77 Customer magazine by Putzmeister Concrete Pumps GmbH

Customer magazine by Putzmeister Concrete Pumps GmbH
77
Long-reach boom pumps and
bulk material conveyors at
power plant construction site
PM pumps and
service in Russia
The RoLine pump concept
Shotcrete placement in 32 km
long, high-altitude tunnels
PM 4276 GB
Contents
1
Foreword
3
4
Power plant construction
TITLE STORY – Long-reach boom pumps and bulk material
conveyors at power plant construction site
Food for the Telebelt ® –
Bulk concrete for dam project
4
27
High-rise construction
Clever boom solution
PM elephants in the land of the Russian bears
8
10
2
10
Bridge construction
Long-reach boom pump at the Unstrut valley bridge
9
Service
Also in Russia: “PM expertise near you”
14
Excavation
Pumping for all it’s worth
BSA pumps concrete S.O.B. piles in Trinidad
16
26
3
20
Background
EU imposes stricter inspections on imported
construction equipment
17
Technology
The M 47-5 in practice
Growing within its niche – the Roline pump concept
18
20
Tunnelling
Shotcrete placement in 32 km long, high-altitude tunnels
24
4
24
Imprint
Editor:
Putzmeister Concrete Pumps GmbH
Max-Eyth-Straße 10
72631 Aichtal / Germany
Editorial department:
Jürgen Kronenberg
Putzmeister Concrete Pumps GmbH
Max-Eyth-Straße 10
72631 Aichtal / Deutschland
2
Layout & Print:
Offizin Scheufele GmbH + Co. KG
Tränkestraße 17
70597 Stuttgart / Germany
PM 4276 GB
Foreword
Dear customers
and friends
of Putzmeister
5
2009 is drawing to a close – a difficult year
that has been like no other in the 51-year
history of Putzmeister. The global economic
crisis has affected us greatly, as it has you.
Concrete consumption and the quantity of
pumped concrete, which is so important for
us, have declined globally – to a greater or
lesser extent, depending on the country.
Taken as a whole, the decline has been dramatic and we are all working hard to adapt
to the new situation.
All the same, Putzmeister has demonstrated
this year that it is possible to adapt successfully. After many years of growth, we were
able to apply the brakes in good time. But
this braking manoeuvre was not easy,
because it meant parting with many things
that we had come to cherish and even many
that we believed were absolutely necessary.
Putzmeister started a restructuring project
for the entire group at an early stage, which
streamlined the structure of the company
considerably and allowed it to adjust to the
new requirements.
The reduction of the number of employees
in Germany is taking longer than originally
envisaged due to the agreement that was
amicably reached with the works council
and trade union and, under the current
framework conditions, will not be completed
before the 1st quarter of 2011. However,
the reduced working hours regulations in
Germany are enabling capacities to be
adjusted until then with considerably reduced costs for the company.
Since September, the restructuring has
been actively moved forward by Norbert
Scheuch, who was originally Managing
Director of Putzmeister Holding and who
is now Managing director of Putzmeister
Concrete Pumps GmbH. He has many years
of experience of successful restructuring in
comparable companies. With his support,
we are implementing the necessary measures in line with the plan that was drawn up
in the spring. The key points of this plan
have proven themselves in the last six
months. Even though our forecasts have
been considerably lower than those of the
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previous positive years, this has enabled
us to ride out the turbulence of the start of
the year and bring some stability back to
the markets we operate in – even if it is at a
much lower level.
At the same time, there has been an
increase in spare parts turnover that our
customers are achieving with increasing
numbers of orders. This is also confirmed
in the many meetings that Putzmeister
employees have held on customers' premises throughout the year and which fortunately are increasingly resulting in sales.
As well as the attractive conditions for new
machines, these customers are frequently
also taking advantage of the wide range
of high-quality used “Putzmeister Value
Pumps” in order to enhance their fleet in
light of the current favourable conditions or
to open up new markets with special
machines. Please visit www.putzmeister.de/
value-pumps for information about Putzmeister used machines.
At the end of the year, however, we are
also looking to the future and 2010, which
will provide us with the highlight of the
construction machinery trade fairs, Bauma,
in April. This time, India – which represents
one of our largest growth markets – has
been selected as the partner country. We are
already looking forward to welcoming you
to our stand in Munich, which will be in the
usual spot. There, we will have the opportunity to discuss with you new products,
experiences, market trends and general
development. We are already looking forward to it.
