- Putzmeister

The Magazine for our Customers and Friends
63
PM 3675 GB
Contents
Latest News
2
Latest News
3
EU standard
requires cleaner
diesel engines
6
EU standard requires cleaner
diesel engines
High-pressure concrete pump on
the Trump Tower
While it was still possible to maintain the
Euro 3 limit values by means of internal
engine measures, on modern trucks the
requirement according to Euro 4 and Euro 5
can no longer be achieved by further optimization of the combustion system. An
additional after-treatment of the exhaust
gases is required to reduce emissions to
below the limit values that will apply in
the future.
Title Stor y
4
6
M 6X-6 in a holiday paradise
Super: 63 metre boom combined with
an extremely quiet-running pump unit
Engineering
8
11
M 42
also available as a ”quintuplet“
3
5
18
10
How can you work safely with a long
end hose?
Applications
10
14
15
Automated concrete placement in a
precasting plant
Powerful pump unit for stiff concrete
”Hallenmeister“ shows its strengths
under a roof
6
12
Plant Construction
12
Numerous underwater drilled-in caissons
for the 2nd Strelasund crossing
Ba c k g ro u n d
18
19
16
Burj Dubai: the walls of the lower storeys
are completed
Information
20
2
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Reader survey with a pleasant result
7
4
Pioneering in the desert
Highrise
Four years before the statutory standard
comes into force, IVECO will follow
MERCEDES-BENZ and be putting diesel
engines on the market as of September 2005
that meet the strict exhaust gas regulations
according to Euro 5. These clean diesel
engines will be offered first of all in
Austria, Switzerland and Germany for
several models in the MB Actros series and
in the heavy Stralis series from IVECO.
Like other truck manufacturers, both these
companies will be using a new generation
of engine control devices and the so-called
SCR technology (Selective Catalytic Reduction). This means after-treatment of the
exhaust by a catalytic converter with the
admixture of a non-toxic agent, so-called
AdBlue (carbamide dissolved in water).
AdBlue is carried by the truck in a separate
tank and is injected into the exhaust pipe
before the catalytic converter.
The SCR technology is an optimized combustion process in the engine itself and a
targeted after-treatment of the exhaust gas.
By this method the NOx values (nitrogen
oxides) allowed in compliance with EU
exhaust standards Euro 4 and Euro 5 can
be considerably reduced and the particulate
values of the exhaust gas can be drastically
lowered.
Solid temporary storage facility for the
nuclear power plant Biblis
Bridge Construction
16
High-pressure
concrete
pump on the
Trump Tower
PUMI® adapted to the British market
Practical Tip
9
8
19
A lower fuel consumption of the vehicles
results on account of the higher degree of
efficiency of the engines. In the case of the
V8 engines in the Actros series a savings
potential of approx. 5 % is expected. This
is offset by the additional costs for the
AdBlue additive, which MERCEDESBENZ claims to be 4 to 6 % of the diesel
consumption.
(Photomontage: SKIDMORE, OWINGS & MERILL)
When the 415 m high ”Trump International
Hotel & Tower“ is complete Chicago will
have another tower block, the upper storeys
of which – depending on the weather – will
penetrate the clouds. Like Burj Dubai, soon
to be the highest building in the world, the
Trump Tower was also designed by the
tower block specialists SKIDMORE,
OWINGS & MERILL. Completion of the
92-storey tower block is envisaged for 2008.
The construction company McHUGH
CONSTRUCTION based in Chicago has
been awarded the contract for the complete
”concrete package“ (production, supply,
pumps and distribution). Concrete delivery
will be performed by a version of the
Putzmeister BSA 14.000, which is currently the strongest pump available. This
stationary concrete pump is driven by a
6-cylinder CATERPILLAR diesel with
470 kW (639 HP), which operates on the
ground and achieves a concrete pressure
of 250 bar. At the same time a delivery
output of 36 m3/h is possible (all values
max. theor.).
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Title Stor y
M 6X-6 in a holiday paradise
If you think there are already enough
crete elements in a grid structure. Only the
cavities between the individual elements
and the wall formwork are therefore
concreted out. Because of the narrow construction roads the long-reach boom pump
is safely supported in OSS mode – narrow
on one side.
hotels and apartments on the Spanish
Mediterranean coast, you are mistaken.
Putzmeister truck-mounted concrete
pumps with vertical reaches of over
60 m and flexible 6-arm technology are
being used increasingly for the construct-
A convincing working radius
ion of more holiday facilities.
The demand of holidaymakers for accommodation near to the beach is unrelenting.
Work therefore continues at high pressure
on the completion of new, spacious holiday
homes across a wide range of price categories. An ideal terrain for the Putzmeister
M 6X-6 long-reach boom concrete pump.
This is the flagship of the BEDMAR fleet
of concrete pumps, which covers an enormous working radius from one location with
its highly flexible concrete placing boom.
The radius of over 57 m that the M 6X-6
reaches from one location is considerable.
Not only this gross value but also the lateral
reach that is actually available after deduction of the support width and the safety
distance from the construction pit (in this
case about 12 m) is in a class of its own.
As building progress advances the M 6X-6
long-reach boom will also fully utilize its
impressive working radius in height, bearing in mind that the typical building height
in Marina d’Or is about 33 m (10 storeys).
