be easy to relocate. Accordingly, a choice was made between a fixed, mobile and a mobile mixer for the grains.
"Although the mobile mixing plant can be relocated quickly with the right infrastructure, it is only capable of producing a limited number of mix types. The semi-mobile, on the other hand, can be relocated in two to three months and can serve a full range of products with high throughput." - explains Zoltán Hegyi.
The mixing plant has been equipped with the latest technology to produce WMA asphalt. "The asphalt produced does not have to reach 185 oC, it can be released at up to 140 oC, which saves energy and produces less harmful vapour, an important aspect for the health of the workers who process the asphalt."
Another outstanding feature of the new plant is related to recycling. "The plant is capable of recycling mastic asphalt to current specifications, but is technically capable of using up to 35-40 % of reclaimed asphalt material when properly prepared."
In response to a question, he also explained the background to the decision to invest in Fehérvár. "The first major task of the mixer is to produce the 80,000 tonnes of SMA needed to replace the wearing course on the 30 km stretch of the M6 and M8 motorways. At the same time, we can see that there are currently no significant resources for new road construction in Hungary. Sooner or later, further improvements will be inevitable. And if we start developing when we need it, it will be too late."
Interview photo by Mihály Nagy/magyarepitok.hu
Extreme volumes on the M1: eight lanes and five layers of asphalt
He also gave a more specific answer as to what trends they can rely on. „The MKIF Zrt. investment, the upcoming widening of the M1 motorway will generate extreme asphalt capacity requirements, regardless of who the contractor is. The development of a well-thought-out asphalt production and transport logistics system is essential for the economical and well-scheduled implementation of the project. The entire asphalt layer will be removed from the M0 ring road to kilometre 95. The earthwork will receive a new FZKA top layer, and according to current plans, four to five layers of asphalt will be laid on top of it, creating an innovative flexible pavement structure. All this will be implemented on a total of eight lanes, as in addition to the two three-lane sections, there will be a fourth lane that can be activated in any traffic situation.”
Maximum trust from owners
He added that if they find work in the project in question, or in other large-scale work, the relocation of the White Village mixer is technically easy to do, it really depends on the economic decision.
The fact that the owners of the multinational group of companies place maximum trust in the Hungarian managers was an important background for all these strategic considerations. "They said that if we think this investment in Fehérvár will pay off, then let's go for it. Of course, we have to raise the financing ourselves, which means we don't get it as a gift."
You can't run a company in fear!
Summing up the background to the move, he said that regardless of the economic situation, the company is basing its decisions on its own strategy. "I believe that you can't run a company in fear and dread!" This is the approach he tries to take in different areas of the company.
"Learning about new technologies, introducing them and constantly maintaining and renewing machines is essential, even in difficult market conditions. Appearance is an important positive message to the market."
The same message to their own colleagues is crucial. "You need to see the faces of the professionals who are working on a new machine. I've seen time and time again that an investment like this has a positive impact on morale and performance."
The Vecsés bypass section of Highway 4 was their breakthrough
We also asked the Managing Director about the main milestones of the SWIETELSKY Magyarország road construction division, after a very interesting presentation on the past 33 years at the inauguration in October in Belgrade. First of all, he highlighted the construction of the Vecsés bypass section of the main road 4 in the early 2000s. "This was a breakthrough for us in the field of road construction, followed a year later by the launch of the large-scale M6 motorway project. This is a unique achievement in the history of Hungarian road construction, as it took only 18 months to build 60 kilometres of motorway with all the necessary structures, motorway engineering and police complexes!"
The M6-Duna Autópálya Koncessziós Zrt. contracted SWIETELSKY Magyarország Kft., Bilfinger-Berger Kft. and PORR Kft. to carry out the works, with the section being abandoned. According to Zoltán Hegyi, the execution of this project was a qualitative leap for all three companies. "Until then, SWIETELSKY Magyarország Kft. had predominantly only worked on projects of minor local interest, but from then on it successfully bid for single and double digit road improvements, on which it performed successfully."
The next major period started in 2010. The SWIETELSKY Magyarország Kft. was involved in major projects such as the construction of the M43, the Szolnok section of the M4 (stalled for known reasons, completed years later - ed.), the Seregélyes bypass section of the 62, the Várpalota-Veszprém bypass section of the 8, the western bypass section of the 8 Székesfehérvár bypass.
Subsequently, the company worked as a consortium member and general contractor on 3 sections of the four-lane road 21, the Fertőd-Endréd section of the M85 expressway, as well as on the M44 (Kunszentmárton-Csabacsüd section). It also played an important role in the construction of the road 260 in the Kazincbarcika area. "During these years, we have been involved in the construction of a total of 155 kilometres of motorways and expressways in consortium, of which 75 km were built by our own contractors."
Sometimes they have even increased their production to 550 thousand tonnes per year
The driver also has accurate statistics on the work done on multi-digit roads. "Since 2017, we have carried out interventions on a total of 400 kilometres in 160 projects in the 2-3-4-5 digit road rehabilitation projects tendered by Magyar Közút Zrt in framework contracts."
He added that in the years that saw a boom in infrastructure investment, asphalt production rose to 550,000 tonnes per year. But even in more modest years, 350-400 thousand tonnes of asphalt are produced annually at 8 sites.
Forward capacity planning has proved effective
An important detail is that all the above works were carried out with their own mixing plant. "We were so conscious about the location of the mixing plants that we only had to relocate one mixing machine in one case: on the M43, we relocated one specifically to the project area."
The coverage in Hungary is also shown on a map in Zoltán Hegyi's office, showing the network of mixing plants. "We are present in all regions except South Transdanubia," he pointed out.
