1. business and industrial
2. construction

Customer magazine by Putzmeister Concrete Pumps GmbH
76
Big boom pumps
win big jobs
Heavy concrete for
underwater tank
Huge tunnel elements for the
Bosporus Crossing concreted
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Content
Foreword
5
1
Foreword
3
Dear Customers
and Friends
of Putzmeister
4
Title story
Heavy concrete for under water tank
4
Background
Sprightly Grandmother
Champagne before first development
Test bay determines wear data for concrete pumps
Fleet management with DAISY
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24
29
30
2
8
Training
Attractive construction sites, sophisticated pumps
and highly skilled machine operators
Fit for the new season
22
24
Bridge Construction
Big boom pumps win big jobs
8
Pre-cast Concrete Parts
Telebelt® completes the concrete pump fleet
Strong caissons made from steel-reinforced concrete
Concrete pumps rationalised pre-cast parts production
10
14
20
3
22
Dam Construction
Urgent repairs to the Mosul dam
12
High-rise Construction
Top equipment, reliable support
and local service
17
Tunnel Construction
Spray head kinematics has a decisive influence
Huge tunnel elements for the Bosporus Crossing concreted
4
18
26
10
Airport Construction
Long-reach boom pumps at the new Berlin airport
25
Practical Tip
Mobile partial flow filter improves service life
and saves on oil changes
2
31
As a result of the global financial and economic crisis Putzmeister, like many other
German machine manufacturers – particularly in the area of construction and textile
machinery, is witnessing a significant
downturn in demand. Many customers are
uncertain of the continuation of major projects and financing, and are thus reducing
or postponing their investments in new
machines.
Faced with these market changes due to
external effects, Putzmeister is unable to
significantly influence demand in the short
term, for example through new developments. We are therefore faced with no choice
but to implement optimisation measures
within the company. The targeted and rapid
implementation of these measures is driven
by the organisation and costs. Not least for
this reason, there have been some changes
in the management board of Putzmeister
Concrete Pumps GmbH. Following in the
footsteps of Felix Selinger, I am a representative of the founding family. As your new
CEO I will have direct operational responsibility for the marketing and sales of concrete
pumps. This is in addition to my existing
function as chairman of Putzmeister
Holding, a post which I have held for some
time.
In terms of reducing costs, the cost reduction measures in all global PM locations will
be specifically adapted according to the relevant local situation and adjusted to local
regulations and general conditions.
In German locations, this has involved the
abolition of shift work since the end of 2008,
and the increasing introduction of reduced
working hours in 2009. The process is
driven by the aim of reducing personnel
costs while also avoiding redundancies of
experienced employees for operational reasons during the current economic crisis
period. At other Putzmeister sites, these
steps have unfortunately been unavoidable
due to local conditions.
However, despite these internal changes, at
Putzmeister we have set an clear objective to
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minimise any effect on you, the customer.
Although our German locations will in theory be closing on Fridays, you will still be
able to contact our sales, distribution, and
service staff. Should this lead to problems in
isolated cases – particularly during the
implementation phase – please contact our
sales management directly. We will then try
to offer immediate help along more unconventional channels, and work hard to optimise our processes wherever possible.
In these difficult times for all of us, we
would like to remain true to our motto to
"serve, improve, and add value" and remain
a reliable partner for our customers and
dealers. The positive results from our recent
successful fiscal years will stand us in good
stead. As a foundation-owned company,
Putzmeister has not used this profits for distributing huge dividends. Instead we have
invested our profits in buildings and plants,
and in maintaining the traditionally high
level of equity capital endowment.
Putzmeister is therefore in a strong position
to withstand even a longer period of economic downturn.
Like yourselves, our customers and partners, we also are unable to provide any reliable predictions as to how long the current
crisis will last. However at the start of the
year we heard almost exclusively bad news,
whereas now - alongside the continued bad
news - we also hear the occasional positive
report. We have the impression that the
ratio of bad news to good news will continue
to improve, albeit extremely slowly.
Signs of this trend include, for example, that
the massive investment program in the
Chinese infrastructure already appears to
be having an impact on the construction
industry. In the USA, the number of newly
initiated construction projects has risen
month-on-month for the first time in eight
months. In contrast to the global trend,
investments in some smaller markets are
also continuing. In these markets, customers are increasingly taking the opportunity
to purchase new machines in combination
with PM service packages. This reduces the
running costs for the operator, making the
costs more economically viable, while also
retaining the value of the machine.
Particularly in markets in which there has
so far been no sign of a slowing down of concrete consumption, our customers are also
taking the opportunity to renew their machine fleets.
In this sense, we hope that we have already
reached the base of the trough and will soon
have made our way through this period. If
this is the case, the only way is up. This
means that we must all seize every opportunity in order to prepare for the future. I
wish us all every success!
Your
Dr. Ralf von Baer
Chairman of the Management Board
Putzmeister Concrete Pumps GmbH
Putzmeister Holding GmbH
Imprint
Editor:
Putzmeister Concrete Pumps GmbH
Max-Eyth-Straße 10
72631 Aichtal / Germany
Editorial department: Jürgen Kronenberg
Layout: Monika Schüßler
Putzmeister Concrete Pumps GmbH
Max-Eyth-Straße 10
72631 Aichtal / Germany
Print:
Offizin Chr. Scheufele GmbH + Co.KG
Tränkestraße 17
70597 Stuttgart / Germany
3
Title Story
Title Story
6
Underwater tank in the North Sea
ballasted with heavy concrete
In order to ballast a huge oil tank, Ølen Betong AS used two BSF 36.16 H truck-mounted concrete pumps to pump a special heavy
concrete into the base of a steel construction. The tank is part of the YME MOPUstor project and has now been placed on the
sea bed. To compensate for the increased pump torque of the concrete placing boom when pumping and distributing the heavy
concrete, important safety aspects had to be considered.
The ballasting of the floating oil tank took
place in the port of Ølensvåg (southern
Norway), the headquarters of Ølen Betong
AS. The company is one of Norway's largest manufacturers of concrete and prefabricated concrete parts and has its own
pump service which is equipped with
modern machines. The works took a total
of two weeks and the specialists from Ølen
Betong installed the entire concrete pumping equipment required for the contract on
one of the quays.
Concrete mixing plant and pump installation on the quay
Pumps convey and distribute concrete
which is 40 % heavier
The concreting station consisted primarily
of a mobile mixing plant, several storage
hoppers for the concrete aggregates, three
cement silos, one separate additional mixer
and also two Putzmeister BSF 36.16 H truckmounted concrete pumps. In addition, there
were containers for the control centre, concrete lab and workshop. The additional concrete mixer with a capacity of 8 m3 – it was
also used as a temporary storage facility –
was set up directly under the mixing plant.
Sensors registered the fill level in the additional mixer and automatically gave the
command to refill via the mixing plant or to
discharge directly to the two Putzmeister
truck-mounted concrete pumps. Truck
mixers were not required for this job.
The tank is part of a storage and offloading
terminal ("single buoy mooring"), which
has now been finished and placed on the
sea bed off the coast of Egersund, Norway,
at a depth of 93 m. The vast tank is a hollow container, 66 m long, 54 m wide and
20 m high, which supports a platform
above the water by means of a tower and
three steel stanchions. Connected to the
working platform is the actual tanker
transfer station for the crude oil that is
temporarily stored in the underwater tank.
In order to ensure as large an oil tank volume as possible, the works in the port of
Ølensvåg did not ballast the tank base with
fresh concrete at the usual bulk density
(D = 2.4), but with heavy concrete with the
specific weight of 3.4 t/m3. The iron orecontaining aggregates, which are distinctly
heavier compared to usual, were brought in
by sea from the deposits in Kiruna (northern Sweden). In total, the two M 36 machines,
each equipped with the powerful 160 m3/h
pump unit, installed 7,300 m3 of heavy concrete. The 2 m-thick layer had a mass of
approx. 25,000 tons.
Because pumping the iron ore-containing
concrete, which is more than 40 % heavier,
caused the pump torque at the placing boom
to increase by the same degree, the M 36
machine operators took the last boom arm
out of service and folded it back – parallel to
arm 3. At the same time, the pipeline was
disconnected at the articulated joint of arm
3 and an extension hose was attached. Both
hoses lay on the deck and were lengthened
using each 100 m lengths of pipeline which
ran into the inside of the steel construction.
To distribute the high-density concrete, the Ølen Betong machine operators
deactivated the final arm of their M 36 truck-mounted concrete pump. The
concrete delivery hose was connected to the delivery line of arm 3.
