Customer magazine by Putzmeister AG 70 Enormous chamber

70
Customer magazine by Putzmeister AG
Enormous chamber concreted
with a minimum of expense
Japanese PM subsidiary on its
own premises
BAUMA review
New concrete pumping record at
the Burj Dubai
Strong models in the Schmücke
tunnel
PM 3925
Content
In brief
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In brief
University of Karlsruhe honours Putzmeister founder
Karl Schlecht
University of Karlsruhe honours
Putzmeister founder Karl Schlecht
On celebratory occasion and in the presence
of around 150 guests, Mr. Karl Schlecht,
Putzmeister company founder and PM
supervisory board chairman, was presented
with the Karlsruhe Innovation Prize for
Construction at the beginning of May 2007.
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First M 63-5 long-reach boom pump in Ireland
Ultra high strength concrete with six times the compressive strength
The Karlsruhe Innovation Prize for Construction was awarded for the first time in
2002 by the association of friends of the
Institute for Technology and Management in
Title story
Kops II power station
Enormous chamber concreted with a minimum of expense
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Construction. The aim of this honour is to
recognise the achievement of particularly
active figures for outstanding developments
in the building and construction machinery
industry. When making its decision, the
association pays particular attention to the
close cooperation maintained between
industry and science. The investments made
in the future of Germany are also evaluated
when nominating the winner. This accolade,
incidentally, is not to be confused with the
BAUMA innovation prizes awarded to
Putzmeister by the VDMA.
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PM in Focus
Japanese PM subsidiary on its own premises
BAUMA review: The best atmosphere and some great orders
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New concrete pumping record at the Burj Dubai
®
The formulation for a particularly resilient
concrete, which is able to withstand up to
six times more pressure than standard concrete of property class C30/35, has been
developed at the University of Kassel. This
story was recently covered by the magazine
TECHNOLOGY REVIEW (issue 3/2007). The
ultra high strength concrete (UHSC) achieves a compressive strength from 150 N/mm2
to 200 N/mm2 and has a remarkably low
water/cement value. Due to the extremely
dense packing of the fine grain, the ultra
high strength concrete is significantly more
structurally leakproof, making it particularly resistant to corrosion. The first large-scale
bridge to be made from UHSC has recently
been completed in Kassel.
The new ultra high strength concrete consists of, among other substances, very fine
gravel particles measuring around 0.1 mm,
which acquire such a smooth surface after
setting that they even become reflective. In
addition to this, approx. 2.5 % of the UHSC
volume consists of 0.1 mm thick, and 10 to
17 mm long, steel fibres. Depending on how
the ultra high strength concrete is pumped
into the formwork, these fibres are either
aligned randomly or parallel. During the
hardening process they then bind inseparably with the concrete. This allows the production of particularly delicate and significantly lighter components.
On site
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Container terminal almost 1,700 m long concreted seamlessly 14
PUMI at track construction works
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Tough models in the Schmücke tunnel
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Ultra high strength concrete with six
times the compressive strength
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Practical tips
Caution: High voltage!
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First M 63-5 long-reach boom pump in
Ireland
Technology
Electronic wizards
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Competition
Wanted: Putzmeister Story(ies)
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Title: Vorarlberger Illwerke
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In its March edition, the Irish construction
trade magazine, "Plant Man", reported on
the delivery of the first M 63 long-reach
truck-mounted concrete pump to Kilbride
Concrete Pumping in Ireland. The official
hand-over of the keys was conducted by
John Ledwith, owner of the local PM subsidiary, Irlequip Ltd. Here is an extract from an
interview in "Plant Man" given by Seamus
Kilbride, founder and owner of Kilbride
Concrete Pumping, where he said: “Our
commitment is to give the best possible
service at competitive rates with reliable
operators and well maintained machines.
…and this [the new M 63-5 (ed.)] has been
the cornerstone of the company since its
foundation.”
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And his son, Leonard Kilbride, is also
quoted in the article as saying: “The
addition of the Putzmeister M 63 to
our fleet with its 200 m3 per hour
pumping capabilities brings concrete pumping to a higher level
in Ireland and reflects changing demands in the marketplace with high rise projects
becoming the norm.”
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Title story
Title story
Kops II power station –
Enormous chamber concreted
with a minimum of expense
passes via the pressure tunnel and the pressure shaft from a fall height of 800 m and is
driven onto the turbines' impeller blades.
Schematic diagram of the subsurface power station area
Transformer chamber
Machine chamber
Pressure shaft
Stationary boom able to change position
Underwater
surge tank
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Access tunnels
for chamber
power station
Vorarlberger Illwerke AG is significantly expanding its capacities for the European
electricity market through the construction of the pumped storage power station,
Kops II, which has a turbine output of 450 MW. During the construction the cavern
cavity, the extensive concrete work in the enormous machine chamber is performed
with just one stationary BSA concrete pump and one stationary concrete boom, which
is operated alternatively on two tubular columns. Work is carried out around the clock
in a 3 shift operation. The construction costs for the cavern power station and the
underwater systems are estimated at approx. 30 million €. The work on Kopswerk II
started in September 2004 and the start up operation is planned for 2008.