Our photo shows one of the extensive areas
of Marina d’Or in the Castellón region
shortly after the commencement of construction work on the carcass. For months
these beach-near holiday domiciles have
been heavily advertised for purchase all
over Spain on the TV, radio, in newspaper
advertisements and on large-sized posters.
This holiday complex, which is located
right on the Mediterranean coast, consists
of dozens of apartment tower blocks which
are arranged parallel to the sandy beach in
chess board style. Work is currently being
performed on one of the floor slabs, which,
like the ceilings, consists of precast con-
The long-reach boom pump is stationed at
the BEDMAR depot in Castellón, work
being performed within a radius of about
400 km. In the opinion of the operator
Rubens Sanz Bachero the M 6X-6 drives
on the road like an M 52. A little more
circumspection is required only when
marshalling and setting-up on the construction site. According to the pump
driver Rubens also the changeover from
”quintuplet“ to ”sextuplet“ on the radio
remote control is also not difficult. He does
not have a good word to say about longarmed ”quadruplets“ in the long-reach
boom class: ”Truck-mounted concrete
10
pumps with placing boom lengths of over
50 m and only four arm segments are absolute nonsense on Spanish construction
sites. Whoever develops such a technique,
is a theorist and has absolutely no idea
about practice. In my opinion it would be a
good thing, if Putzmeister were to offer the
M 6X with seven boom arms!“ Operator
Rubens is still looking for the right name
for his ”sextuplet“. Up till now he has been
managing with provisional nicknames like
la mole (”the Giant“) or la peregrina (”the
Wanderer“) .
Construction rage on the Spanish
Mediterranean coast just goes on and on.
In the immediate neighbourhood of Marina
d’Or the 1.2 million square metre segment
Torre la Sal is currently being stamped out
of the ground. Numerous detached houses,
terraced houses and another 6,600 apartment flats are to be erected here. The
11
method of construction is comparable with
that in Marina d’Or. Efficient truck-mounted concrete pumps with flexible boom
technology and a long reach are needed
there as well.
The photos and the short report on the
following double page show you how the
5-arm version of the M 6X long-reach
boom pump can be used for concreting
large floors.
The ”ideal“: flexible boom with variable support
In a conversation with PM Post’s editorial staff back in March 2003 Eusebio
Martinez, founder of the BEDMAR
concrete pumping service, sketched out
his idea of the optimum long-reach
boom pump, ”For me versatile placing
booms on large truck-mounted concrete
pumps are simply a must. Plus a variable
support system that adapts itself to the
local conditions on construction sites –
that’s the long-reach boom pump for
us!“ (Compare PM Post issue 53, p. 8).
9
Operating the BEDMAR flagship:
Rubens Sanz Bachero
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Title Stor y
14
Super: 63 metre boom combined with an
extremely quiet-running pump unit
The IFEMA Feria de Madrid (Madrid
Fair) extends its existing exhibition area
by two new buildings and a multistorey
car park. The large floor sections are
currently being concreted with the new
63 metre long-reach boom pump provided
by TECHNICAS BOMBEO Y GRUAS.
The exhibition grounds are located very
conveniently in the northeast of the Spanish
capital, in the immediate proximity of the
airport, and can also be reached easily on
the underground. A multistorey car park is
currently under construction as part of the
expansion of the fair, which will later provide car parking spaces for almost 2,500
cars on two levels. The total cost of the
expansion measures is estimated at approx.
1 115 million.
To start with the M 52 and M 58
truck-mounted concrete pumps from
TECHNICAS BOMBEO Y GRUAS, S.L
(TBG) have taken on the concrete emplacement work. Since July 2005 this Madridbased pumping service has been using
nothing else but its new PUTZMEISTER
BSF 63-5.16 H LS on this site. The machine
pumps and places approx. 600 m3 of
concrete daily (C30/35). The M 63 longreach boom, designed as a ”quintuplet“,
operates from just one location on formwork sections of 60 m x 55 m. Conversion
of the truck-mounted concrete pump and
connection of a rotary distributor swung by
hand are no longer necessary. Altogether,
about 25,000 m3 of concrete will be pumped into the car park.
15
Ingo Melzer, a shareholder of TECHNICAS
BOMBEO Y GRUAS speaks about the
typical construction sites for his M 63-5:
”Many buildings are built with eight to ten
floors here in Spain. Until now we have
been using our M 52 together with a concrete round distributor on these construction sites. Since we have had the M 63 in
the fleet, this equipment combination is
superfluous.“ He also mentioned the ”icing
on the cake“ that makes his flagship something special: ”My M 63 is equipped with
the pump unit, ’16 H LS’, which has a
delivery cylinder diameter of 250 mm and
a piston stroke of 2,100 mm. I consider this
to be a successful compromise between the
’16 H’ version and the ’20 H’ pump. At an
output of what is after all 100 m3/h I have
only 16 switchover procedures on the
transfer tube. Even at a pumping rate of
160 m3/h – i.e. on full load – with 26
switchovers per minute the machine is
still astonishingly quiet!“
T.B.G. pump driver Norbert Weyh actually wanted to
give his Spanish colleagues support for just three
months. Meanwhile, he has been here for almost five
years. He likes the country, the people and his longreach boom pump.
Quiet concrete delivery on full flow:
The ”16 H LS“ unit needs just 26 switchovers per
minute at a pumping rate of 160 m3/h.
12
13
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Engineering
Practical Tip
PUMI® adapted to
the British market
How can you work safely with
a long end hose?