8
The complete concrete mixing station including silos, mixing plant, additional mixer
and concrete pumps was located directly at the water's edge on the harbour pier
The giant oil tank is filled with high-density concrete as ballast in a fjord on the south coast of Norway
(All photos in this article are courtesy of Steinar Skartland / Ølen Betong)
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Title Story
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Caution: Heavy concrete!
All Putzmeister concrete placing booms
and pipe holders are approved only for the
conveying and distribution of concrete
with a specific weight of 2.4 t/m3 (density
2.4). If you need to convey and install concrete with a higher specific weight – e.g.
loaded concrete to protect against x-rays,
neutron rays or electron beams in hospitals, ballast concrete as a bridge abutment or to stabilise ships – individual
authorisation may be obtained upon
request and following inspection and
approval from Putzmeister technical
management. As a rule, this approval is
given under certain conditions whereby,
for example, the last one or two boom arms
must be put out of service when pumping
heavy concrete. However, not only the
boom but also the pipe holders are put
under markedly increased pressure when
pumping with higher-density concrete.
Putzmeister is at your disposal for any
technical queries you may have and will
also, upon request, suggest solutions for
implementation. For example, larger construction projects have already seen design
measures being implemented on the machines – such as the use of a shortened 4th
arm. This is an issue not only when pumping heavy concrete but also when pumping
types of concrete with aggregates larger
than 32 mm and correspondingly larger
delivery line diameters.
Placing the concrete down in the tank
proved to be complex, because the accumulator was divided by numerous bulkheads
and stiffened by tween decks. In order to
Of course, the pump aggregates also work
under increased load when pumping heavy
concrete. The greater mechanical load and
the increasing energy requirement results
in greater wear and increased fuel consumption. The costs incurred as a result should be
included in the quotation costing produced
by concrete pumping services.
After pumping the heavy concrete, work at
the quay was finished for only one of the
two Putzmeister M 36 machines. The other
machine was still on the job. But its workload was to become lighter in two ways: in
order to ensure that the pipelines that run
on the upper surface of the tank would be
protected under water, another layer of lightweight concrete, approx. 60 cm thick, would
have to be applied. It involved a total concrete
quantity of 1,900 m3 at a density of D = 1.7,
i.e. a total mass of approx. 3,200 tons.
For pumping and distributing the lightweight concrete on the top surface of the
tank, the M 36 once again provides the maximum horizontal boom reach
15
Crude oil transfer at sea
distribute the concrete, the employees of
Ølen Betong designed small rotary distributors specifically for this use. They were able
to be separated into individual components,
60 x 80 cm in size, so that they fitted
through every bulkhead opening. Under
these difficult conditions and taking into
consideration the mixing plant's limited
80 m3/h (max./theor.) capacity, the two
truck-mounted concrete pumps achieved a
heavy concrete output of 200 t/h (59 m3/h).
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11
The underwater tank which was ballasted
with heavy concrete in the port of Ølensvåg
originates from Singapore and was transported to Norway by a special vessel in the
winter of 2007/08. The platform protruding
from the water was built in Abu Dhabi – it is
now firmly joined to the underwater steel
construction. The owner of the oil storage
and offloading terminal is the company SBM
Inc. The Canadian oil company Talisman
Energy Inc. leased the whole station from
SBM for five years. The plant will probably
then be moved and used in a different location.
At the start of 2009, Talisman Energy recommenced oil production at the YME Field.
Oil is extracted via twelve boreholes and
then pumped into the above-mentioned ballasted underwater tank. The operating company at the YME field can expect an output
of 56 million barrels (8.9 billion litres) and a
production time of 10 years. To transport
the oil to land, tankers take the crude oil
from the offloading terminal which towers
over the surface of the sea. In the business
world, the docking and transfer of the oil
from temporary storage facilities on the
open sea is also known as "single buoy
mooring" or "single point mooring".
The site of the storage and offloading terminal described here is the YME oil field.
The crude oil field is located under the
Egersund basin in the southern part of the
North Sea. The field was opened in 1996,
however, in 2001, during a period of low oil
prices, it was abandoned again. During this
first phase of exploration, a large tanker
(capacity over 1 million barrels or 160 million litres) served as a temporary storage
facility for the crude oil which was shuttled
by transport ship for processing near the
town of Bergen. By comparison, the storage
capacity of the YME MOPUstor tank is
300,000 barrel (47.7 million litres).
Small slewing distributors are used to insert concrete between the closely
aligned bulkhead walls
6
13
Lightweight concrete protects pipelines
under water
Drop lines lead under the deck for
filling the base of the tank
Special rotary distributer for
concreting work in tight spaces
12
Moving the partly deluged underwater
tank to its final position
Delivery line leading through an
opening in the bulkhead wall
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Systematic representation of the combined oil storage and transfer terminal
in the North Sea (Image: Westcon)
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Bridge Construction
Bridge Construction
17
16
Big boom pumps win big jobs
Three large PM truck-mounted concrete
pumps – with the new M 70-5 leading
the way – were on site at the same
time recently, as the “Oakland Touchdown”, the eastern approach of the
new Bay Bridge in San Francisco Bay,
was concreted.
The extensive pumping work was contracted
to Associated Concrete Pumping, a concrete
pumping company based in Sacramento, who
are a longstanding partner of Putzmeister
and the first customer to order the BSS
70-5.16 H large-boom truck-mounted concrete pump. To make it possible to continu-
ously concrete the massive area of the
bridge-approach superstructures using a
wet-on-wet laying process, Associated
Concrete Pumping also placed a BSF 584.16 H and a BSF 63-5.16 H from its fleet
alongside the truck-mounted concrete
pump.
A new bridge to replace a truss
construction over 80 years old
The San Francisco Bay Bridge basically
consists of one 3.1 km long western and
one 3.2 km long eastern bridge construction, connected near the bay's midpoint by
an island tunnel. The eastern span of the
bridge, a double-decker truss suspension
bridge built in 1936, will soon be replaced
by a new bridge. The “Oakland Touchdown”, at its eastern end, is where it
reaches the California mainland.
A machine operator observes proceedings at the end hose of his Putzmeister large-boom pump
20
The new East Bay Bridge is being built
slightly to the north of the old bridge.
Instead of a double-decker cross section, it
will have two parallel superstructures, one
to hold each of the two 24 m carriageways
(carrying five lanes in each direction) with
hard shoulders, and also a path for cyclists
and pedestrians.
The customer for the $ 6.2 billion project
(some € 4.92 billion) is the California
Department of Transportation, with some of
the financing set to come from toll revenues.
The tender for the “Oakland Touchdown”
part of the bridge was won by Californian
construction company MCM Construction,
with a bid of $ 178 million (some € 139 million). All work on the bridge is expected to
be finished by 2012.
Overview of the multi-span San
Francisco Oakland Bay Bridge
(image from Wikipedia)
18
Putzmeister large-boom pumps on the major bridge construction site: with limited space available, both machines were able
to use their OSS (One Side Support) position. This allowed the M 70-5 (in the foreground) to reduce its support width by around
4.5 m and the M 63-5 (in the background) by some 3.5 m.
The boom tip and end hose of the M 70-5
remain steady even at higher delivery
rates
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Pictured (right) is Mike Paragini,
proprietor of Associated Concrete
Pumping, in discussion with Gary
Schmidt (left), regional sales manager
of PM America, during the main concreting process
21
A view over the eastern expanse of San
Francisco Bay. On the right, the old
double-decker bridge construction from
1936 can still be seen; to the left the
new bridge with its two parallel superstructures (image from Wikipedia)
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Prefabricated Concrete Parts
Prefabricated Concrete Parts
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25
Telebelt® completes the concrete
pump fleet
For its work enlarging the port in Jeddah (Saudi Arabia), the Al-Tawi Readymix Company did not use a truck-mounted concrete
pump to convey concrete; instead, they use their new Telebelt TB 130 for 12 hours each day. The reason: the installation of large
quantities of concrete which, due to its composition, could only have been pumped with unjustifiably high wear costs.
At the Jeddah Islamic Port, work is being
carried out on a new container terminal
which is situated close to the shore of the
Red Sea. The contract for the $ 230 M
(about 180 Mio. €) "Red Sea Gate" project
was awarded to the China Harbour
Engineering Company (CHEC). The customer is the Saudi Trade and Export
Development Company. Work began in
January 2008 and the planned construction period is 22 months.
New pier consists of 865 concrete
boxes
Currently, CHEC's main concern is the
construction of the wharfage. The new pier
consists of numerous caissons made of
concrete, which are poured into formworks
on shore. After completion, a large gantry
crane lifts the concrete elements onto a pontoon, from which they are placed into the
water, at predetermined points. Afterwards,
the area of water between the artificial quay
wall and the shore is filled in and fortified.
