The BOROPLAST stuffing piston process:

Ideal borehole filling

and soil compaction

The piston-type method is the multi-tool in specialist foundation engineering. It allows for the layered, compacted filling of exploratory boreholes, the creation of exploratory boreholes without drilling, and the precise compaction of the subsoil. All this is accomplished with just one machine.

One machine solution – many applications

BOROPLAST stuffing piston process

Sondieren ohne zu bohren. Mit dem Schubloch statt dem Bohrloch

Prepare with the displacement tip

Many boreholes have partially collapsed due to lateral seepage. Use the displacement tip to clear the borehole.

densify carrier site

The sheet pile wall beam will loosen the soil as it is pulled. The tamping piston will then compact the soil to the desired target density, preventing any subsequent settling.

Compact sheet pile wall

Compact the soil behind the sheet pile wall. Ideal application for the tamping piston.

Patented groundwater protection

Many borehole backfills consist of poured materials. They create a hydraulic connection from surface water directly into the groundwater, with serious consequences for the vital resource of groundwater.


We invented, developed, tested, patented, and brought to series production the machine-based layer-by-layer compaction process. For absolute hydraulic sealing.


We protect groundwater.

Patented protection against sagging

Many borehole backfills are subject to compaction and subsequent settling, with serious consequences for safety.




We invented high-density borehole backfilling; we supply the process, the machinery, and the materials for it. For the safest borehole backfilling ever.


We deliver security.

CO2-free out of responsibility

Some borehole backfilling processes generate enormous amounts of CO2. 800 tons of CO2 per kilometer of road construction is an avoidable environmental burden.




We have developed a safe, void-free, cyclically dynamically resilient, yet climate-friendly borehole backfilling system ready for mass production. It is the most responsible borehole backfilling solution available.


We deliver a clear conscience.

FILLING

Ideal, professional borehole filling in sounding, soil compaction and beam shoring

Sealing material: Swelling clay homogeneously mixed with hydrogel

For ideal compaction, the poured swelling clay is homogeneously mixed with hydrogel in a 12:1 ratio. A mechanically compactable, swelling mineral building material with a target moisture content of 17–22% H₂O is used. Ten percent water is added to the swelling clay by precisely dosable hydrogel in a 12:1 ratio (swelling clay:hydrogel).
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Verdichtung Trägerstandorte im Bohlwandverbau

2025

Our principles in specialist foundation engineering

No borehole filling without mechanical compaction

The best resolution for 2025 is: Don't fill boreholes with loosely poured bulk materials like crushed sand, gravel, chippings, etc. In 2025, ensure proper layer-by-layer compaction.
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Groundwater protection out of personal conviction and responsibility

Many borehole backfilling processes have previously neglected groundwater protection. From 2025 onwards, we will protect groundwater with professional, layer-by-layer borehole compaction.
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BASICS

Professional planning and execution

Legally sound from a water law perspective



The BOROPLAST® process is approved by the Hamburg Authority for the Environment and Energy (BUKEA). As part of the approval process, BUKEA critically examined its environmental safety.




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Approval by KMBD


The BOROPLAST(R) process is professionally recognized and approved by the Central Service of the Police of the State of Brandenburg - Explosive Ordnance Disposal Service (KMBD).





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BFR-KMR 2024

State-of-the-art methods

The BFR-KMR 2024 guidelines provide precise specifications for the proper backfilling of KaMiSo boreholes. Layered backfilling, homogeneous mixing with hydrogel, compacted backfilling up to ground level, and documentation of the backfilling process represent the state of the art.


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FAQ

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FAQ - Frequently Asked Questions

  • How does layer-by-layer compaction work in the borehole or cavity?

    In the first step, a highly compactible sealing material is poured into the borehole or cavity. Then, the plugging piston moves into the borehole and compacts the sealing material with a powerful stroke. This works similarly to how espresso is made in a portafilter machine.

  • How is the plugging piston driven?

    Inside the machine, a push chain is responsible for advancing the tamping piston. When coiled, the push chain is a chain; when extended, it is a rod.

  • What density and soil mechanical properties can be achieved with this?

    The sealing material was specially developed for this piston-type compaction process. It achieves a system tightness of kf > 1 * 10⁻¹¹ m/s to 4 * 10⁻¹² m/s. The seal is hydraulically tight. The compacted material typically achieves a density of 1.74–2.10 kg/l. This density is so high that subsequent settling due to gradual re-compaction is prevented.

  • What happens if the borehole has already closed up due to lateral seepage?

    This happens very frequently. Especially in unstable, soft, and less homogeneous soil conditions, the borehole often closes up after the probe casing is removed. Then, backfilling with fill material is no longer possible. In this case, the plugging piston is fitted with a displacement tip that forcefully clears the borehole again.

  • How does the plugging piston method work?

    The core component is the borehole compactor. This is an excavator attachment that connects to the excavator via a quick-coupler attachment. The unit can be quickly swiveled from borehole to borehole, keeping setup costs low.

  • What is the main advantage of the procedure?

    There are two key advantages. First, the borehole is filled in such a way that there will be no subsequent subsidence. Second, the borehole is hydraulically sealed. This protects the groundwater reliably and permanently from the ingress of contaminants.

Choose the method that will dramatically reduce your CO2 emissions.

A conscious decision to choose the right method reduces CO2 emissions by approximately 700-800 tons of CO2 per km of track construction or renovation.

15.000

KaMiSo boreholes per 1 km of railway construction during full exploration

3.750

cbm drilled volume per 1 km KaMiSo in railway construction

250

Liters of volume per borehole are backfilled in the KaMiSo

700-800

You can avoid tons of CO2 per 1 km KaMiSo in railway construction

We'll plug your holes.

Sondierungsbohrung in der Kampfmittelsondierung
Sondierungsbohrung

Our motivation


There are still approximately 200,000 World War II bombs buried in the ground beneath our transport infrastructure that could still explode. This means we still have 200 million boreholes to drill. We ensure they are properly filled.

Patented processes


We invented, developed, tested, and patented the Boroplast process. This process involves the layer-by-layer compaction of elastoplastic building materials in boreholes.

State-of-the-art technology

We supply state-of-the-art technology for producing the ideal borehole backfill. The most modern, environmentally friendly building material, the most modern machinery, the most modern process.

So you can sleep peacefully

Our Boroplast process protects you from liability claims. No more disasters caused by unstable ground, subsiding structures, or settling borehole fillers. A Boroplast filler won't give way.


BOROPLAST process: Void-free, non-sagging compaction of boreholes

Every borehole drilled during ordnance detection disturbs the building ground.

We'll plug your holes.