Many years of intensive work were necessary before we succeeded in launching
A longer end tube than the one supplied
our truck-mounted mixer concrete pumps
as standard can be advantageous, e.g.
on the English market. The first PUMI®’s
when concreting deep formwork or when
placing concrete under water. In both
were then sold in 2003. By the middle of
16
2005 18 of these machines were then
already licensed in Great Britain, the last
but the concrete level must be built up
three with rotor pump systems. This had
from bottom to top with an immersed
been preceded by market analyses and
end hose.
adaptation of the PUMI®’s design to meet
special customer specifications and several approval regulations specific to Great
Britain.
The trend reversal that has meanwhile set
in is the result of close cooperation between the English Putzmeister subsidiary
(PMUK) and the POCHIN group, the
largest concrete pumping service in the
country. POCHIN recognized very quickly
the growth potential that the PUMI® offered.
To exploit these opportunities, POCHIN
developed a special package solution for
the manufacturers of fresh concrete. The
package covered the provision of a trained
engineer and the assumption of all
maintenance costs for servicing, fuel,
insurance etc.
17
PUMI® with a 21-metre boom and a
concrete payload of 6 m3
The requirement of the ready-mix concrete
manufacturers for a payload as big as
possible was the greatest challenge for
Putzmeister. At the same time, the machines
did of course also have to comply with
British approval regulations. Every detail
of the PUMI® was therefore analysed by
PMUK in close cooperation with POCHIN
and Putzmeister’s technicians in Aichtal to
achieve optimized adaptation.
The result is a PUMI® 21.67 Q with a rotor
pump with a hopper attached crossways to
drive direction. The pump system and hopper are arranged adjacently as individual
assemblies so that the rear overhang has
been considerably reduced. A relatively
light VOLVO FM 9 8x4 chassis serves as
the carrier vehicle, on which a weightoptimized LIEBHERR truck mixer drum
is mounted. As only comparatively little
water is needed to clean the rotor pump
system, it was also possible to reduce the
volume of the water tank. A sensible compromise had to be found between a service
life that is as long as possible and a favour-
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PM 3675 GB
cases the concrete must not drop down,
able weight for the delivery line. These
individual measures yielded a noticeable
overall weight saving. At the same time the
maximum concrete payload increased to
6 m3 (including driver, 300 l of water and
170 l of fuel) at a specific concrete weight
of 2.3 t/m3.
Consideration for older mixing plants
A mixer drum offset more to the rear is of
advantage primarily for the older concretemixing plants in Great Britain, because the
conventionally designed PUMI®s could be
loaded only with difficulty due to the short
distance between the mixer outlet and the
mixing plant’s rear wall. Filling would
have been quite impossible on some older
plants.
By the way, on construction sites the rotor
PUMI® also copes well with broken aggregate, which is encountered in many areas
of Great Britain. Time and again one is
pleasantly surprised on construction sites
that the machine delivers completely the
concrete quantity that has been ordered and
leaves practically no concrete residue for
cleaning, thanks to the rotor system.
Austin Quier, managing director of the
English PM subsidiary, sees the opportunities realistically: ”If one looks to the
future, the PUMI® still has a long way to
go in Great Britain in comparison with the
other European markets. Primarily this
concerns the concrete volume to be transported and pumped. There is, however,
considerable potential for the typical
PUMI® applications.“
Joint efforts are appreciated
While PUMI truck-mounted mixer pumps
are still relatively new in Great Britain,
POCHIN’s efforts to develop the market
are earning a lot of appreciation. For
example, the construction trade journal
CONTRACT JOURNAL awarded
POCHIN the prize ”Plant Hirer of The
Year“ in 2004.
Austin Quier: ”This is a good start and
confirms that we emphasize the interests of
our customers and the constructive cooperation with them when we are looking for
solutions.“
®
In connection with this, David Pochin,
director of the pumping service of the same
The rotor PUMI® also copes well with
broken aggregate
name, made an interesting remark: ”Development of the PUMI® project in Great
Britain was made possible by the partnership between POCHIN and Putzmeister.
And there was success in meeting exactly
the demands made by the market. The
PUMI® is not only successful in the present
concrete pump market, but it has also
pointed out new paths where, till now, concrete placement by means of a pump has
never even been considered. PUMI® has a
splendid future.“
Certain PM placing booms can therefore
also be operated with longer end hoses –
though, only if the last boom arm is put out
of operation. On the M 42-4 ”roll-and-fold
boom“, for example, end hoses of up to
12 m in length are allowed subject to this
restriction. To do so the end hose is
connected to the elbow of the ”D“ joint,
i.e. between arms 3 and 4. In connection
with this, however, further safety regulations have to be taken into account
without fail:
■ The non-used arm 4 must be shut down
and be lying on the last but one boom
arm. It must not be moved.
■ The delivery line of arm 4 must be
empty.
■ While the end hose has to be secured at
the very tip of the boom with an arrester
cable, no coupling, spout or anything
similar may be fastened to the bottom
end.
■ The overlength end hose must not be
guided by hand. It should consist of one
piece and be not put together from
several hoses. Otherwise the couplings
can get caught in the reinforcing.
are normally laid horizontally. The actual
danger area is 2-times the length of the
end hose (double the radius), i.e. as a rule
a circle 8 m in diameter (for 4 m) or 6 m
in diameter (for the 3 metre version).