A total of 865 caissons are being built, in six
different sizes. The dimensions vary between 9.5 x 9.5 x 4 m and 16 x 9.5 x1.8 m.
On average, 180 m3 of concrete is needed for
one caisson. When concreting first started,
tests using concrete pumps from various
manufacturers resulted in an extremely
high level of wear on the machines.
According to experts, the reason for this was
that the smaller grain sizes were absent
from some of the aggregates ("gap grading"), and that the structural imperviousness of the concrete could not be guaranteed.
Telebelt does not matter of
unbalanced concrete mix
The Al-Tawi Company brought their
Putzmeister Telebelt telescopic belt conveyor to the harbour as the ideal alternative. Like a truck-mounted concrete pump,
it is mobile on the road and on a construction site. The Telebelt transports the
material to the placement site, first via a
feed conveyor and then via a 4-stage telescopic conveyor belt. Incidentally, this 45
cm wide main belt can be placed at an
angle of up to 29° – this corresponds to a
height of almost 21 m. The Telebelt conveys practically all bulk materials required
for construction, such as top soil, sand,
gravel, rubble and both pumpable and
non-pumpable concrete. At the end of the
conveyor belt, the material is transferred
to a 4.5 m long flexible drop hose, from
which it flows smoothly and evenly onto
the placement site. As belt transport is
particularly suitable for dry materials, it
does not matter if the concrete consistency
is only earth-moist, the w/c value is particularly low, or the concrete grading curve
is extremely unbalanced.
"The dryer, the better" – the consistency of the conveyed material does not affect
the telescoping conveyor belt (only liquids are unsuitable)
On this construction site, none of the
fine grains so crucial for pumping were
available
26
24
Another advantage of the Telebelt system
is its huge output up to 275 m3/h
(max./theor.). The TB 130 Telebelt used in
Al-Tawi manager Hossam Abdel Aziz ensures that all concreting is performed accurately
Jeddah has a horizontal reach of 39 m –
smaller Telebelt models have a working
range of over 24 or 32 m. A considerably
larger model (TB 200) with a horizontal
reach of 61 m is being planned.
With the Telebelt TB 130, the main conveyor has a 39 m horizontal reach and can be extended diagonally to 4 times its reach and
up to a height of approx. 21 m
At the harbour construction site on the Red
Sea, the Telebelt keeps having to be moved.
This means that it achieves a concrete placing rate of "only" 100 m3/h. On average, the
9 m3 and 11 m3 truck mixers are emptied
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after only five minutes and can drive back to
the mixing plant. The concreting work is
coordinated and supervised by Site Manager
Hossam Abdel Aziz, a 27-year old civil engineer, who has worked for the Al-Tawi
Group for a year and a half.
Nationwide well established
A flexible drop line is used for the
installation
main fresh concrete manufacturers. The
company uses more than 100 truck mixers
throughout the country and also has a large
fleet of truck-mounted concrete pumps,
including 22 Putzmeister machines with a
vertical reach of up to 63 m. Since the BIG 5
trade show (November 2008 in Dubai), the
company's fleet also includes a Telebelt
TB 130 truck-mounted belt conveyor.
With mixing plants at seven locations, AlTawi Readymix is one of Saudi Arabia's
11
Dam Construction
Background
29
Urgent repairs
to the Mosul dam
The foundations of the Mosul dam, Iraq's
largest retaining dam, are no longer
watertight. The authorities responsible
fear that the dam could burst, with
potentially disastrous consequences for
the nearby city of Mosul and its 500,000
inhabitants. A Putzmeister M 36 truckmounted concrete pump and a Dynajet
high-pressure cleaner are assisting in
the preparations for the urgently needed
renovation work.
Sprightly Grandmother
The dam is built on a substrate of gypsumcontaining rock, which forms cracks and
dissolves as soon as it comes into contact
with water. The responsible ministry for
water economy has therefore been trying for
years to have the gaps on the interior of the
dam sealed. Following invitations to tender
at national and international level, specialist
companies have now been tasked with sealing the dam through the injection and filling
of cement slurry, bentonite, and other sus27
View of the silo elements and the
Mosul dam reservoir
pensions, stabilising the dam with additional reinforcements, and ultimately fully renovating the dam. A task of this magnitude
requires the appropriate logistics and infrastructure, including load-bearing foundations for the large material silos which
house the building materials.
Concrete foundations for the silos
The concrete pump, truck mixer and formwork are cleaned using the Dynajet
high-pressure cleaner
28
The contract for delivering the total of 16
silos (4 silos with a capacity of 1,500 t and
12 silos with a capacity of 500 t) was awarded to the company DIB Iraq (German-Iraqi
Office). DIB-Iraq is an Iraqi construction
company with offices in Baghdad, Basra and
Dubai. Alongside its own construction activities, DIB provides support for German and
European investors in networking and providing business contacts in Iraq. DIB-Iraq
fulfilled the complete order from delivery of
the silos to their erection and preparation
for use. The company's engineers calculated
the statics of the silo foundations to be concreted, undertook the full construction, and
assembled the silos, which were delivered
in segments.
It is a well-known fact that Putzmeister
concrete pumps do not retire until they
have been used for many years and have
thousands of operating hours under
their belts. On the Mediterranean island
of Cyprus, however, it appears they can
expect to be treated with particular
respect and enjoy great longevity.
In actual fact, the history of this BRF 2112
truck-mounted concrete pump with threesection placing boom is not unique – there
are certainly other machines that have had
more owners and may have been around for
longer.
This particular veteran was mounted on a
Mercedes Benz chassis 2222 K 6x4 in
August 1983 and delivered to the Frankfurt
branch of Hochtief AG. The machine remained the property of the original owner
until the mid 1990s, who always ensured
that the oil service intervals were adhered
to and the wear parts on the boom, pump
and truck were replaced regularly.
To Cyprus in its teenage years
In 1996, the 13-year-old M 31 drilling pump
was sold to the expanding company GGS
(concrete plants and concrete pumping services). With its short wheel base, extensive
horizontal reach and large-volume 120 m3/h
core pump, the machine fulfils the ideal prerequisites for pump applications on this
Mediterranean island with its winding
roads. Andreas Photiou, managing director
of GGS for many years: "The M 31-3 was the
very first modern machine in our fleet of
concrete pumps – reliable, with a high
pump output. With a large 230-mm cylinder
cross section, it is also ideal for sucking
even the most rigid concrete!" The robust
and powerful truck-mounted concrete pump
was well received on construction sites –
the other pumps used by GGS at that time
were capable of a maximum 80 m3/h.
Even in subsequent years, the machine was
never put up for sale for sentimental reasons, due to its close association with the
company history. The pump was fully paid
off, and maintenance costs were negligible.
The BRF 2112 truck-mounted concrete
pump with 31-meter boom has also been
operated by the same machine operator
since 1996, who cares for the machine as if
it was his own.
No sign of retirement
In 2006, it was finally decided to fully renovate the truck-mounted concrete pump,
which was then 23 years old. The truck
engine, hydraulic pump, hydraulic lines,
and all other important mechanical wear
parts were expertly refurbished, and the
truck was treated to a new coat of paint.
Since this time, the now 26-year-old trusty
old-timer runs under the nickname "e giagia
mas e kali" (emblazoned on the placing
boom) – which roughly translates as: "Our
best Grandmother"! In its 13 years in
Cyprus alone, this trusty Grandma has
pumped over 310,000 m3 of concrete. And
its owners estimate that it could easily
pump 310,000 m3 more. The pump has
become known as "Grandma" on the construction sites of Cyprus and is known all
over town.
30
1,200 m3 of fresh concrete was required to
ensure that the silos were securely positioned. The concrete supply from a mixing plant
60 km from the construction site was performed entirely without incident. The North
of Iraq is a region home to approx. 4 million
inhabitants and which has been economically and politically stable for years. Numerous
high-output concrete plants have been operating here for some time. The concrete was
delivered using a PM M 36 truck-mounted
concrete pump.
A Putzmeister M 36 concretes the foundations for the
construction material silos
12
For cleaning the formwork, truck mixers,
and concrete pump, a Putzmeister Dynajet
high-pressure cleaner was available on the
construction site. A worker involved in concreting the foundations wonders how thoroughly even the most stubborn concrete
residues can be removed using this cold
water high pressure cleaner.