Entrance
Underwater tunnels
(Fig.: Vorarlberger Illwerke)
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The new pumped storage power station is
close to Kopswerk I in Montafon and, like
this station, it also makes use of water from
the Kopssee lake. The project comprises
construction sections 1 and 2 (pressure tunnels, surge tank and pressure shaft) as well
as section 3 with the machine chamber and
transformer hall together with the supporting systems and underwater systems. The
work on construction section 3 is being conducted by a consortium made up of Betonund Monierbau Gesellschaft m.b.H (Innsbruck), Alpine Mayreder Bau GmbH (Salzburg/Wals), Ed.Züblin AG Zweigniederlassung Tunnelbau (Stuttgart) under the
overall management of Jäger Bau GmbH
(Schruns).
The PM stationary boom MX 28-4 with
"Z" fold system, which is operated
alternatively by two tubular columns,
adapts easily to the space conditions
in the chamber.
The construction of the six underground
stories and the assembly level is performed
using cast-in-place concrete; altogether
more than 39,000 m3 of concrete is poured
in the machine chamber. The base of the
enormous rock hall and individual ceilings
are up to 4 m thick and the walls which
measure up to 8 m in height are constructed
in thicknesses ranging between 0.2 and
4.0 m. The dimensions of the chamber mean
that two stationary concrete booms would
actually have been necessary for a uniform
placement of concrete. After consulting
engineers from Putzmeister AG, the consortium decided, however, to install just one
MX 28-4 stationary boom, which is operated
alternatively by two tubular columns. Due to
the fact that the individual sections for each
floor are never constructed at the same
time, it hardly ever disrupts the work process; this is ensured if the arm assembly of
the MX boom is removed from one of the
tubular columns, raised from the gantry
crane, transported to the other end of the
chamber and then attached to the second
tubular column. The entire procedure takes
approx. 30 minutes, with the removal and
connection of the delivery line likewise
taking approximately 1/2 hour to complete.
Up to 360 m3 of concrete is used for each
section.
A 60 m high machine hall hewn from
the rock
MX boom concretes from 40 m high
tubular column
The machine chamber is considered an
essential structure of Kopswerk II. It is located approx. 150 m within the mountain and
can be reached via an entrance tunnel from
Silvretta alpine road between Gaschurn and
Partenen. Its dimensions, at 88 m in length,
60.5 m in height and 30.5 m in width, are
extremely impressive. The blasting drive
was started in January 2006 to excavate the
enormous cavern, in one crown section and
ten side wall sections. The crown section
was excavated during this process with two
wall headings and a core. Four layers of
structural steel lattice and a coat of shotcrete measuring approx. 10 cm thick per
reinforcement provided safety during the
excavation procedure. The long-term safety
of the enormous cavern is ensured by
numerous prestressed strand anchors that
are up to 32 m long. The three armoured
turbine head race tunnels of the high pressure distribution pipe flow into the machine
chamber, through which the driving water
A striking feature of the unballasted MX 28-4
stationary boom is not only the flexible Z
fold system of the arm assembly, which can
even be used to concrete individual base
sections of the turbine head race tunnels,
but the overall length of the two tubular
columns from which the boom is operated is
also remarkable. By placing several tubular
columns on top of one another (which are
available in lengths of 4, 6 and 10 m) they
can be continually adapted to the building
progress and reach an ultimate height of
40 m in the final stage of the Kops II machine chamber. Two braces provide additional
stability for the tubular columns, which are
provided at a height of approx. 18 and 24 m
and anchored into the corresponding intermediate ceilings.
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Title story
Title story
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System concept of Vorarlberger
Illwerke AG (Fig:. Vorarlberger Illwerke)
The boom receives the concrete from a
stationary PM concrete pump, which is
connected to the MX boom and its two tubular columns via a 150 m long delivery line
(DN 125). The BSA 1408 E is actuated by a
75 kW electrical motor and it achieves a
delivery rate of 79 m3/h or 71 bar concrete
pressure in rod side operation (piston side:
53 m3/h or 106 bar). By using less machinery concrete can still be placed economically in a chamber of this magnitude.
Four operators for both the MX stationary
boom and the BSA concrete pump have been
instructed on how to operate the machines
by the Austrian PM subsidiary, Hans
Eibinger (Söding). Eibinger service engineers had also assisted previously in the
installation of the tubular columns and in
the setting up of the concrete boom.
General site manager Christian Töchterle
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The neighbouring transformer chamber,
measuring 35 m in length, 16 m in width
and 20 m in height, also exhibits imposing
dimensions, however it is clearly smaller
than the machine hall. The placement of
concrete for the foundations, wall formwork
and ceilings was partly conducted with a
PM truck-mounted concrete pump BRF
24-4.09 H, whose ZR fold boom had the
necessary slip characteristics. The volume
of concrete placed was approx. 2,200 m3.
The construction work for the shell in the
transformer chamber has been finished
since November 2006.
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Solid components require low w/c value
A concrete of property class C25/30, which
is manufactured on the construction site in
its own mixing plant, is used as a standard
formulation. Generally speaking a water/
cement (w/c) value that is as low as possible
is used to limit the hydration heat for the
solid components, and in warmer seasons
the ratio of cement to fly ash is changed
from 230 kg: 90 kg to 200 kg: 120 kg per
cubic metre.