Putzmeister draws particular attention to
the fact that no persons are permitted to
stay within this danger area while pumping
is being started up or during any attempt to
release a blockage.
18
Subject to compliance with the safety regulations mentioned above, a considerable
horizontal reach is also available. In the
case of the example of the M 42-4 ”rolland-fold boom“ this is after all 28.8 m.
Pump drivers who do not take this into
account – whether requested to do so by
the site supervisor or on the instruction of
their own superior – are acting negligently
and risking the lives of others. If in doubt,
please consult us.
By the way: in the area around the concrete
placing hose there is an acute danger of
injury, if the hose, independently of its
length, lashes out when pumping starts or
as a consequence of a blockage in the hose.
This concerns both the end hose of truckmounted concrete pumps, stationary concrete placing booms and delivery hoses that
are held by a crane and concrete hoses that
An extended end hose on the last non-shutdown boom
will overload the statics of the placing boom. This will
endanger the construction site personnel and is therefore expressly forbidden.
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Applications
Engineering
Automated concrete placement in a precasting plant
20
With AUTOCOR (”Automatic Concrete
Placing On Rail“) Putzmeister AG has
developed a trend-setting system for the
automated delivery and placement of con-
M 42 also available
as a ”quintuplet“
crete in precasting plants. The AUTOCOR
21
installation makes particularly sense in
In September 2005 Putzmeister will intro-
plants that process pumpable and prefer-
duce and deliver the first M 42 with a
ably self-compacting concrete for medium
5-arm folded placing boom. The small
and large-sized precast elements. If an
version in the 40 metre compact class has
expansion is planned for older plants, the
the size and the maximum amount of
AUTOCOR system can be easily retrofitted.
flexibility where it matters for truck-
Provided that there is requirement-compliant
planning, the AUTOCOR offers the precasting plant operator solid advantages
over traditional concreting with finishers,
semi-gantry distributors or bottom discharge buckets:
mounted concrete pumps – on the con-
■ constant concrete quality
■ considerably higher emplacement
performance
■ lower manpower requirements
■ constant production even with formwork
elements of different dimensions and
varying heights
■ cleanliness in the complete production
process
struction site. Above all, when little space
is available.
The Putzmeister M 42-5 supplements the
M 42-4 model, which has been extremely
successful in this market segment up to
now. The M 42-4 has been on offer since
1997 and will remain in the range. The
new ”quintuplet“ will now complete the
M 46 / M 47-5 series downwards.
Schematic diagram of the AUTOCOR in a precasting plant.
The flexible placing boom makes it possible to fill varying types of formwork.
19
Putzmeister uses tried and tested components and controls for the AUTOCOR
system. For example, the rotor pump
system that is well known from the PUMI®,
flexible placing booms with a horizontal
reach of 16 m to 28 m and a mixer drum
with a capacity of 7 m3 as temporary
storage. The complete unit is mounted on a
rail-guided working platform and needs no
support devices. There is also a control unit
which is integrated into the production process and the EBC system which has proven
its worth for many years on PM truckmounted concrete pumps. Among other
things it damps unwanted boom vibrations,
that can arise e.g. from the shifting and
rotating of the boom and, if required, it
limits the working radius of the placing
boom, so that it does not collide with any
floor beams or other obstacles in the area.
The squeeze valve on the end hose prevents the concrete
from after-dripping when the boom is swivelled. The
EBC control on the AUTOCOR also damps any unwanted boom vibrations and prevents the unintentional
touching of floor beams and pillars in the production
workshop.
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Working with AUTOCOR
A typical example of rational, automated
concrete placement in precasting plants
is the production of tower segments for
wind power systems. Due to the varying
diameter the tower segments consist either
of half-shells or of differently dimensioned
one-piece ring elements. These parts are
manufactured from pumpable standard concrete and from self-compacting concrete
(SCC). To avoid the penetration of air
during the processing of the SCC material,
when filling the differently sized formwork
units you must ensure that the concrete
level is built up from the bottom, i.e. that
the end hose is immersed deeply into the
unset filled concrete. This is ensured at all
times by the automated concrete placement
performed by the AUTOCOR system,
because in connection with the EBC control unit and additional sensors the placing
boom is raised automatically.
A monorail overhead bucket transport
system provides the AUTOCOR with concrete from the mixing plant. The material is
treated once again and homogenized with
the previous batch in the AUTOCOR mixer
drum. In addition the drum serves as a
temporary storage facility and ensures that
the AUTOCOR can operate continuously.
The concrete is delivered by a rotor pump
which Putzmeister offers in two versions
for use in precasting plants. An optional
flow rate of 60 or 80 m3/h (max. theoretical) is available. Due to the design hardly
any residual concrete arises with this pump
system. The workshop remains clean
because the concrete is transported within
a closed system (overhead bucket transport
system – mixer drum – pump – boom
delivery line – formwork). When the
machine is moved a pneumatically actuated
squeeze valve attached to the end hose
ensures that there is no concrete after-dripping during relocation.
Operating experience with AUTOCOR is
nothing but positive. According to customer information production can be increased
by up to 60 % compared with the previous
method using automated concrete placement for precast elements. Due to the
intensive treatment in the AUTOCOR
mixer drum a consistently high quality of
unset concrete is also obtained. Any later
labour-intensive reworking of the precastings, like smoothing and grinding, is
reduced to a minimum. A change in the
concrete type is also possible without
difficulty.