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Highly valued and still working on the construction sites of Cyprus every day – the 26-year-old Putzmeister "Drilling" M 31 with
robust core pump
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Pre-cast Concrete Parts
Pre-cast Concrete Parts
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33
Strong caissons made from
steel-reinforced concrete
On the Mexican Pacific coast, 23 km
north of Enseñada, the world's largest
breakwater with a caisson structure
has recently been constructed. The
construction of the giant elements, with
the use of three stationary Putzmeister
concrete pumps and two large placing
booms, required a specialist concreting method. The caissons are a part of
the US $ 875 million project "Energia
Costa Azul", and provide protection for
the new arrival terminal for liquid gas
(LNG).
The tender for planning and construction
of the artificial breakwater, an order to the
value of US $ 170 million (approx. € 133
million), was awarded to a joint venture
between the China Harbour Engineering
Company (CHEC, Hong Kong) and Costain
Group PLC (London). The customer was
Sempra Energy, one of the largest regional
energy suppliers in the US state of
California.
Work on this unconventional project began
in January 2005 with the 12 m-deep excavation for a large basin. Giant concrete
caissons in two sizes were formed in the
basin. With a surface area of 125 x 50 m,
the basin enabled the caissons to be produced as if on dry land, and allowed sufficient space for the simultaneous produc-
tion of two caissons. According to the plan,
once made, the concrete elements were
towed along the coast to their final destination, where they were sunk, connected to
each other and ballasted. The artificial barrier constructed in this way now performs
the function of a breakwater, offering protection against the high waves of the Pacific
ocean for the large specialised tankers when
pumping the liquid gas, which is cooled to
minus 162 °C, into the new LNG storage
facility.
Large Putzmeister placing booms with a horizontal reach of 38 m perform concreting of the giant caissons – here initially in the
dry dock
32
Rapid relocation of the concrete
placing booms with lattice towers
The stationary trailer concrete pumps are characterised by reliability and large
power reserves
14
Due to the enormous dimensions of the
total of 12 caissons (L/W/H approx. 68 x
46 x 28 m or 38 x 25 x 28 m), only standalone concrete placing booms with an extra
long horizontal reach were considered for
the concrete installation. The constructors
decided on two Putzmeister stationary
booms of type MXKD 38. The two 4-arm
booms do not require any ballast and offer
a horizontal reach of 38 m. The large
MXKD booms are not built on tubular
columns, but are based on lattice towers,
similar to those used by construction site
cranes. The base structures are designed
for a pump torque of up to 400 kNm.
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In order to enable work on different sections, the booms as a whole, including
hydraulic drives and crane-type base structures, were deployed in a rotation system in
five locations inside and outside the dry
dock. Bob Liebermann, who was involved in
the project planning for Putzmeister
America, sums it up: "Since, in contrast to
conventional stationary booms, the booms
were pretty much used in one piece and no
counter-weights had to be dismantled and
then re-mounted, this procedure considerably reduced the set-up times and personnel
requirements."
Trailer concrete pumps for rapid
concrete construction
Three stationary Putzmeister concrete
pumps were used to deliver the concrete.
The BSA 1407 D and the two BSA 1409 D
are known for their reliable operation with
constant high delivery rates (up to 71 or
91 m3/h) and their considerable pressure
reserves (up to 106 bar). In the construction
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of the giant caissons, the pumps also ensured rapid concrete installation. "We decided to use the Putzmeister booms and pumps
because they have a good reputation in the
industry. And the machines also offered the
power that we needed for this unconventional project", explains Martin Orells,
managing director of the joint venture partner Costain.
The concrete used was a high-density
C40/50, which was fabricated by Cemex on
the construction site in two mixing plants
(each with a capacity of 60 m3/h). The installation and service work on the three stationary pumps was performed by Construmac
S.A., a local Putzmeister dealer for many
years, who has nine branches in Mexico.
Leaving the dry dock
The interior of the caissons was subdivided
into 6 x 6 m chambers in a honeycomb
design, and initially only filled with concrete
to approx. two-thirds of their height. The
constructional elements were massive, even
in this phase, and a considerable effort was
required to transport them from the dry
dock. First, the whole concrete equipment
had to be moved to a storage location at a
higher elevation. In a cycle that lasted several days, the basin was then flooded, the
sluice gate removed, and when deluged, the
caissons were towed using towboats,
winches, and bollards across approx. 90 m
of open water to a pier. Here the next concreting section was performed, in which the
walls of the caissons were raised by a further 11 m and closed with a roof of partially
prefabricated concrete elements. The pouring of the top layer, with approx. 25 cm
thick cast-in-place concrete, was again performed by a trailer concrete pump, together
with one of the stationary booms on the lattice tower which had been transported here
from the dry dock.
Meanwhile, site personnel in the dry dock
were already starting to replace the gate
bulkhead and its seals, pump out the sea
15
TitelstoryConcrete Parts
Pre-cast
High-rise Construction
34
Top equipment, reliable support
and local service
After a successful start to construction of Arraya Office Towers contractor Ahmadia
Contracting Co. also won the order for building Al Hamra Tower – the largest high-rise
project in Kuwait. For concrete pumping and placing Ahmadia cooperates closely
with AGECO, Kuwait based Putzmeister dealer for many years, and with Putzmeister
specialists from Germany. The high-strength concrete necessary for Al Hamra Tower
construction is not easy to handle by pumps. So experience and advice is most
welcome.
38
37
On top of the building the delivery pipes are
connected to two stationary concrete placing
booms with 32 m vertical reach. The booms
of type Putzmeister MX 32-4 T are set on
columns integrated into the hydraulically
operated self-climbing formwork manufactured by PERI.
The top third of the caisson wall formwork and the internal chambers and tops are
concreted on the water
36
On-site asistance
by PM specialists
water, clean the basin and prepare for the
construction of the next two caissons.
800,000 t against the breakers
Once the concreting was complete, the caissons (which were still floating) had reached
a mass of 24,000 tons (long version) and
16,000 tons (short version). Towboats with
powerful engines towed the box sections 23
km along the coast to their final destination.
The precise position for sinking the caissons
was accurately determined using GPS. The
hollow box sections were flooded and positioned on the prepared seabed by the
metered opening of individual gate valves.
The 12 caissons were then securely fastened to each other and to add yet more weight,
the individual chambers were then filled
with sand which displaced the ballast water.
The mass of the caissons was thus more
than tripled to over 86,000 tons (the smaller
caissons to approx. 58,000 tons). The final
result of the project is a 652 m-long artificial
barrier made from steel-reinforced concrete
and sand with a mass of over 800,000 tons
that provides protection against the breakers of the Pacific ocean.
The BSA 14000 HP D trailer concrete
pump awaits the arrival of the concrete…
Further information on the project
35
The project "Energia Costa Azul" is of
significant importance for the energy
supply to the Mexican state of Baja
California, which currently relies solely
on imports of natural gas over land from
the USA. The new terminal on the coast
enables the state to receive natural gas,
which has been liquefied at low temperature (minus 162 °C) and compressed to
approx. 1/600 of its volume, from other
suppliers by sea. The project "Energia
Costa Azul" also includes the construction of two liquid gas storage facilities
(volume 2 x 160.000 m3) and a LNG regasification plant with a capacity of 29
million m3 of gas per day. In this plant,
the liquid gas will be prepared (tempered) so that it is suitable for feeding into
the existing gas supply network. This
connection required the construction of a
new, 72 km-long gas pipeline.
When completed the 412 m high Al Hamra
Tower will top all other buildings in Kuwait
and become a landmark for the region.
Especially the attractive design of the 77
level Al Hamra Tower – a curved shape – is
striking.
Delivery line system designed for
up to 200 bar
For conveying concrete into the top slabs
Ahmadia Contracting Co. is working with
two stationary Putzmeister concrete pumps
type BSA 14000 HP D. The units are designed for high pumping pressure and connected to two separate conveying pipes
including gate valves and diversion valves.
Due to the expected pumping height the
most stressed part of the pipe systems can
be operated up to 200 bar concrete pressure.
Guiding and support of the vertical pipelines is similar to the Putzmeister solution
practiced at Burj Dubai high-rise concrete
pumping.
The attractive architecture is already evident in the first 40 floors of the Al Hamra
Tower, which will stand 412 m high on completion
Towboats can only tow the partially deluged caisson to its final location in calm
waters
16
While setting-up the concrete pump, installing the pipe systems and concrete placing
booms the local dealer AGECO was supported by Putzmeister application and service
engineers. During construction of Al Hamra
Tower these specialists will
also be available if a
problem might come
up. If wear parts for
the pump, pipes and
booms need to be replaced AGECO will
have them on stock.
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17
Tunnel Construction
Tunnel Construction
39
41
Spray head kinematics
has a decisive influence
telescopic spraying arm and the spray head,
is equipped with a hydraulic parallel guide.