Vorarlberger Illwerke was founded in
1924 as a private limited company and it
has been a public limited company since
1927. When Kopswerk II is completed,
the Austrian power supplier will be operating several facilities including ten
power stations and four high altitude
storage lakes (beneath the Silvrettastausee lake), which are interconnected
via a 100 km long tunnel system. Since
the beginning in 1925, the network for
harnessing water power to generate electricity has been consistently expanded.
Today, Illwerke plays an important role in
the European electricity network by supplying its contracting partners Energie
Baden-Württemberg (EnBW), Vorarlberger
Kraftwerke AG (VKW) and Tiroler Wasserkraft AG (TIWAG) with surge current and
control energy. The entire installed turbine output currently stands at 1,248 MW;
when Kops II is put into operation it will
be 1,700 MW. The rated input in pumping operations would then increase from
533 MW to 983 MW.
The BSA 1408 E is set up in the access
tunnel and connected to both tubular
columns of the MX boom via a delivery
line measuring approx. 150 m
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Title story
PM in Focus
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Surge tank
Pressure tunnel
Access tunnels
Tafamunt
Pressure shaft
Machine chamber
Why Kops II ?
When completed the Kops II power station will be the largest pumped storage
power station operated by Vorarlberger
Illwerke AG. Thanks to modern technology the machines in the chamber
power station achieve a particularly
high degree of efficiency. This means
that Kops II has the best conditions for
electricity network regulation for both
controlled operation and during times
of peak demand. The purpose of the
power station's three machines, each
with an output of 150 MW, is not just
the generation of electricity however,
but also to pump the water from the
sub-basin using excess electricity from
the network back into the storage
reservoirs located several hundred
metres higher.
When electricity is supplied for
industrial and private household use a
differentiation is made between basic,
medium and peak load, which depends
on the time of day and the day of the
week. For public utilities this means
having to make alternating capacities
available at short notice. While hydro
and thermal power stations are suitable for supplying basic and medium
loads due to their continuous function,
pumped storage power stations are particularly suitable for supplying electricity during times of peak demand. In
these stations water flows from an
upper storage lake, through pressure
lines into lower-lying power station
turbines coupled with generators, from
where it is discharged into a lower storage lake. Generally speaking, during
the night hours where consumption is
low, more electricity is available than is
used. This excess electricity is used to
pump the water upward again from the
lower storage facility to ensure that no
water is wasted. The difference in altitude in Kops II is around 800 m.
Underwater tunnels
The new company premises of Putzmeister Japan (PMJ), with its modern office buildings and service area, was officially opened
amidst celebrations at the end of May this year. Customers, suppliers and local authority representatives as well as employees of
PMJ were invited. The move from the previous rented property into the new premises situated in its own grounds was not merely
for capacity reasons. As the parent company, PM AG would also like to use this investment to underline its desire to further
develop the market position of its Japanese subsidiary company.
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A part of the PMJ team in front of their new building. Alongside them is the
Putzmeister truck-mounted concrete pump M 20-4, which is particularly successful in
Japan, and a high pressure water cleaner from the DYNAJET series.
In keeping with Japanese tradition, the
drummer wishes PMJ's new building
luck for the future
Germany to Japan and assembled on
Japanese trucks in PMJ's workshop by its
own personnel. Generally speaking these
vehicles usually come from Nissan.
Japan is considered throughout the world as
one of the countries with the widest range of
tunnel construction activities. This is why
PM also places such significant importance
on contact with Japanese tunnel constructors. This includes consultation, sales and
customer service during the entire operating time of the machines. This also applies
to the shotcrete manipulators from the SikaPutzmeister alliance.
The new Putzmeister location is situated in
the city of Togane in the Chiba Prefecture,
approx. 50 km east of Tokyo. The positive
investment climate here is not the only
aspect PMJ has discovered. The area also
has outstanding transportation links to the
transatlantic harbours in Tokyo Bay. PMJ's
new factory premises comprise an area of
approx. 18,000 m2, of which approximately
900 m2 is designated as office space. An
area in excess of 1,800 m2 has been adopted
for the service and production area.
Putzmeister Japan currently has approx. 30
employees. In the new building, which has
been designed for expansion, there is already space for around 60 workstations.
In principle PMJ's sales programme comprises all Putzmeister products except for the
systems engineering sector (the PM subsidiary RASA is responsible for this). The
sales emphasis is traditionally on the truckmounted concrete pumps with boom models
M 20-4, M 28-4 and M 36-4. However, after
conducting extensive special tests,
Putzmeister Japan has also brought larger
machines, such as the M 52-5, into the
country. In the meantime the machines are
being delivered as so-called X-units (i.e.
complete, but without chassis) from
Course of the pressure water tunnel at the Kops II pumped storage power station (fig.: Vorarlberger Illwerke)
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Japanese PM subsidiary
on its own premises
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PMJ has spent the past few years developing
a close dealer network in order to maintain
as short a route as possible to their Japanese
customers. Several well-equipped service
stations are also developing in the country.