The 5-arm placing boom is designed as a
flexible roll-and-Z-folder so that when
concreting in building construction an
optimum of vertical and horizontal reach is
always available irrespective of the storey.
The low support width of only 7.9 m (front
and rear) is also highly suitable for construction sites. This can be reduced still
further in OSS mode (5.1 m or 5.8 m at
the rear).
Reach diagram of the new M 42-5
The comparatively short overall length of
less than 11.6 m and the low support requirement brings decisive advantages, particularly when working on narrow (inner
city) construction sites. When marshalling
or driving through narrow double bends the
short wheelbase of only 5.5 m proves to be
extremely positive. In particular concrete
pumping services whose catchment area is
in a low mountain range or in an Alpine
region will find this quintuplet to be an
interesting alternative.
22
The compact design and short boom segments are the main features of the new ”roll-and-Z-folder“
11
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Plant Construction
Plant Construction
24
Solid temporary storage facility
for the nuclear power plant Biblis
1,400 m3 of concrete in one piece
25
When we visited, the last one of the total
of four sections of the 1.5 m thick floor
slab was being concreted. The concreting
was performed by the company BRM
Concrete Pumping Service Rhine-Main
(Lorsch), which provided two of its truckmounted concrete pumps this contract.
While a 52 metre long-reach boom pump
was set up within the power plant site and
used only for placing concrete into the
ground formwork, a Putzmeister BSF
36.16 HLS took over the actual concrete
delivery outside of the nuclear power
station area. For this purpose the BRM
personnel had laid a delivery line (nominal
diameter 125) 140 m in length from the
hopper of the M 36 to the long-reach boom
pump. The pipe was laid several metres
under the soil surface so as not to activate
the security system of the nuclear power
station. The concrete was of type C30/37
with a plasticizing admixture and a grain of
0/16. Altogether, 1,400 m3 of concrete were
delivered ”wet onto wet“ within 22 hours
for this section of the floor slab.
Concreting in a nuclear power station is
always something special: a maximum
degree of reliability is expected of the
machines and engineers, compliance with
safety regulations is constantly supervised
and as a rule cameras must remain outside. We were also able to observe this
while working in Biblis nuclear power
station.
HOCHTIEF AG is erecting a new on-site
temporary storage facility for spent fuel
elements, commissioned by the power
plant operator RWE. For this purpose a
large warehouse (92 m x 38 m x 18 m) is
being erected next to the actual reactor
complex on the power station site. The
building consists of a loading area and two
portal buildings for the accommodation of
castor flasks. After completion the building
will look externally like any other ordinary
industrial portal building. However, the
temporary storage facility is an extremely
heavy construction with a 55 cm thick concrete roof and enormous 85 cm outer walls.
After completion of the building up to 152
castor flasks will be kept in the temporary
storage facility. As an annual average of
about six castor flasks are filled at the
power station Biblis it is ensured that all
fuel elements of the nuclear power station
Biblis can be accommodated for the remainder of its technical and economic
operating life.
Enormous outer walls surround the future temporary storage facility of the nuclear power station Biblis.
The concrete delivery line was laid under the soil surface from the M 36 into the nuclear power station area.
The concrete was supplied by a delivery line (nominal
diameter 125) 140 m in length with the boom raised
23
26
In nuclear power plants heat is created
by nuclear fission in a reactor which
contains fuel rods. In Biblis each block
contains 193 fuel elements with a total
of approximately 45,000 fuel rods and
about 100 tons of uranium dioxide.
The nuclear power plant Biblis comprises two pressurized water reactors
(blocks) which have been in operation
for about 30 years and together generate an electricity output of 2,500 MW
per annum. This corresponds to the
annual electricity consumption of five
million households in Germany.
The disposal concept for German
nuclear power plants provides that
waste from atomic plants must be securely enclosed for an indefinite period
in terminal storage depots. Punctual
provision of the permanent storage
depots has been promised by the
Federal Government. Until then the
spent fuel elements will be put either
into the temporary storage facilities at
Ahaus and Gorleben or taken to reprocessing plants abroad. To reduce
the number of transport journeys the
additional possibility will be created at
the request of the Federal Government
of depositing the spent fuel elements
for a limited period of time on the
terrain of the nuclear power stations.
To do so temporary storage facilities
will be erected at the nuclear power
station sites that can accommodate the
fuel elements until their storage in permanent storage depots in 30 years time
at the latest.
The Biblis site:
view of the new temporary storage facility
(All illustrations with the courtesy of RWE)
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Pumping was performed by the BSF 36.16 HSL without interruption even during the night
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Applications
Applications
27
Powerful pump unit for stiff concrete
”Hallenmeister“ shows its strengths under a roof
31
The following article, written straight
With an investment of three billion Euros
from the heart, was received by PM Post’s
the South Korean project company IREX
editorial staff. Its author is Robert Heider,
is currently having a line built for high-
who together with his father and wife
speed trains between the new Incheon
Manuela, manages the concrete pumping
International Airport and the capital
service Heider (Rossberg). He was simply
Seoul. For placement of the concrete,
really pleased to see the extreme space
which is usually very stiff, they put their
conditions in which his new Hallen-
trust in a truck-mounted concrete pump
meister, a ”quintuplet“ of the type
made by Putzmeister’s South Korean
BSF 31.16 HLS with EBC control,
company. The reason: the machine with
is able to work. Here is his report:
the ”16 H“ unit is in a position to be able
to deliver 50 m3/h even at a concrete
30
pressure of 85 bar.