Thanks to this hydraulic coupling the entire
telescopic spraying arm is automatically
maintained in a horizontal position – regardless of whether the first boom arm is
raised or lowered.
A joint venture safeguards the driven tunnel section of the B 29-Schwäbisch Gmünd
bypass with two highly manoeuvrable wet-spray concrete manipulators. As the tunnel
will lie below the water table after completion, it is imperative to produce a thick shotcrete lining with a surface that is as even as possible. The special spray head kinematics of the two wet-spray concrete machines ensures optimum conditions.
The 2,530 m construction project is being
undertaken by the joint venture Tunnel
Schwäbisch Gmünd (J.V. TSG: Züblin,
Baresel, Hinteregger, ÖSTU-Stettin). The
tunnel is divided from west to east in an
open cut (215 m – previously manufactured
in a separate development stage), an open
cut tunnel section (230 m) and the driven
central tunnel (1,687 m). A 315 m tunnel
section in an open cut excavation joins a
connecting open cut (90 m) in the east.
During the first development phase, the
structure is going to be operated for two-way
traffic. In addition, an accessible rescue tunnel, which is connected to the road tunnel
via six escape tunnels, runs parallel to the
main section. The incorporation of a second
main section and operation as a dual twolane tunnel is planned for a later date.
Wet-spraying concrete system for
medium and large tunnel cross-sections
An essential combination: spray arm
kinematics and engineering experience
The tunnel section running from west to
east, which has been constructed using
crown and base driving methods, is broken
up into various lengths and safeguarded
with wet-spray concrete. The consortium
uses two robust SPM 500 PC wet-spray concrete machines to apply the shotcrete.
Putzmeister developed these highly mobile,
extremely rugged and all-wheel-driven
spraying systems specially for medium and
large tunnel profiles. The machines can
therefore be used by the TSG consortium in
both the main tunnel as well as in the smaller rescue tunnel. The flexible, 90° spray
arm of the SPM 500 PC unit can even be
used from the main tunnel to apply the shotcrete in the narrow escape tunnels.
The consortium demands a high degree of
robustness and maximum manoeuvrability
of the spraying systems. "In order to be able
to apply a seamless sealing layer and prevent the risk of perforation at a later date,
the shotcrete, as a carrier for the sealant,
should exhibit as homogeneous and even a
surface as possible," states construction
manager Dierk Schmidberger. "Besides the
experience of the nozzle operator, the kinematics of the working arm is particularly
crucial. Rotational movement of the nozzle
alone won't get very far!"
The spray arm of the PM concrete wet spraying machine is characterised by an
extensive working range
42
Electronics effectively protected from
dust and water
The Putzmeister spray arm is controlled via
nine axes. To facilitate working procedures,
the second boom arm, which carries the
40
In areas with low coverage, such as in the
vicinity of portals that are supported by
high-pressure injection columns, the sections are initially 80 – 100 cm; these later
extend to approx. 200 cm in the bench. The
shotcrete contains, among other things,
aggregate (up to max. 8 mm) and 420 kg/m3
of binding agent (380 kg/m3 of cement and
40 kg/m3 of fly ash). It corresponds to
strength class C25/30 and is applied in multiple layers that are 27 cm thick on average.
Due to the hydraulic parallel guidance, the telescopic spraying arm with spray head
automatically remains in a horizontal position – precondition for an even spray application
43
The Putzmeister concrete spraying systems
are equipped with the latest in control technology. Breakdowns thereby would be preconditioned under the conventional tunnelling conditions. But construction manager
Schmidberger has had completely different
experiences with this spraying equipment:
"Despite the electronic components and
numerous 'high-tech' elements, the SPM
500 wet spraying machines are wholly suitable for the construction site!" Conventional
servicing work is conducted by the consortium's own workshop technicians; the
Putzmeister after-sales department, which
is located just 100 km away, is easily available if more extensive work is required.
When the crown has been driven to around
the centre of the tunnel the base is subsequently excavated. After sealing the shotcrete lining, the inner lining is concreted
with stationary concrete pumps in a followup operation.
Cross section through the tunnel in Schwäbisch Gmünd showing the main tunnel,
emergency gallery and rescue tunnel (picture courtesy of Stuttgart regional council)
A two-year construction period is planned
for both the headwork with shotcrete protection and for completion of the inner lining.
The cost for construction of the lining is estimated at around € 180 million, of which
approx. € 80 million is allotted for the actual
tunnelling process.
Equipment and technical data for the SPM 500 PC wet spraying system
Working height of the SA14 telescopic spray arm:
up to 16 m
Output of the double-piston pump BSA 1005:
up to 30 m3/h
Volume of the additive tank:
1,000 l
Volume of the water tank:
195 l
Additive pump compressor (optional):
11 m3/min (75 kW)
Power cable:
100 m on drum
The Putzmeister SPM 500 C manipulator evenly applies the sealant layer of wet shotcrete
18
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19
Pre-cast Concrete Parts
Pre-cast Concrete Parts
44
46
Concrete pump
rationalises pre-cast
parts production
Manufacturers of pre-cast concrete parts
are often faced with the problem of how
to offer cost-effective production even
for small volumes of concrete. This is an
issue, for example, in the production of
pre-cast parts for shafts for rainwater
and sewage drain systems. The pre-cast
concrete parts for this application are
required in a variety of diameters and
connecting angles and in a range of vertical inclines. However, there are solutions that are worth a closer look.
For this reason, the Austrian company
Schlüsselbauer Technology GmbH & Co.KG
has developed a manufacturing system that
is able to produce even highly individually
formed pre-cast concrete parts in an uncomplicated way using negative moulds and
special formwork. And production is costeffective even for small quantities. The new
method is ideal when used in conjunction
with a mechanical concrete distributor and a
concrete pump that is specially designed for
relatively small outputs.
Technical data for the
P 715 SE concrete pump
Pump:
2-cylinder
piston pump
Delivery rate:
max. 18 m3/h
Delivery pressure: 68 bar
Motor:
400 V / 50 Hz, 30 kW
Length:
4200 mm
Width:
1310 mm
1180 mm
Height:
48
The moulds are filled with self-compacting concrete using the Putzmeister RV 10
rotary distributor
The P 715 concrete pump, which has been developed for small outputs, is located
underneath the mixing plant (Photo: Betonika plus)
47
Cost-effective parts manufacturing even
with customised dimensions
A new plant based on the "Perfect" system
has recently been commissioned in the
Czech concrete and pre-cast concrete part
works of Betonika plus s.r.o. in Luzec nad
Vitavou, about 25 km north of Prague. With
approx. 90 employees, Betonika manufactures approx. 30,000 m3 of ready-mixed concrete per year and a 20 % market share
makes it one of the most successful Czech
manufacturers of pre-cast parts for rain and
sewage water drainage. The parts produced
include concrete containers, concrete channels, pipes, shaft bases, shaft segments and
special parts that can be cast out of concrete
in a single operation.
bases (pipe connections up to DN 600 are
possible), Betonika plus uses self-compacting concrete. In a two-hour process, all of
the 30 moulds are filled with about 25 m3 of
this material. As the concrete compacts
itself, there is no need for it to be vibrated.
This not only reduces the noise, but also
does away with what used to be an important step in the production process. After the
pumping process, the delivery pipes are
easily cleaned with a water-soaked rubber
ball, which is pushed through the pipe by
the pump and caught in a container.
45
View into a two-part formwork containing a negative mould made from rigid
polystyrene foam (Photo: Schlüsselbauer)
Shaft bases into which the drain channels
run used to present a particular manufacturing challenge. In the first production
step, the shaft base was made using the
traditional casting method. This was followed by a highly labour-intensive second step
where it was manually clad with ceramic
tiles. In the "Perfect" system, this is solved
by the use of a negative mould made from
rigid polystyrene foam that has been cut to
the desired diameter, angle and inclination
of the channel and which is held in the twopart formwork.
From its central position, the Putzmeister RV 10 rotary distributor is able to reach more than 30 casting moulds in the Betonika
precasting works, which are filled with self-compacting concrete in a single operation (Photo: Schlüsselbauer)
20
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Use of a concrete pump for small
quantities
A stationary Putzmeister P 715 SE concrete
pump is used to pump the concrete over the
40 m from the mixing plant to the formwork
hall. With this machine, the output can be
reduced to nearly "zero" if required, which
is important if there are comparatively small
quantities of concrete and/or slow concrete
placement. The concrete is poured into the
moulds (average capacity approx. 0.75 m3)
by an elevated, slewable concrete distributor
(Putzmeister RV 10) which has a working
radius of 20 m. When manufacturing shaft
The alternative to concreting using a pump
and rotary distributor would have been to
install a bucket conveyor. However, according to Jiri Strobl (Dipl.-Ing.), managing director of the precasting works at Betonika
plus s.r.o., this solution would have been
considerably more expensive and the overall production of the pre-cast concrete parts
would have been less efficient.