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Representatives of the Chiba Prefecture with Dr. Ralf von Baer (centre), managing director
of Putzmeister Holding, and Felix Selinger (left), managing director of Putzmeister Ibérica
and director of the international company PM Underground Construction (PUC)
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PM in Focus
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BAUMA review:
The best atmosphere
and some great orders
BAUMA 2007 closed its gates at the end of April accompanied by the honking of
thousands of construction machines. With over 3,000 exhibitors and more than
500,000 visitors, it was a resounding success for the organisers of the Munich
International fair. The Putzmeister sales department were also pleased with the
results over the seven days of the fair.
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Putzmeister were once again able to present
numerous innovations on several stands at
BAUMA. The innovations presented not only
concerned actual mechanical engineering,
but also its associated areas. This included,
for example, the flexible variant of the
space-saving support (EFS) for truck-mounted concrete pumps, a wide range of additional information on the graphic display of
the new radio remote controls, the fleet
management feature supported by the
Internet and GPRS and much much more. A
focal point of attention was the “Follow Me”
control system, which enables the entire
concrete boom to be guided by merely manipulating the end hose by hand. The new
design of the three BSA stationary pumps
also proved to be a real "eye-catcher".
Particularly vigilant PM dealers had already
reserved these pumps for their customers
before BAUMA opened its doors.
Shortly after the opening of the fair, the
Federal Minister for Economic Affairs,
Michael Glos, paid a visit to the Putzmeister
BAUMA stand. Company founder and chairman of the supervisory board, Karl Schlecht,
and Dr. Mehmed Varlik, board member for
technology, welcomed the guest from Berlin
and explained the technology behind
individual exhibits. Federal Minister for
Economic Affairs Glos was not the only
prominent politician to visit the PM stand.
Other foreign ministers, or their deputies,
visited Hall B6, with some wearing jeans
(who for the most part were not publicly
recognised) and others with their official
companions.
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Many visitors not only expressed appreciation regarding the exhibits, but also commented favourably on the image and overall
appearance of Putzmeister during BAUMA.
"You got the stand absolutely right again,"
read one of these typical comments from the
visitors. The "Arabian Lounge" was also
relocated to the PM pavilion, which handed
out Arabian sweets, in addition to its traditionally prepared coffee and mocha coffee.
Putzmeister wanted to pay tribute to this
gesture by the Arabian Peninsula (which is
the partner region of the Munich fair this
year). The visitors (and not only those from
the Near and Middle East) obviously appreciated it.
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PM in Focus
On site
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New concrete pumping
record at the Burj Dubai
On 13 May 2007 at 9.30 pm the 125th floor (level 126) of the Burj Dubai was concreted.
With the three Putzmeister high performance concrete pumps set up below the ground
floor (level 0) (-0.075 m), the upper height was found to be 452.025 m. This meant a new
record in high-rise concrete pumping using vertical risers for the UNIMIX team that had
been assigned the task of pumping the concrete. This height breaks the previous record
in "high-rise concrete pumping" of 448 m set at Taipeh 101 Tower in 2003.
The highest concrete pumping height ever
recorded of 532 m is still untouched.
This world record was set in 1994 by a BSA
2100 HE stationary Putzmeister concrete
pump when a lightly inclined water pressure pipe measuring approximately 790 m in
length was backfilled. The concrete pump
BSA 2100 HE used at that time is the "fore-
father" of the BSA 14000 S-HPD highperformance concrete pumps used at the
Burj Dubai. According to planning, they will
set a milestone in high-rise concrete pumping by the end of September 2007 with a
pumping height of approx. 570 m through a
vertical riser.
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BAUMA Innovation Prize
Putzmeister had every reason to celebrate a
day before the opening of the fair. This was
due to the accolade and award of two
BAUMA innovation prizes that were awarded by the VDMA. PM won the prize for the
development of the “damped end hose” (SH
hose) in the "safety" category. The new SH
hose means that the risk of injury associated with concrete pumps caused by the end
hose overshooting (e.g. when air is trapped)
can be clearly reduced. Putzmeister received another VDMA accolade for its involvement in the field of high-rise concrete pumping at the Burj Dubai. The jury assessed not
only the development of particularly efficient concrete pumps as exemplary but also
the elaboration of the numerous detailed
solutions for the guidance and securing of
delivery lines, as well as the all-round support provided on the construction site.
The Putzmeister Group's five exhibition
stands were dismantled by the dismantling
crew a few days after the end of BAUMA and
all of the displayed machines were transferred back to the works. Each one was
rechecked, reworked if necessary and only
then released for delivery. Putzmeister
"state of the art" technology can be found
with immediate effect on construction sites
at home and abroad.
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Putzmeister also received a BAUMA Innovation Prize for its involvement in the field of
extreme high-rise concrete pumping at the Burj Dubai. And the pumps operate without malfunction or failure. Here, Sheikh Khalid Mohd S.Baklit, proprietor of Unimix,
expresses his thanks to Karl Schlecht, chairman of the supervisory board of
Putzmeister AG, for its exemplary cooperation and presents him with a model of the
Burj Dubai. Next to the Unimix service manager, J.P.Santosh, is the managing director
of Putzmeister Holding, Dr. Ralf von Baer, and Dr. Hinrich Mählmann, Chairman of the
Board of Putzmeister.
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Everyone here (and a few more besides) have helped to ensure that everything runs smoothly in the world's most spectacular
high-rise construction project
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On site
On site
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Container terminal almost
1,700m long concreted seamlessly
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Systematic diagram of the quay with bracing and installed container bridge. The
working area of the truck-mounted concrete pumps M 42-5 and M 52-5 can be
seen clearly.