They can also produce high-quality mastic asphalt
He also pointed out that about half of the total production is sold on the market. It is interesting to note that their customers include a relatively large number of small companies that, due to their size, work on road construction at low costs and low prices, but cannot produce the asphalt.
He added that they also derive a significant turnover from the fact that they and a few other large companies are the only ones able to produce quality mastic asphalt. "For example, when they need a quality mastic asphalt that meets specifications for bridge sealing, they often turn to us because it's a special technology product."
Innovative professionals are highly valued
In response to a question, he also explained what is needed to provide a high quality service in the road department. "Constant professional development only works if the construction team, both managers and middle managers, are dedicated and love their profession."
The other prerequisite was the right technological background. "It is important to plan and monitor processes and test products in an accredited laboratory. In addition to all this, it is a great advantage that we have innovative colleagues who work as experts in different working groups of HAPA and MAÚT, so we are also involved in the development of new road specifications. These colleagues are highly valued because their knowledge and experience is very important to us."
It also draws attention to the importance of the latter relationship. "I always say that standardisation improvements can only be achieved if there is feedback from industry."
Technical aspects are often overridden by regulations
We also asked to what extent can the aspects of market change be reconciled with the challenges of technological change, and which is the stronger argument for capacity development? "The stronger argument is clearly the market and the regulatory environment: we can invent anything if there is no demand."
At this point he drew attention to a problem in public procurement that affects several companies. "We need to improve a number of tenders, basically for two reasons: one is to get a good product and the other is to make it more economical." He adds that it often happens that a technical proposal is given to the client, who gives feedback that it is basically good, but cannot allow it because it was different in the tender, and if it is not fulfilled, sanctions come. "In my view, this is a big barrier to Hungarian innovation."
The Germans are close to recycling, but we still have barriers to recycling
A similar issue was raised regarding the reuse of mart asphalt, which is important for sustainability. "All our mixers are designed to be able to feed mastic asphalt. We have the knowledge and the tools to do it."
He also gave a sense of where we could improve. "In Germany and the Czech Republic, more mart material can be incorporated into the wear layer than in our country. And the Germans are maximising this rate because they can achieve a replacement of the wearing course every seven years on a given road. This means that only a small amount has to be spent on repairs, because the road does not deteriorate as much as it does here. It's very close to the sustainable cycle of construction that we often talk about nowadays."
The Hungarian asphalt industry has a greater capacity for innovation
Similar obstacles to the use of new types of asphalt mixes or additives are encountered. "These cannot be incorporated purely to optimise technical aspects because we are bound by road regulations."
In conclusion, he said, the Hungarian asphalt industry has a much greater capacity for innovation than is currently being achieved. "We are also in the HAPA working groups, among others, working on these changes."
The MKIF approach starts a good process
Despite these problems, the expert is optimistic about the future. "The fact that part of the investment and operation of motorways has been taken over by one company is very positive for the sector. The concessionaire really does think like a farmer. Design, construction and operation are managed by a single stakeholder. If they find a fault, they don't just fix it, they think about the cause and fix it in a way that reduces repair and operating costs." He added that the standards also bind the concessionaires, which he believes gives the operator of thousands of kilometres of stock greater lobbying power to optimise standards.
Overall, he warned that in the standards strategy it is of utmost importance to consult and involve market players in decision-making.
This structure provides a direct working link to European development trends
For the SWIETELSKY Magyarország road builders, the multinational background is a great help both in technological development and in building the necessary knowledge base. "We are constantly seeing what our German, Austrian and Czech colleagues are developing and how much they are producing. We also have specific databases that show how much was produced by which blender in which country in which month." The data also shows that around 10 per cent of SWIETELSKY's global asphalt production of 3.5 million tonnes a year is produced in Hungarian mixer plants.
There is also a more concrete way of harnessing international contacts: 'We have regular consultations with our colleagues abroad. We have a level of cooperation where we have joint working groups on a particular topic. At the moment we are working together on an innovation topic: we are discussing parallel drum asphalt mixing, which is the solution of the future." He added that this tool is essential to ensure that a large proportion of the asphalt can be recycled.
They now have 12 thousand employees and a turnover of €3.5 million
As background to the international cooperation, he also described a process: "The group has grown steadily in recent years, with 12,000 employees and an annual turnover of €3.5 billion. In line with this growth, a major structural change has been underway for a year and a half now to make the knowledge we have acquired in each area and country more widely available throughout the group."
With the German method, many more roads could be built with the same amount of resources!
Looking at the situation of the road construction sector at national level, he said that it would be useful to follow the example of Germany and Austria, where it is common practice for several companies to jointly determine the allocation of asphalt mixing capacity. "At the moment, in Hungary, the total mixing capacity available is 3.5 times greater than what is needed: in my opinion, this is a luxury! Mixing plants have high maintenance costs even when they are not in operation."
He said that there are very good models abroad for the cooperation we lack. "In a given region, for example, several companies operate in a consortium to make the best use of capacity, treating the site as a 'community mixer'. At present, half of the hundred or so mixers operating in our country could be eliminated by this method, and all asphalt producers would be better off. At the same time, it would also be worth it from a national economic point of view, because I think the cost of mixing asphalt would be cheaper, and overall we could build more roads with the same amount of resources."
Thinking about the future instead of downsizing
He concluded the interview by saying that the SWIETELSKY Magyarország is ready for change and has much more road building capacity than it can use in the current market environment. "I am determined to get and keep both the human and machine base in a state where we are able to make the leap whenever the opportunity opens up. While we see downsizing in other industries, the SWIETELSKY Magyarország road construction team is thinking about the future instead of downsizing!"
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