Solutions for larger plants too
As well as this "small-scale solution",
Putzmeister also offers more powerful concrete pumps and larger rotary distributors,
as well as hydraulically controlled placing
booms for use in concrete pre-casting works.
A particularly attractive concreting solution
is provided by the AUTOCOR system, in
which the concrete pump, mixer and computer-controlled concrete placing boom - which
can be moved on rails - are used to largely
automate the manufacturing of pre-cast concrete.
21
Training
Training
50
49
Attractive construction sites,
sophisticated pumps and highly
skilled machine operators
Amazing as it seems, large-scale construction projects can still be realised in densely populated urban areas. Putzmeister customers are often present at such sites with their pumps and placing booms – first to concrete the foundations and base plates
and then later for the superstructure. With their trained personnel and reliable machine technology, they meet the expectations
for a smooth execution of work at the construction site.
That is the case in Singapore, where the
home grown multi-national conglomerate,
Keppel Corporation, and its property arm,
Keppel Land Ltd, is building an extensive
upmarket residential and leisure complex
along a 750 m shoreline. The project is
named “Reflections at Keppel Bay”.
Construction work of the architecturally
very attractive residential complex started
in the first quarter of 2008 and is expected
to be complete by 2013.
The main contractor entrusted with this
project is Woh Hup Pte Ltd, is one of the
largest construction firms in Singapore.
Judging by the plans, this new district of
the island state is characterised above all
by its attractive location and ambitious
architecture. Investment for the project
amounts to 1 billion SGD (approx. 513 million EUR).
Property sold before construction
begins
“Reflections at Keppel Bay” will include six
glass towers and eleven villa apartment
blocks comprising 1.129 luxury homes. On
top of the 24-storey to 41-storey high towers
sky gardens will be created, and the towers
are linked by so called sky bridges. Open
spaces and platforms will provide almost a
360-degree view. The development will be
supplemented by underground car parks,
retail outlets and the district's own marina.
Foreign real estate investment trusts, from
Kuwait for example, bought several of the
apartment buildings even before construction began.
The contract for the concrete pumping was
awarded to the pumping operation Tanglin
Corporation Pte Ltd, a subsidiary of Woh
Hup. They work with extremely well qualified machine operators and have a well
maintained fleet of Putzmeister concrete
pumps. Their machines include an M 46-5,
three M 42-5, two M 36-4, a MOLI 2109, a
BSA 2109 HD stationary high-pressure
concrete pump together with an MX 28-4 T
and MX 32-4 MULTI stationary boom.
Regular training reduces operating
costs and increases safety
As well as providing the Tanglin machine
operators with instruction on newly supplied PM machines, Putzmeister service
engineers regularly take on the training of
the customer's personnel – and not only
for pumping operations in Singapore.
Topics and tips cover the maintenance and
care of the machines and safety issues
when working with the truck-mounted
In the space of 20 hours, three Putzmeister M 42-5 machines operated by the Tanglin Corporation fully concrete the foundations
of six apartment blocks
51
concrete pumps. Operators also have the
opportunity to deepen their knowledge of
pump hydraulics and control electronics –
all of which is important in order to reduce
wear and fuel consumption, to increase operational safety and to further optimise
reliability.
This photo of the construction site was taken
when Tanglin Corporation was concreting
the base plate for six of the new apartment
buildings at Keppel Bay "in one go" over 20
hours with its three BSF 42-5.16 H machines. The output of the machines – all
three were equipped with the powerful and
particularly quiet 160 m3 pump unit – was
around 80 m3/h each. In view of the heavy
urban traffic that kept delaying the truckmixers and the time required for moving the
truck-mounted concrete pumps from one pit
to the next, this represented a very respectable pump output.
Model view of the apartment complex "Reflections at Keppel Bay"
(courtesy of Keppel Land International Ltd.)
22
Machine operators from the Tanglin Corporation receiving concrete pump training
from PM service consultant Josef Posepny
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23
Airport Construction
Background
55
Champagne before first deployment
The company Budokrusz Sp.Z.O.O. (Warsaw) recently celebrated the commission of
their new BSF 58-5.16 H with a small party and a hearty buffet. In keeping with the
colour of the long-reach boom pump, the machine was christened with medium-dry
red sparkling wine.
53
52
The M 58-5 is christened with red
sparkling wine ...
… then guests are fortified at the buffet
Company owners, the Charzynski family,
invited their employees and selected business partners to the christening of the new
machine, including representatives from
Putzmeister and the Polish PM agent
Alltech. They certainly had reason to celebrate: The new M 58-5 is Poland's newest
long-reach boom pump.
The company Budokrusz owns around a
dozen truck-mounted concrete pumps, two
ready-mixed concrete works, and a pre-cast
concrete parts works in the Warsaw area.
The Putzmeister concrete pumps were mostly manufactured in recent years, and form a
large proportion of the pump fleet with a
PUMI 24.67 CS, one each of M 28, M 36,
M 46 and M 58. and two M 42s.
Training
Fit for the new season
At the start of the year, the Putzmeister Academy organised all the details for four training events exclusively for the employees of three concrete pumping services (BRM,
BRF, "Die Pumas") in the PM seminar rooms. The participants were machine operators and employees from workshops and scheduling. The 2 1/2-day workshops were
held jointly by PM trainers and Ingo Melzer, a partner in one of the pumping services.
"You have the ideal technology, personnel,
and space available for this type of training
course" replies Ingo Melzer when asked
why the training is not held at his own com-
pany headquarters. It is otherwise standard
practice for PM trainers to hold their pump
operator training courses directly at the customer's site. However, according to the com54
pany management, it benefits the operators
to have a change of scenery and visit an
external site, and also improves the working
atmosphere.
Long-reach boom pumps
at the new Berlin airport
The construction of the new Berlin Brandenburg International Airport (BBI) does not
consist solely of terminals and runways, but also involves numerous other structures
that make up the major airport for a capital city. PM long-reach boom pumps have
been used here to concrete huge surfaces "in one go".
The development of the future airport site
included a main terminal ring with 13
bridges and six retaining structures, a
motorway crossing, and numerous road and
underground works, which were undertaken by PORR Deutschland GmbH.
At the time of our visit in mid-February, the
concreting work to cover the floor of the
main terminal ring was well underway. To
pump the concrete, PORR employed specialists from the company Lichtner Neuland
Betonlift GmbH & Co.. Lichtner Neuland is a
pumping service with its headquarters in
Velten, to the North-East of Berlin. For this
job, the company provided the use of three
of its large Putzmeister truck-mounted concrete pumps (two BSF 52-5.16 H and one
BSF 42-5.16 H). It was essential that the
concreting was performed "wet on wet" and
all interruptions were avoided. Lichtner
Beton therefore placed the three large
booms on three sides of the 2,000 m2 substructure in a configuration, so that the
machines for pumping and distributing the
1,500 m3 of concrete could be operated from
a single location.
The main terminal ring is a brick-built structure with deep foundations, with dimensions of approx. 488 m long by 45 m wide.
For static reasons, longitudinal and transverse beams are used to support the large
area underneath the road surface. The
weight of the construction is supported by
bored piles (0.9 to 1.2 m Ø), which are sunk
to a depth of 25 m.
Machine operators from Lichtner
Neuland Betonlift dressed up warm in
the cold morning weather
BBI to replace 2 existing inner-city
airports
The BBI airport will aim to handle all of the
increasing passenger and air freight traffic
for Berlin and the surrounding area. The former inner-city airports Tempelhof and Tegel
will both be closed. The new airport, which
serves the capital city from the southern outskirts of Berlin, is located partly on the site of
the former Schönefeld airport and once complete will be home to two 3,600 and 4,000 m
long runways and landing strips. Even the
Airbus A 380 will be able to land and reload
here. Planned changes to the local public
transport network (inter-city train connection and local trains and buses) will reduce
the journey time from the new airport to the
centre of Berlin to approx. 20 minutes.
Construction costs for the project are currently estimated at € 2.83 billion. The airport is scheduled to open at the end of 2011.
The training focussed on the operation,
safety aspects, service and maintenance of
concrete pumps. For some participants,
these topics served to refresh existing
knowledge, while for others the information
was new. Ingo Melzer explains: "The technology of concrete pumps is continually developing – and our machine operators therefore also require ongoing training." The
machine operators are therefore provided
with information to supplement their basic
understanding of all the hydraulics and electronics involved in their machines. These
topics are then covered in more detail in
training courses for workshop personnel.