No branch of industry in the state of Bremen is currently expanding as quickly as the port and logistics sector. The reason for this
is predominantly the extremely dynamic development of container handling. The construction of the new Container Terminal 4
(CT 4) with an additional dock measuring almost 1,700 m in Bremerhaven has created optimum conditions for strong, continued
growth. This requires the creation of enormous concrete components.
Container ship
Replacement pump not needed
for 1 1/2 years
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The base, wall and roof of the solid wave
chamber are some of the areas concreted.
An element associated with this chamber is
the development of heavy-duty girders to
support the tracks of the container bridges
for unloading cargo, which are supported by
hundreds of concrete piles. The concrete
purchase order for CT 4 has been acquired
by Transportbeton Bremerhaven GmbH &
Co. KG, a subsidiary of CEMEX (Deutschland). Pumping the total volume of concrete
of approx. 60,000 m3 is being undertaken
by the pumping service Betonlift of
Neuland Beton H. Burgis KG (GmbH & Co.).
Putzmeister BSF 52-5.20 H and BSF 42-5.16
truck-mounted concrete pumps are being
predominantly used in this project. The consortium manager, Michael Max, states: "The
machines have been in continuous use here
over the past 1 1/2 years during wind and
all types of weather. In anticipation of a
pump loss we have asked the Neuland concrete pumping service to always keep a
third machine in reserve on the construction site. However, we have never needed it!"
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By using flexible "quintuplet" booms
and their practical reach, the betonlift
BSF 42-5.16 H and BSF 52-5.20 H are
used to concrete the 1,681 m long wave
chamber at the new Container Terminal
4 at Bremerhaven.
The new Container Terminal 4 with a surface area covering 90 hectares and a 1,681 m
long dock joins the existing Bremerhaven
quay in the north and runs parallel to the
Weser waterway. The port management
company "bremenports" assigned the construction of CT 4 to a consortium of Bilfinger
Berger, Hochtief Construction AG, Gustav
W.Rogge and Strabag. Work on the 500 million € project began in November 2004 with
the ramming of the bulkheads and is likely
to be finished by the middle of 2008.
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The base measuring almost 1 m thick is
constructed in 24 sections, each with a
length of 70 m. Approx. 16 hours has
been calculated for the placement of
each section of the 1,500 m3 of concrete.
The betonlift machine operators always have the placement sites in view. A sensitive
radio remote control is advantageous if the end hose needs to be threaded through
the narrow reinforcement.
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As the riverside quay, i.e. at the Outer
Weser, replaces the sea wall with its container bridges, particularly high demands are
made on the construction and the concrete
for the wave chamber. The new 1,681 m
long mooring area for large ships is therefore to be created as a uniform constructional element without expansion joints. This
is the only way to prevent seawater from
penetrating into the concrete. A special concrete formulation with low heat development has been created based on a scientific
report. This concrete has a strength of
C 30/37 and consists of blast-furnace
cement CEM III/A 42.5 N (270 kg/m3), fly
ash (60 kg/m3) and broken aggregate of
0/32 mm or 0/16 mm in the floor area.
The photographs illustrated here were taken
when concreting the almost 1 m thick and
20 m wide base of the wave chamber. It is
constructed in 24 sections, with each measuring 70 m in length and requiring around
1,500 m3 of concrete per piece. The wall and
roof are also manufactured in 24 sections,
each requiring 250 m3 or 750 m3 of concrete
respectively pumped by the Neuland machines. It has been calculated that each construction section requires 16 hours of concreting time for the base, nine hours for the
wall and approx. twelve hours for the roof.
At its rear, the quay wall is filled with
approx. 10 million m3 of sand, which is to
subsequently support the load-bearing
terminal surface.
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On site
On site
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PUMI® at track construction works
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Bremerhaven
HAMBURG
Wilhelmshaven
The "bremenports" constructor
flies its flag at CT 4
Oldenburg
BREMEN
Well prepared for container competition
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Sea cargo handling, transport and logistics
are among the economic strengths of the
German North Sea Coast. In the two-city
state of Bremen and Bremerhaven more than
80,000 jobs depend on smooth-running harbour operations. With an annual turnover of
4.4 million TEU boxes ("Twenty-foot
Equivalent Unit" – one of several internationally standardised container dimensions) the
modern harbour facilities in Bremerhaven
are among the most efficient in Europe. And
this growth seems set to continue.
For most of its journey, the track runs directly alongside the heavily trafficked main
street of Riegelsberg. During our visit,
approximately 30 m of the rail bed's superstructure was placed with 20 m3 of fine concrete (C30/37, grain 0/16 mm). This work
was undertaken using a PUMI® 24-3.67 CS
from Cemex Deutschland AG (Saar-Mosel
region). Due to the low degree of support
(4.0 m in the front, 2.3 m in the rear) and
the construction site reach of the 24 metre
boom, the Putzmeister truck mixer concrete
pump was preferred for deployment.
