We are pleased to announce the successful commissioning of the newly constructed Hansenhütte hydropower plant in Kapfenberg, Austria. This project, completed for the world-renowned chain specialist pewag, features a state-of-the-art 718 kW Kaplan turbine and represents a major step forward in sustainable energy production for the Austrian industry.
Modern Infrastructure for Peak Performance
While the site has a historical connection to hydropower, the new Hansenhütte plant was built from the ground up to meet modern industrial standards. GUGLER provided a comprehensive “water-to-wire” package that included a newly designed powerhouse and an optimized waterway.
A key element of this project was the significant extension of the waterway. The original plant utilized a pipe bridge to cross the stream immediately before reaching the old powerhouse. In the new design, a transition was constructed at this pipe bridge to connect a new 530-meter pressure pipeline. By relocating the powerhouse approximately 500 meters further downstream, a substantial increase in head was achieved, unlocking a new dimension of power generation capacity for our client.
Technical Highlights
Flow rate: 6,8 m³/s
Net head: 13,4 m
Installed capacity: 718 kW
Scope of Supply – Hansenhütte
Our comprehensive GUGLER “water-to-wire” solution for this project included:
Double-regulated Vertical Kaplan Turbine: designed for a flow of 6,8 m³/s and a capacity of 718 kW.
Main Inlet Valve & Hydraulic Power Unit (HPU)
Water-cooled Synchronous Generator directly coupled to the runner
Complete Control & Protection Systems: state-of-the-art automation by our subsidiary H&W Control for seamless plant management and grid stability.
Number
of units
Total Output
(kw)
Head
(m)
Flow
(m³/s)
Diameter
(mm)
Two Months Ahead of Schedule
Efficiency was a priority not just in operation, but also in execution. To ensure a rapid and seamless installation, we delivered the entire drivetrain-including the generator and runner-as a fully pre-assembled, “ready-to-install” unit.
This approach allowed us to overcome spatial challenges within the new powerhouse and complete the assembly two months ahead of our original deadline, with the equipment arriving on-site in August 2025
High-Performance Infrastructure
Beyond the powerhouse, the project involved a technical upgrade of the external water systems to ensure long-term reliability. The solution featured a new intake area equipped with a 6-meter-long fine screen and a high-capacity automated rack cleaning machine. With a thrust of 1.5 tons, this system ensures the intake remains clear of debris, maintaining optimal flow at all times.
For the newly extended 530-meter penstock, DN1800 GRP Flowtite pipes were selected. These were chosen specifically for their exceptional hydraulic flow characteristics, which minimize friction losses, and their proven resistance to corrosion—ensuring a durable solution for decades to come.
Powering Green Industry
Since beginning operations in November 2025, the Hansenhütte plant has proven its strength, achieving nearly 100% of its capacity by February 2026. This facility now enables pewag to cover more than half of its total electricity demand in Kapfenberg from its own renewable resources
At GUGLER, we are honored to have delivered thisstate-of-the-art project, reinforcing our commitment to providing industrial partners with reliable, efficient, and sustainable hydropower technology.
Modern Infrastructure for Peak Performance
While the site has a historical connection to hydropower, the new Hansenhütte plant was built from the ground up to meet modern industrial standards. GUGLER provided a comprehensive “water-to-wire” package that included a newly designed powerhouse and an optimized waterway.
A key element of this project was the significant extension of the waterway. The original plant utilized a pipe bridge to cross the stream immediately before reaching the old powerhouse. In the new design, a transition was constructed at this pipe bridge to connect a new 530-meter pressure pipeline. By relocating the powerhouse approximately 500 meters further downstream, a substantial increase in head was achieved, unlocking a new dimension of power generation capacity for our client.