56
The management of all three companies
places great emphasis on the continued
theoretical and practical training of their
employees. This is considered important for
equipping employees to help themselves,
reducing the number of machine shutdowns, and increasing the sense of responsibility among the machine operators.
The PM long-reach boom pumps concrete the covering structure of the main terminal ring at Berlin's future airport from three
sides (photo: Hülsmann/Lichtner Neuland Betonlift)
Ideal conditions for machine operator training course
24
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25
Tunnel Construction
Tunnel Construction
Huge tunnel elements concreted
for the Bosporus Crossing
The new intercontinental
tunnel consists of eleven
prefabricated concrete elements, which will be accurately positioned into a predug channel on the seabed
by a specialist ship.
Tunnel elements concreted
in the dock
The metropolis of Istanbul, which boasts a population of 15 million and stands at the dividing point between Europe and Asia, is
currently home to a spectacular railway tunnel construction that has been designated the Marmaray Project. Putzmeister concrete
pumps and a concrete wet-spraying machine are involved in producing the huge tunnel elements for the underwater section, in
tunnel lining with shotcrete and in backfilling tunnel formworks on land.
57
Concreting of the eleven 135 m long, 15.3 m
wide and 8.6 m high tunnel segments is
being conducted in a dry dock on the Asian
side of Istanbul in the suburb of Üsküdar.
This is where Oyak Beton is utilising several
of its Putzmeister truck-mounted concrete
pumps (with boom sizes M 24-4, M 36-4 and
M 47-5) to fill the base, wall and ceiling
formworks of the caissons from the edge of
the dock. Approximately 5,000 m3 of concrete
in varying strength classes (up to C40) is
required for each tunnel element. The upper
segment is concreted with a flooded basin.
1.387 m
Section of the immersed tube tunnel
58
Filling
58 m
135 m
Excavated tunnel
Immersed tube tunnel
Systematic representation of the Marmaray tunnel project
(picture: Wikipedia)
Lowering the 30,000 tonnes elements
requires a fine touch
Sturdy tugboats tow the finished and sealed,
reinforced tunnel segments from the dock to
a floating platform in the Marmara Sea in a
catamaran construction. The 30,000 tonnes
reinforced concrete constructions are carefully towed between the two hulls. The catamaran is manoeuvred to the exact pre-calculated position above the seabed, in which
dredgers have excavated a deep channel.
The special ship is held in place by thick
steel coils, which are secured to 13 buoys
anchored on the seabed. The catamaran
houses huge cranes with cable winches,
which are used to lower the tunnel sections
into the artificial ditches. Cameras and
measuring instruments monitor the precise
alignment of the tunnel segment, which is
achieved by filling and emptying ballast
tanks in a similar manner to a submarine.
The critical period is during the final phase
where there is a risk of the large rubber
seals being damaged. This is because these
are required to produce a watertight connection between the segments. The top of the
tunnel element is subsequently protected
against damage with a 4.5 m thick sediment
layer.
Long-reach boom pumps concreting the upper part of one of the giant tunnel segments in the deluged dry dock
(photo: Oyak Beton)
Flexible tunnel connections prevent
damage during earthquakes
Istanbul is home to around a fifth of the
population of Turkey. Traffic planners are
focussing on modernising public transport
and developing the infrastructure in order
to relieve the burden on the city's chronically congested bridges over the Bosporus and
the associated access roads. The Marmaray
Project, which was established in the 1980s,
is an integral component of this measure. In
May 2004, tenders were finally approved
and the project was started. An important
section of the structure is a 1.4 km tunnel
segment which lies on the floor of the
Marmara Sea at the southern end of the
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Bosporus. This segment consists of enormous prefabricated concrete elements
which are lowered to a depth of up to 58 m,
sealed and interconnected. The tunnel connects the European suburb of Halkali with
Gebze on the Asian side of Istanbul.
Work is being conducted on both sides of
the waterway to establish a connection between the tunnel and the existing rail and
metro network. The construction measures
include, among others, 9.8 kilometres of
driven tunnel sections, 2.4 km of open cut
tunnel sections, three new underground sta-
tions and 37 stations located above ground,
which are currently undergoing a comprehensive modernisation programme. A 63
km existing railway line is being expanded.
The customer is the Turkish General
Directorate for Rail, Port and Airport
Construction (DLH). The project is being
undertaken by a Japanese/Turkish consortium (contract section BC1) under the
management of the Taisei Corporation,
together with Kumagai, Gama and Nurol.
The construction costs are estimated at US $
3.5 billion (approx. € 2.7 billion).
PM 4170 GB
A significant challenge for the tunnel constructors is posed by more than 10,000
earthquakes that are registered in the region every year (most of which, however, are
barely perceptible). The reason for these
earthquakes is the Anatolian Fold, which
meets at the two continental plates. It is
only located some 15 km from the tunnel.
The safety measures include, for example,
special protection for the connection points
of each individual segment under water.
And where the Marmaray tunnel merges
with the land tunnel, particularly powerful,
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Truck-mounted concrete pumps are often in use on land, where the tunnel segments
are fabricated using open construction methods (photo: Oyak Beton)
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Precise positioning despite
strong currents
It has long been known that a dangerous
current runs through the passage between the Black Sea and Mediterranean
Sea. Strictly speaking, there are even two
directions in which the water flows
through the Dardanelles, the Marmara
Sea and the Bosporus: In the lower water
layer there is a strong current running
from south to north; in the upper layer,
however, the water flows in precisely the
opposite direction. In order to be able to
position these tunnel segments accurately at the calculated positions, despite this
strong and often fluctuating current
speed, the Japanese experts use a specially developed system for predicting
current.
View of Istanbul, which is split into
a European and an Asian side by the
Bosporus Strait. To the north is the
Black Sea coast, with the Sea of Marmara to the south (photo: Wikipedia)
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Tunnel Construction
Background
63
61
Test bay determines
wear data for
concrete pumps
This type of shotcrete manipulator the Japanese construction company Taisai Corporation operates at different stages of the
Marmaray tunnel construction
flexible and elastic rubber seals are used
which will not break in the event of an
earthquake.
Varied tunnel construction methods
While the 1.4 km tunnel section is being
established from caissons at the bottom of
the Marmara Sea, entirely different tunnelling methods are being utilised at other sections of the 76.3 kilometre Marmaray
Project. Tunnelling in areas along the banks
and those susceptible to soft ground conditions, for example, is conducted in a shield
tunnelling process with tubbing support. In
other sections the inner formwork is concreted by stationary Putzmeister concrete
pumps, which are made up of both modern
BSA 1408 E units and older fully functional
pumps. Other sections are built using an
open construction method, often involving
the use of PM truck-mounted concrete
pumps. For shotcreting, Putzmeister provides a compact SPM 400 wet spray manipulator. The spray arm of these machines
has a working range of 2 m – 8.5 m and its
spraying capacity is up to 20 m3/h.
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Oyak Beton
With an annual production capacity of
4.5 million m3, Oyak Beton is one of the
largest ready-mixed concrete producers
in Turkey. Oyak Beton has its own concrete laboratory and is represented
throughout the country thanks to its
multiple mobile and stationary mixing
plants. Besides numerous truck mixers,
the company also operates a fleet of
around 70 Putzmeister truck-mounted
concrete pumps in varying sizes. In addition to concreting the tunnel segments,
the company also delivers and pumps
concrete to other sections of the
Marmaray Project (contract section BC1
and CR1). Furthermore, Oyak Beton is
currently involved in other major construction projects in Turkey.
The cavernous tunnel segments are not only home to modern stationary concrete
pumps, but also a selection of reliable veteran machines such as this Putzmeister BRA
concrete pump. In the background, the large diameter of both tubes in one of the
caissons can be clearly seen at the transition to the mainland tunnel.
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Throughout their many thousand operating hours, concrete pumps are continually in contact with highly aggressive
media. In particular hoppers, agitators,
delivery cylinders, spectacle plates and
automatic rings, as well as the transfer
tubes and delivery lines are exposed to
the concrete. In order to shed more light
on the wear process (and hence also the
associated costs), which differs greatly
from region to region, Putzmeister uses
a test procedure specifically designed
for concrete pumps.