The revitalised metropolitan railway connection is a public transport system on a
"European level", because after completion
it will run from Riegelsberg via Forbach in
France to Sarreguemines. The first electrical
trains were being operated on a section of
the track 100 years ago by the Saarbruecken train company. They contributed
significantly to connecting the remote
mining villages and coal pits, which were
blossoming at that time, to Saarbruecken,
the economic centre of the region.
Apart from the expansion of capacity in the
container port, investment is also being
made in the development of storage spaces.
After completion, the 3,000,000 m3 area will
provide around 50 % more space in the
Bremerhaven terminal for the turnover and
storage of containers.
A fine concrete with a higher degree of rigidity is used for the superstructure of the
track bed. Covers protect the rails that have already been laid from concrete splashes.
Up to the end of 2006, the 3,237 m long container quay offered ten mooring areas for
large container ships on the Weser. After
the expansion of Container Terminal IIIa
was completed, a further 340 m of mooring
area was made available. With the construction of Container Terminal 4, measuring
almost 1,700 m in length, enough mooring
space will be made available for an additional four large container ships. According to
its own data this means that the port
management company "bremenports" will
be operating the longest quay in the world
from 2008. Investments have also been
made in a 600 m wide extended turning
area in front of the container terminal. In
addition to this, the deepening of the Outer
Weser waterway is also planned for the near
future, which means that Bremerhaven will
be enhancing its location even further.
Experts estimate the creation of more than
10,000 new jobs for the city state and the
region by 2020.
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The metropolitan railway connection to
Saarbruecken that has been planned for
decades in Riegelsberg in the Saarland is
currently being constructed. Due to the
extremely restricted space conditions
only a very narrow supporting concrete
pump can be used for the concreting
work on the track bed.
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With such active traffic it is not feasible to block the road with concrete pumps as well.
The solution: the narrow supporting PUMI® is more than enough for the route of the new metropolitan railway.
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On site
On site
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40
Strong models in the Schmücke tunnel
Up to four shotcrete machines from the Sika-Putzmeister alliance have been used by
the Schmücke tunnel consortium for 14 months to safeguard the tunnel excavation
work. The section lengths vary substantially due to the very different geological conditions present. In the meantime four stationary PM pumps have begun to concrete
the inner shell using cast in place concrete.
The two 1,720 m and 1,729 m long tunnels
are part of the new construction section of
the A 71 motorway between Erfurt and
Sangerhausen. In total, the section is 7.5 km
long and is being constructed by a consortium consisting of building contractors
Baresel AG, Herman Kirchner Hoch- und
Ingenieurbau GmbH and Alfred Kunz
Untertagebau GmbH. The construction costs
for the project are approximately 100 million €.
Four shotcrete machines
speed up construction
The prevailing ground conditions mean that
a full outbreak would not have been controllable for a tunnel excavation between 105
and 147 m3. The consortium therefore decided to excavate the east and west tunnel
using separate crown/side wall blasting and
crown/side wall/base blasting drive
methods respectively. As the tunnelling
South entrance of the Schmücke tunnel
This Sika®-PM500 is occasionally used for work on the base shortly before conclusion
of the shotcrete process in the Schmücke tunnel
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39
One of the few wear parts on the SikaPM shotcrete spraying manipulators is
the spray nozzle. This can be replaced
within a few minutes.
Water level lowered with 35 wells
"Moving mountains!"
The Schmücke mountain has considerable
water resources. The ground at the central
area of the two tunnels was so saturated
with water that excavation with the chosen
drive method would not have been possible.
Therefore a gallery consisting of 35 wells
had to be sunk in a depression on the rear of
the Schmücke at depths up to 90 m for
drainage purposes. When work is completed
the wells will be restored to their previous
state so that natural groundwater conditions
can be reproduced in the Schmücke mountain.
Of course this enormous demand also subjects the six shotcrete machines to natural
wear, e.g. of the spray nozzles. Downtime,
however, was reduced to a minimum because
two of the six shotcrete manipulators were
kept available as reserves during the service intervals. Foreman Rüdiger Appel stated:
"After experiencing coordination problems
at the start, cooperation between the construction site and machine manufacturer
has run very efficiently. If we now need
parts for one of our Sika®-PM500 machines
urgently, the order is placed via the
Putzmeister branch in Gera that's not far
away. And the lads there move mountains
for us!“
Up to 30 cm thick shotcrete shell
work in both tunnels progressed simultaneously from the north and south side, the
consortium used four independently operating Sika®-PM500 shotcrete machines for
the concrete spraying work. Two additional,
identically constructed spraying machines
were on standby over the period.
The consortium has been well on schedule
since the tunnel operation started in
December 2005. At the end of November
2006 the semicircular crown profile had
already been completely excavated in both
tunnels. Different section lengths between
0.8 to 2.0 m were necessary for the headwork as a result of the strongly fluctuating
load bearing behaviour of the surrounding
mountains. For safety reasons a total of five
emergency galleries, which run in parallel
at a distance of 20 m, connect the two tunnels.