After the great economic crisis in Asia in
the middle of the 1990s the Korean government decided in close coordination with
the city of Incheon, located west of Seoul,
to draw up a long-term development plan.
To achieve sustainable economic growth
for the region it was necessary to create an
attractive centre for service, research and
technical development. The prerequisite
for this was the construction of a new international airport, a site with favourable
traffic links and basic economic incentives.
The prerequisites for long-term investments
in Korea were to be created by this means.
The measures included among other things
the construction of a line for high-speed
trains.
An output of over 50 m3/h at a
concrete pressure of 85 bar
A large goods terminal is under construction in conjunction with the first stage of
construction between Incheon Airport and
Gimpo Airport. After completion it will be
used by domestic and foreign investors as
an international turntable for goods handling. For the carcass work the local pumping service YOUNG JONG received from
the general building contractor DAELIM
INDUSTRIAL COMPANY an order for
the delivery of about 70,000 m3 of concrete. As a rule the stiff, plastic material
has a slump dimension of just 12 cm.
The flagship of the pumping service is a
BSF 36.16 H which was delivered by
Putzmeister’s Korean subsidiary in
February 2005. Since then the machine has
been deployed on this huge construction
site and delivers between 300 and 1,000 m3
of concrete daily. The purchase decision in
favour of the Putzmeister BSF 36.16 H was
taken by Hyeon So Chang, the owner of
YOUNG JONG, primarily due to the
14
PM 3675 GB
A lot of work to be done at the goods terminal of Gimpo Airport: the Putzmeister BSF 36.16 H, produced in Korea
28
enormous power reserves that the pump
unit ”16 H“ has at its disposal. With an
engine performance of 180 kW the machine
achieves an output of more than 50 m3/h at
a concrete pressure of 85 bar. With such
performance data the ”16 H“ unit differs
considerably from the concrete pumps of
other – and not only Korean – manufacturers.
Robert Heider
Acrobatics between the pillars and under the beams
”The building contractor Krattenmacher
asked whether we would like to visit their
construction site. They needed a truckmounted concrete pump, but questioned
whether it would be possible to use such a
machine there. So I met the site supervisor
on site. The construction site was located
on the site of the sawmill of the company
Schneider (in Eberhardzell). The floor slab
of a new works building was to be concreted in several sections. The problem was,
though, that 4 m high walls and pillars,
crossbeams and even some of the suspended ceilings had already been partly built in
and the roof put on. The site supervisor
made it clear straightaway that with this
amount of concrete – roughly 120 m3 had
been calculated – the concrete should not
be distributed by a hose line. There must be
another way. And when? This could only
be done on the next Saturday, because production in the sawmill had to continue
during the week. So, I thought, Saturday
work is not the problem, but it is a damned
tight space in there. However, we do have a
special concrete pump. We shall manage to
do it with this.
I was also able to dispel these doubts, because when the boom of our M 31-5 is
swung over pillars and inner walls there is
no dripping or drops. That is because our
”Hallenmeister“ has a squeeze valve on the
end hose. This closes automatically whenever there is a pump interruption and it
functions pneumatically perfectly.
‘That is the answer I wanted to hear!’, said
the site supervisor.
All fig. Fa.Heider
32
Since the commissioning of the Incheon
International Airport in March 2001 they
have been working at full stretch on a better
connection between the airport and the
capital Seoul. With an investment volume
of approx. 1 2.5 billion the new airport is
designed to handle 50 million passengers
per annum. This corresponds approximately to the passenger incidence at Frankfurt
Airport. Korea’s new airport was erected
on an island regained artificially from
alluvial land off the Korean west coast. Till
now Incheon Airport was attainable only
via a 6 to 8-lane motorway. The new rail
line will relieve the local public transport
system. In its first expansion stage the new
line will connect the new airport with the
previous international airport Gimpo and
will later be extended to Seoul central railway station. Completion of this section
with a total length of 61 km is planned for
the end of 2009. The costs amount to over
three billion Euros.
The mixer driver has to really scrape the remainder of
the relatively stiff concrete off the chute
29
So we tackled the job on the Saturday.
Pumping started at 7.30 h and it was
finished at 11.40 h. After that 118 m3 of
concrete had been placed in the floor slab.
The building owner, site supervisor and the
foreman were really enthusiastic. They
wondered at how concreting could be performed with this pump in the tightest of
spaces despite all the obstructions and at
the fact that the ”quintuplet“ boom reaches
over all kinds of hindrances.
After this job the construction site then
placed another four orders with us. We
pumped another 350 m3 of concrete there,
even though the remaining sections could
also have been concreted by truck mixers!“
According to the site supervisor there is
something else to be taken into account,
though: ‘the pillars, which are made from
precast elements, must not get dirty, and
especially not get splashed with concrete.’
A saturated jet of concrete with a slump dimension of
12 cm
Concrete distribution in the narrowest of spaces
with the M 31-5
15
PM 3675 GB
Bridge Construction
Bridge Construction
Numerous underwater bored piles for
the 2nd Strelasund crossing
The 2nd Strelasund crossing is currently
being built as part of the feeder road
Stralsund/Rügen to the federal trunk road
B 96 n using PM truck-mounted concrete
pumps on land and water. After its completion this popular holiday island will be
connected via a second bridge with the
federal trunk road network on the mainland. Not only holiday traffic, but also the
Baltic Sea ferry port of Sassnitz/Mukran
will profit from this.