To promote longer service life, Putzmeister
has particularly strict requirements for the
materials from which the above components
are manufactured. However, it was still not
possible to provide clear statements about
the service life of important concrete pump
wear parts. This is because hardness and
abrasion vary greatly depending on the geographical origin of the aggregates contained
in the concrete. In practice, this means that
the service life of the wear parts may therefore differ by a factor of more than 10. Wear
is generally classified into four different
mechanisms:
■ Abrasion wear
· Friction wear (material wear due to scratching, i.e. microscopic splinters)
· Impact wear (at high delivery rates, the
aggregates impact at an angle of almost
90°, e.g. on the down pipe)
· Jet wear (observed at high delivery rates:
concrete impacts against the wear part at
a flat angle)
■ Adhesion wear
· Cold wear due to high pressure
· Shear due to mechanical movement
■ Tribochemical wear
· Chemical reaction between two friction
surfaces and/or intermediary substances
(Tribochemistry is a branch of physical
chemistry concerned with the chemical
changes that occur to solid objects under
the influence of mechanical energy such
as impact or friction)
■ Fatigue wear
PM 4170 GB
PM 4170 GB
The wear behaviour with regard to concrete pumps depends
on the composition of the aggregates. Samples from different deposits.
However, the greatest influence on the
above-named components of PM concrete
pumps is abrasion wear.
Objective and purpose
In order to provide customers with accurate
statements on the service life of PM concrete pump components, and to enable a
realistic cost/risk analysis for large projects
in different countries, Putzmeister operates
a test bay for the comparative analysis of
aggregate mixes and materials. Even before
the introduction of materials, this analysis
method enables us to quickly obtain informative results.
ing aggregates from the Middle Rhine
Valley ("ball-bearing gravel"), the Wurzburg
region (black basalt), the Alps (limestone),
as well as from Hong Kong (corundum) and
Mauritius (volcanic rock), and many other
deposits and construction sites. Increasing
consideration is given to the origin and consistency of the fine components, since these
have a decisive influence on the abrasiveness of a concrete mix.
Putzmeister is happy to offer advice on any
issues regarding wear characteristics.
Please call us on +49 (0) 7127-599-3355.
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This procedure, developed and executed in
the main works in Aichtal, specifically tests
the friction wear of typical tribological
systems. A two-dimensional matrix enables
us to make both comparative statements on
the service life of different component materials with a selected aggregate, as well as on
the abrasiveness of different aggregates
with a specified component material.
Without entering into too much detail, the
process can be summarised as follows: The
experiments provide information on the
weight loss (= wear) of assay grains after
processing in a standardised test process.
The obtained values can be used to quickly
draw comparative conclusions. This reduces
the necessity for cost-intensive experiments
in the field, while also providing the customer with a much quicker economic assessment for purchase decisions. Results are
available, for example, for concrete contain-
Test bay for determining
wear data
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Background
Practical Tip
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Fleet management
with DAISY
When Putzmeister launched the data
information system DAISY in 1993, noone could have predicted the success of
this mobile computer system with industry-specific software. The initial concept
was to provide computer assistance in
routine tasks and for transparent cost
management within a concrete pumping
organisation. Today over 250 truckmounted concrete pumps in Germany
alone are equipped with PM-DAISY onboard computers.
For almost 20 years, PM-DAISY has enabled
full business processing capability for concrete pump service providers. From the
beginning, this included scheduling, personnel time recording, order processing,
and invoicing. In the on-board computer version, the data information system ensures a
constant flow of information between materials planners in the headquarters and the
machines and their drivers on the construction site.
What data is transferred?
In PM-DAISY, the order data is transmitted
from the headquarters to the vehicle via
remote data transmission. The machine operator can process the order using the onboard computer in the vehicle. The on-board
Mobile partial flow filter
improves service life and
saves on oil changes
computer sends current data relating to the
order back to the headquarters, such as the
pumped volume, idle time, pump operating
hours, and the current position of the vehicle.
The filtering of very fine contamination particles and water from the hydraulic fluid
circuit in a partial flow is often the deciding factor for maintaining the cleanliness of
the hydraulic fluid at a consistently high level. For concrete pumps, this pays off with
reduced wear, fewer oil changes, and lower operating costs.
Benefits for operators
Some operators claim that concrete pump
service providers with more than 15 machines can simply no longer operate efficiently without the DAISY system. PMDAISY offers complete fleet management in
one system – from order entry to invoicing.
The system therefore also relieves the workload, even for considerably smaller concrete pump service providers. As one user
sums it up: "everyone wants to write invoices!".
Operators with scattered locations and
multiple companies
PM-DAISY also fulfils the preconditions for
efficient business cooperation between multiple concrete pump service providers. Some
concrete pump operators have already been
making use of this technology for over 10
years. Working with PM-DAISY has enabled
them to improve efficiency, optimise planning, and reduce costs through better allocation of vehicle resources.
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Geographically defined areas
The i-DAISY international
web application
Our many years of experience with PMDAISY in Germany have led to the development of the international version "i-DAISY".
Putzmeister is now offering this Internetbased version specifically for customers outside Germany. The system is therefore available internationally, provided that the
language, personnel and technical prerequisites are met in the country of use. Concrete
pumping service providers outside
Germany are now utilising the advantages
of i-DAISY. DAISY is no longer limited to
concrete pumps, but now can also be used
for the whole vehicle fleet, including truckmixers, silo trucks, etc.
Map section showing current position
of the vehicle
i-DAISY can also be combined with modules
for vehicle location and route tracking.
Putzmeister is offering the required software and on-board computer for this functionality for all commercial vehicles – independently of DAISY – under the program
name "i-GOT-U". Machine operators can use
i-GOT-U to display the current locations of
their vehicles and hence the routes that
they have travelled. The system also sends
an e-mail or SMS to report if a vehicle has
left a defined geographical area or if the onboard computer is tampered with.
Due to the different legal requirements in
different countries (software contracts,
accounting guidelines, tax regulations, etc.),
Putzmeister "i-DAISY" does not include an
invoicing module. However, according to
customer-specific requests, delivery note
data can be transferred via an interface to
local invoicing systems.
According to studies of hydraulic component
manufacturers, up to 80% of all faults in the
hydraulic system can be attributed to contamination of the hydraulic fluid. In addition
to contamination by fine and microscopic
solid particles, the contamination of oil with
water is often observed. The water either
enters the hydraulic system as condensate,
or directly from external sources, for example, from the sharp jets of a high-pressure cleaner. Contaminated water can,
however, also enter the hydraulic system
from the water box via the piston rods of the
delivery cylinders (changing the water daily
reduces this effect!).
In concrete pumps, cleaning of the hydraulic
fluid by the integrated system filters should
only represent one part of the maintenance
routine. For concrete pumps, Putzmeister
also recommends the additional measure of
regular partial flow filtration. This ensures
that not only is the hydraulic fluid constantly clean, but the machine also requires con-
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siderably fewer oil change intervals, resulting in a significant cost saving for the operator.
In modern partial flow filters, a circulation
pump is combined with a microfilter and
integrated water-separating filter of suitable
dimensions according to the size of the relevant hydraulic system. During filtration, the
oil is circulated continuously, independent
of the actual flow in the overall system. The
partial flow filter recommended by
Putzmeister is a separate device that can be
used in the whole concrete pump fleet – on
a rotation basis from machine to machine –
even while the pumps are in operation on
the construction site. The purchase costs of
the mobile partial flow filter pay for themselves after the first oil change, which can
be seen from the rough calculations shown.
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i-DAISY offers added functionality
The wearing parts module that can be integrated into i-DAISY provides the operator
with information, for example, on the next
TÜV inspection date or vehicle lubrication
cycles. The type of deadline monitoring can
be manually customised according to certain criteria, such as delivered volumes.
Additional evaluations of fuel consumption,
speed monitoring, concrete pressure, temperatures, pump operating hours, journey
times of the truck-mounted concrete pump
etc., will also be possible in the near future
via connections to modern CAN bus systems.
Monitor in the vehicle for processing
orders
Material planning graph at concrete pump service provider
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PM 4170 GB
PM 4170 GB
Separate partial flow filter with
circulation pump, fine filter and water
separator
The purchase costs of the mobile
partial flow filter pay early for themselves
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Putzmeister Services Special to May, 31 2009
The New Generation
Power Batteries
Blue instead of yellow
2 1/2 times longer
service life
at the same price
NiMH-Batteries
(rechargeable)
3,0 Ah
Part no. 471560
4,2 Ah
6,0 V/1,5 Ah
3,6 V/2,1 Ah
Part no. 458017 Part no. 237745002 Part no. 461523
Order now: Phone +49 (0) 173 3 09 26 63 · [email protected]
All rights and technical details subject to alteration · The illustrations show special mechanical equipment and snapshots in practice on construction sites, which do not always
correspond to the regulations of the Industrial Employers’ Liability Insurance Association · © 2009 by Putzmeister Concrete Pumps GmbH · Printed in Germany (40904Sc)
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PM 4170 GB