Using a Sika®-PM500 to secure the side wall drive with shotcrete
18
As soon as the first cross heading was
reached after 140 m in the crown drive, the
consortium began the side wall and base
drives. The cut sections also varied significantly from each other here, with lengths
ranging between 2.0 and 12.6 m as a result
of geological conditions (including shell
limestone and various types of mottled
sandstone). After an initial application of
shotcrete to stabilise the rock, a second
application of shotcrete shell is applied as a
sealant carrier. Due to the very smooth surface (80 % of the aggregate granulation
measures up to 4 mm, 20 % up to 8 mm) the
shotcrete shell can be lined directly with
fleece and plastic sealing sheeting. On average, the wall thickness of the outer shell is
between 20 and 30 cm. Approximately
75,000 m3 of shotcrete is required altogether
for the two tunnels and the four entrances of
the Schmücke tunnel.
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Foreman Rüdiger Appel
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On site
Practical tip
46
Caution: High voltage!
Four BSA pumps
concrete the inner shell
Before the turn of the year from 2006/07,
the placement of concrete began on the
north and south side of the Schmücke tunnel for the base and the arch in the inner
formwork. When doing this, the consortium
used formwork carriages and up to four
stationary Putzmeister concrete pumps (two
BSA 1408 E pumps as well as a BSA 1405 E
and BSA 1005 E pump).
Before concreting the arch, a section of the
base measuring around 60 m in length had
to be concreted initially to support the arch
formwork carriage. The BSA pumps follow
directly behind the formwork carriages and
are pulled along section by section. The
delivery lines are deliberately kept short
here (max. 10 m). The respective 12 m long
inner shell blocks made from cast-in-place
concrete (C30/37) are constructed in thicknesses ranging from 0.4 to 0.6 m. The time
which the concreting crew requires for placing approx. 135 m3 of concrete for each arch
section is around 5 1/2 hours and they
require around 3 to 3 1/2 hours to place the
approx. 75 m3 of concrete for the base sections. By varying the proportion of cement,
the consortium reached an optimum relationship between processability and hardening temperature. The aim is to concrete one
base and one arch block per day, per tunnel
section. This requires striking times of less
than twelve hours in the arch.
Each of the tunnels is concreted in 144
blocks and each block is approved by the
site management. The total requirement of
concrete for the inner shell is approx.
65,000 m3.
Extreme caution is required when working in close proximity to power cables. This
particularly applies when manoeuvring the booms of truck-mounted concrete pumps
close to high-voltage lines.
The minimum distance to be maintained can
be larger or smaller depending on the rated
voltage (volts) of the line. The following
table from the VDMA safety manual provides an overview of the necessary minimum
distance in relation to the rated voltage of
the power cables.
47
It should be noted that the distance to the
machine can change as a result of swinging
lines (e.g. due to gusts of wind). Larger
minimum distances are also necessary
during periods of high air humidity.
It should also be pointed out that the
machines have to be grounded as well. This
can be done by connecting the grounding
cable to a bare metal surface of the concrete
pump (preferably close to the boom pedestal) and a conductive metal bar, which is
driven at least 1.5 m into the ground. The
correct diameter of the grounding cable of at
least 16 mm2 is important in this regard. If
this is not always possible for whatever reason, it is recommended to forego the use of
the boom and pump the concrete instead via
hose lines laid on the ground.
Caution also required near transmitter
masts
The cable length is kept as short as possible – the Putzmeister BSA 1408 is therefore
directly in front of the formwork carriage
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The Schmücke tunnel consortium procures
both the shotcrete and the cast-in-place concrete from several mixing works in the
region.
Work is usually conducted in two 12 hour
shifts, seven days a week. This is the only
way the schedule can be met. The headwork
was concluded in May 2007 and the inner
shell is estimated to have been concreted by
the end of 2007.
45
The formwork carriage pulls along four
sealing carriages, which are used to prevent the four blocks that have been concreted most recently from cooling too
quickly
48
When working in this environment, there is
danger to life for all persons who are in a
position close to the truck-mounted concrete
pump or connected with it directly or indirectly, e.g. via the end hose, cable or remote
control. Even when approaching a high-voltage line an electric arc can jump and subject
the machine and the surrounding area to a
voltage. The discharge voltage pattern that
forms around machines is referred to in
VDMA's safety manual, StBG's code of
practice and by the Industrial Employers’
Liability Insurance Association for Construction as well as in the operating
instructions for Putzmeister's concrete
pumps.
It is also advisable to pay attention when
concreting in close proximity to transmitter
masts and mobile radio transponders. The
electrical and magnetic fields emitted by
these systems are not a direct danger to site
personnel, the machine operator or the concrete pump. However radiation into the
machine can indirectly result in malfunctions and dropouts during radio remote control.
Not like this!
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44-1
This has got to be fun! One of the construction site service cars with horned
helmet and highly effective aerial for
radio reception in the Schmücke tunnel
B e f o r e concreting in the area of currentcarrying overhead lines or in close proximity to overhead railway lines, it is imperative
that the relevant electrical works or the
authority responsible for the railway is
informed respectively. Even if this is actually the task of the site management, the
pump operator should inquire again in the
interest of safety. Only by doing so will he
receive reliable information concerning the
line voltage. The railway workers can then
also take charge of grounding the overhead
line or they can disconnect the network.
Rated voltage
up to 1 kV
1 kV to 110 kV
110 kV to 220 kV
220 kV to 380 kV
Unknown
rated voltage
Safe clearance
1.0 m
3.0 m
4.0 m
5.0 m
5.0 m
The reinforcements have been set for this block – the formwork carriage can now enter!