The new Rügen connection, the so-called
2nd Strelasund crossing, is subdivided into
several sections. This includes among other
things the two Strelasund Vorland Bridges,
the Ziegelgraben Bridge with a pylon
126 m in height, two structures over the
island of Dänholm, the Strelasund and the
Strelasund bridge followed by the Rügendamm structure. With a construction length
of 2,831 m the Strelasund crossing is currently regarded as being the biggest road
bridge construction project in Germany.
Altogether, the new road connection measures 4,100 m between the rail station
36
34
For the underwater foundations of the
bored piles a large drilling device turns the
bore hole tubes in several tube lengths into
the seabed from a floating platform (drilling catamaran). The material excavated is
collected in barges and transported away.
To concrete the piles the joint venture’s
civil engineering specialists insert into each
drill hole a jacket tube with a reinforcing
cage. The concrete is placed via a pouring
pipe by the so-called contractor process.
The bottom end of the pouring pipe is kept
constantly under the surface of the unset
concrete.
The operator delivers the underwater concrete via the end hose of his truck-mounted
concrete pump into the pouring pipe, which
is fastened to the drilling device. The concrete pump is either an M 32-4 or an
M 31-5, occasionally also an M 36-4
made by Putzmeister, which is used by the
concrete supply joint venture CEMEX/
HOLCIM for concreting on water and on
land. On land, e.g. in Stralsund for the
bridge sections and on the access roads to
the B 96 n, the work is performed in addition by truck-mounted concrete pumps in the
40 and 50 metre classes.
Concreting a pier for the access road to the 2nd Strelasund crossing in Stralsund
33
Rügendamm and the junction Altefähr.
A joint venture led by the corporate group
MAX BÖGL won the order for the project
with a value of 1 85 million. The 2nd
Strelasund crossing was planned by the
”Deutsche Einheit Fernstrassenplanungsund -bau GmbH“ (DEGES), which also
provided support for the work during the
construction phase.
The total of 18 piers in the Strelasund are
founded on bored piles. For each bridge
pier the production of six to twelve bored
piles (1.5 m in diameter) is required, which
are sunk in sheet pile casings. In fact 40 of
these bored piles are required for the pylon.
Altogether, 200 water piles have to be concreted, which, depending on the soil conditions, have foundations up to 40 m below
the seabed. In addition there are 250 piles
ashore.
16
PM 3675 GB
For production of the bored piles
the actual concreting team consists of a
PM truck-mounted concrete pump and
three truck mixers, which are set up together on the pontoon. After emplacement
of the 24 m3 of concrete (three truck mixers
with 8 m3 each) the pump driver folds in
his machine’s boom and the pontoon casts
off to bring the empty truck mixers back
ashore. In return laden truck mixers are
taken on board again. After a short sea
journey the pontoon ties up to the floating
platform of the drilling device once again
and the concreting work is continued.
Approx. 2 m3 of concrete are required per
metre of pile length. C35/45 (WU) is used,
which is protected in addition against saltwater corrosion.
35
Altefähr
Dam section
New Strelasundbrücke
S
Tall bridge
Zielgraben
Dänholm
Rügen
tr
e
la
su
n
d
Stralsund
17
PM 3675 GB
Ba c k g ro u nd
Highrise
39
Pioneering
in the
desert
30 years ago, CONMIX Ltd. was the first
manufacturer of concrete and mortar, and
also the first provider of pumping services,
in the UAE. “Back then it was desert with
hardly a single multi-storey building in
sight,” says Chris Lobel, General Manager
Ready-Mixed Concrete with CONMIX.
Since then, everything has been transformed with 40-storey accommodation and
office buildings towering above the ground,
not only in neighbouring Dubai, but also in
the previously tranquil Sharjah. CONMIX,
with its wide product range, has also played a decisive role in the rapid completion
of construction: cement and gypsum
plaster, coloured mortar, tile grout, soundproofing and insulation systems, concrete
additives and special construction chemicals are among the products offered.
However, the main revenue generator is
ready-mixed concrete, which CONMIX
delivers to customers using a fleet of more
than 120 truck mixers. Supplementing a
total of seven concrete mixing plants is a
fleet of 19 Putzmeister truck-mounted
Burj Dubai: the walls of the
lower storeys
are completed
concrete pumps with booms capable of
reaching heights of between 28 and 42 m.
Two BSA 14000 HP-D and two MX 32-T
stationary concrete placing booms are also
available for structural engineering operations.
CONMIX generally carries out maintenance work on the machines in its own
workshop. Since the concrete pumps are
regularly in operation on the construction
sites until late into the night six days a
week, this leaves only the one workfree
day – Friday – for necessary inspection
work including oil and filter changes.
Says Lobel: “The combination of the
demands placed on the machines and the
heat, sand and dust could soon have dire
consequences if maintenance work is
neglected.” CONMIX has major service
work – e.g. boom inspections carried out
by the Putzmeister agent GERMAN GULF
after-sales service located in the vicinity.