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Technology
Technology
Electronic wizards
New EBC software for new booms
One of the attractions at the PM BAUMA stand was the new M 58-5 RZ long-reach boom pump. The machine was ready for its first
deployment during the fair, yet after BAUMA closed its doors it had still not been delivered to the customer. The reason for this is
that the truck-mounted concrete pump should be able to be operated with the EBC controller and also be able to be guided with
the new "Follow Me" system on the end hose. As this means a complete redevelopment for the M 58-5 RZ, an extensive piece of
software has to be developed or adapted for the computer-aided functions. A reason for us to have a look over the PM wizards'
shoulders.
50
The EBC system (Ergonic® Boom Control)
was introduced around six years ago and
has since been utilised in hundreds of PM
truck-mounted concrete pumps. Among
other things, it enables the boom to be controlled with just a joystick, actively absorbs
inadvertent movements of the placing boom
and it can be adapted to construction site
conditions (e.g. by limiting the work space).
Other Ergonic® components are also based
on the EBC software, e.g. the flexible support system (EFS) and even the "Follow Me"
system. Only the concrete booms of PM
truck-mounted concrete pumps have been
equipped with EBC up to now, however stationary booms have also been provided with
EBC since the BAUMA fair.
In principle, when EBC is installed in boom
prototypes, either a completely new computer programme must be developed or the existing programme has to be modified with
similar boom folding. In the new M 58-5 RZ,
for example, the software is based on the
"folding-technology" of its relative, the
M 46-5 RZ. The development of software
and control is implemented by the
Putzmeister TSR-DM specialists (technology,
control and regulation – digital and measuring technology). In addition to this, they
frequently cooperate with universities in
research projects, the results of which are
only used years later.
Before the new EBC software is installed via
the diagnostics interface on the control
cabinet, extensive tests are carried out in
different boom positions. Doing this ensures
exact parameterisation. In a "quintuplet"
system like the new M 58, the EBC programme has around 100,000 processor instructions as well as approx. 250 setting parameters that have to be checked. Among
other features the damping functions are
adapted, the collision protection feature for
the individual arms is implemented and the
semi-automated folding and unfolding procedures are programmed. The correct valve
characteristics are also determined in this
way. When the setting phase has been concluded, the truck-mounted concrete pump
enters its first phase of deployment, where
all functions are re-examined under real
conditions.
Once these tests have been conducted,
Putzmeister then possesses the basis software and the basis data sets. After approval,
they are sent to PM's main assembly site in
Aichtal. Here, just three parameters per
boom arm (i.e. 15 settings for a "quintuplet"
model) have to be implemented later for the
series machines.
during their initial start-up phases. The
specialists from TSR-DM additionally compile the extensive documentation for
Putzmeister manufacturing processes and
PM customer service. Beside EBC, the development of other technological highlights,
such as the electronically regulated pump
controller (EPS) with graphic display (EGD),
the Teleservice (ETS), the new web-based
generation of DAISY (PM DAta Information
SYstem) as well as the computer-aided test
stands used at PM in Aichtal, in Spain and
shortly also in the USA can be traced back
to the PM engineers and computer scientists
from Hesse.
A small team with a big impact
52
The TSR-DM development team is based at
the Putzmeister site of Gründau near
Frankfurt. Boom manufacturing is conducted here in modern, extensive workshops,
and the Frankfurt branch of PM is also
based here. In these works, the 7-man team
around Kurt Rau not only develops the
system concept for computer-aided controllers, but also the necessary software. They
also accompany the EBC boom prototypes
View from the test stand of the EBC "test candidates" M 58-5 RZ
A look at the monitor:
optimisation of the position regulator
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51
The new long-reach boom pump
M 58-5 is now ready for use
on the construction site
Several software modules are altered
here
54
The EBC software is also installed via the
diagnostics interface on the concrete
pump's switchgear cabinet
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Putzmeister AG, Max-Eyth-Str. 10, D-72631 Aichtal
PSdg, Deutsche Post AG, Entgelt bezahlt, E 60458
Competition
Wanted: Putzmeister
Story(ies)
55
Send us your nicest Putzmeister photo
or most interesting documents and
experiences!
Do you know of an old Putzmeister machine
that's still running? Do you have any old
photos of Putzmeister machines in use? Or
do you have any other material on
Putzmeister in the early years? Then send it
to us or give us a hot lead!
The nicest, most creative, most impressive,
most unusual, funniest and most interesting
entries will win a prize and be published in
the Putzmeister Post and on the Internet.
We will gladly help you taking photographs.
56
57
This hydraulically controlled PM concrete pump (year of construction 1972)
is on permanent loan in the Auto & Technik museum in Sinsheim
1st – 3rd Prize
the original Putzmeister wristwatch
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Send all of your documents by post to:
Putzmeister AG
Anja Steimle
Max-Eyth-Str. 10
72631 Aichtal / Germany
Or by e-mail to: [email protected]
We look forward to receiving your entries.
The closing date for entries is 31/08/2007.
By sending your documents you declare
your consent for unrestricted use and storage by Putzmeister AG. No liability for any
loss or damage is assumed. There is no
right of appeal.
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 · © 2007 by Putzmeister AG · Printed in Germany (3.50706RR)
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