40
At temperatures of almost 50 °C in the
shade, at Burj Dubai work on the lower
floors is progressing well. In this phase,
UNIMIX truck-mounted concrete pumps
with different boom sizes are performing
the concreting. However, the first PM
high-pressure pump and the first MX
stationary boom are already on site for
the actual high-rise pumping.
EMAAR PROPERTIES, the principal for
the building which when complete will be
the highest in the world, has meanwhile
given some interesting details of the foundation work. The 3.7 m thick and 8,000 m2
large ground plate is supported on 192 m
drilled piles, which penetrate the earth to
a depth of over 50 m. Just for the piles of
the subsequent building tower, almost
18,000 m3 of concrete was pumped, and for
the support piles of the so-called podium
approx. 15,000 m3 of concrete was used.
Established in 1975, CONMIX is a joint
venture comprising the Arab BUKHATIR
group, GERMAN GULF ENTERPRISES
Ltd. and KARL EPPLE GmbH (Stuttgart).
With around 400 employees and its headquarters in the Emirate of Sharjah, the
company has become one of the largest
manufacturers of dry mortar and readymixed concrete in the Middle East. Daily
concrete production exceeds 4,000 m3 in
the central works alone. CONMIX has
commissioned three new ready-mix concrete works in the UAE since 1999 and
formed a subsidiary in India for the manufacture of dry mortar.
View onto the three-wing ground plan of the floor slab
of the Burj Dubai
(Photo DOKA)
Meanwhile, the work has progressed. After
completion of the walls in the underground
storeys, at the end of June concrete was
poured into the wall formwork for the first
storey. The concrete of compressive strenght
C80 – an extremely viscous, sticky material – was delivered also by Putzmeister
truck-mounted concrete pumps of the
models BSF 36.16 H and 42.16 H.
The ceilings will be done later.
41
38
At present the flagship of
the CONMIX concrete pump fleet
is this Putzmeister BSF 42.16 H
18
PM 3675 GB
CONMIX sales manager Chris Lobel in front of a tower
block construction site in the emirate of Sharja.
Here a BSA 14.000 HP-D is doing the pumping and
two MX booms are distributing the concrete.
The UNIMIX engineer carefully cleans his Putzmeister M 36 after the concreting.
In the background the first walls of the Burj Dubai erected with DOKA formwork
and behind that the skyline of the UAE metropolis.
19
PM 3675 GB
Information
Reader survey
with a pleasant
result
We were very pleased about the numerous
replies to our reader survey in the
Putzmeister Post issue 61. An evaluation
showed that the layout and concept of the
magazine are highly valued by all our readers. There is great interest, for example, in
machine applications, construction site
reports and practical tips – topics that have
always been the main emphases in our
customers’ magazine and that we intend to
take into account even more intensively in
the future. Detail information about the
technology of PM products and their
accessories are also often requested. In
addition to the reports on spectacular largescale projects many readers also want to
see articles on concrete pump applications
on smaller, less spectacular construction
sites. We shall be glad to take up these
suggestions.
Imprint:
Publisher
Putzmeister AG
Putzmeister AG, Max-Eyth-Str. 10, D-72631 Aichtal
PSdg, Deutsche Post AG, Entgelt bezahlt, E 60458
Max-Eyth-Str. 10
D-72631 Aichtal
Tel. +49 71 27 599-0
Fax 599-520
■ Editor:
Jürgen Kronenberg
■ Design:
Friedrich Pippich
42
As promised, prizes were awarded to the
contributors of three high-quality models
of the PM M 52 truck-mounted concrete
pump. The following were the winners
■ Reiner Herlt, CEMEX (Berlin)
■ Eckhard Lackner, FRISCHBETON
SCHUH (Bad Fallingbostel)
■ Alex Thomsen, UNICON A/S
(Norresundby, Denmark)
Putzmeister AG would like to thank all
those who participated in the reader survey.
Together with them we look forward to the
future issues of PM Post.
Anja Steimle, assistant to PM’s marketing manager, with the winning replies to the reader survey
Your fax for further information
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Position .....................................................................................................
❏ Truck-mounted concrete pump M 6X ..................................................BP 3621
Street .........................................................................................................
❏ Stationary concrete pumps ..................................................................BP 2632
Post Code/City ..........................................................................................
❏ PUMI® truck-mixer concrete pump......................................................BP 2047
Tel. No. ......................................................................................................
❏ Truck-mounted concrete pump M 16-3 Z ............................................BP 3247
E-mail ........................................................................................................
❏ Truck-mounted concrete pump M 42-5 RZ..........................................BP 3623
❏ AUTOCOR............................................................................................BP 3557
❏ Truck-mounted concrete pump M 36-4 Z ............................................BP 3180
Putzmeister AG
Max-Eyth-Str. 10 · D-72631 Aichtal
❏ Truck-mounted concrete pump M 31-5 Multi-Z..................................MT 2128
P.O.Box 21 52 · D-72629 Aichtal
❏ Truck-mounted concrete pump M 32-4 Z ............................................BP 3390
Fax +49 (71 27) 599-520
Tel. +49 (71 27) 599-0
Internet: http://www.putzmeister.de
❏ Truck-mounted concrete pump M 42-4 ..............................................MT 2391
E-mail: [email protected]
PM 3675 GB All rights reserved. Subject to technical amendments without notice. The illustrations in some cases show special-purpose machine designs and snapshots of site
practice which do not always comply with the regulations determined by professional bodies. © 2005 by Putzmeister Printed in Germany (2.50509 RR)