I wish you and your family a peaceful and
contemplative end to the year and all the
best for a successful 2010.
Your
Dr. Ralf v. Baer
Chairman of the Management Board
Putzmeister Concrete Pumps GmbH
Putzmeister Holding GmbH
3
Power plant construction – Title story
Long-reach boom pumps and bulk material
conveyors at power plant construction site
RWE Power AG in Hamm, Westphalia, is investing around EUR 2 billion in the construction of one of the world’s most efficient coal power plants with a total output of 1,600
Megawatts. The placement of around 250,000 m³ concrete of different property classes
and consistencies is predominantly carried out using Putzmeister truck-mounted concrete pumps with up to 62 m placing boom height and two stationary PM placing booms.
But a Telebelt ® TB 130 telescoping conveyor belt is also used on the vast construction
site to deliver the different bulk materials.
6
7
The two M 58-5 and M 62-6 (bottom) Beka long-reach boom pumps concreting one of the huge bottom plates of the power plant in
Hamm, Westphalia (Photo: Alpine)
The client has commissioned ALPINE Bau
Deutschland AG (Industrial and Power Plant
Construction, Dortmund branch) with the
execution of the extensive earth, concrete
and construction work for the two new
power plant blocks “D” and “E” (order volume EUR 135 million). The two-block power
plant with 2 x 800 megawatt power is being
constructed on the site of a previously planned nuclear power plant and next to the
high temperature reactor THTR-300, which
has been shut down since September 1989.
4
The construction of the new power plant includes a building complex of engine and boiler
houses, switching system buildings and water
centre, four stair towers, seven silos with up
to 10,000 m³ capacity for limestone, cement
and ash as well as two 165 m high cooling
towers.
Fleet mix crucial
The order to deliver over 220,000 m³ of concrete was received by the concrete pumping
service BEKA in Kerpen. Crucial in the
assignment was the fleet composition of the
pumping service, which consists of over
40 truck-mounted concrete pumps. Thus, in
addition to machines from the 20, 30 and 40
metre class, BEKA also has three M 52-5s,
three M 58-5s and two M 62-6s. Due to the
vast boom lengths and large working range,
made possible by flexible 5 and 6 arm technology, BEKA’s long-reach boom pumps
gave it a crucial advantage in the invitation
to tender. In addition, there was the possibility of supporting the large 5 and 6-axle
trucks in OSS mode on one side, if the construction site conditions allow for this.
PM 4276 GB
Power plant construction – Title story
8
9
There’s not much space – but the M 62-6 can still be supported correctly
Machine operator enjoys the extras
The extensive concreting began in spring
2008. For the production of the bottom
plate, which is 5 m thick in places, up to
6,500 m³ concrete (C35/45) were integrated
wet in wet. To complete the numerous walls,
floors and beams, the Putzmeister pumps
are used here almost daily. On one of our
visits, we met BEKA machine operator Ricco
Lemm, “My M 58 is equipped with all the
electronic extras offered by Putzmeister,
such as familiar systems like EBC, EOC, EPS.
If you – like me now – are standing on scaffolding at a height of 20 m, the additional
functions are practical, such as being able to
switch the vibrator on the hopper on and off
by radio remote control, and then the graphical display on the remote control shows
me all the important information at all times
– down to the current fluid temperature!”
Ricco Lemm is often at the power plant construction site with the M 58-5. Today he is
pumping concrete with a 16 mm maximum
particle size (C30/37) into the wall formwork of a switching system building. Due to
the narrow reinforcement, he has switched
the bottom part of his 2-part end hose for a
tapering and an 80 mm end hose piece. The
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squeeze valve – also activated via the radio
remote control – remains connected to the
“1 metre piece”, the upper part of the split
end hose. When the boom is swung over the
formwork, the valve squeezes the end hose
together with compressed air, so that no
concrete remains inside.
Boom tip with squeeze valve, tapering and
end hose over the reinforcement
10
Everything in sight and easy to use: The modern PM radio remote control with
graphical display
5
Power plant construction – Title story
11
Attractive Ergonic modules
EBC (Ergonic Boom Control):
Controls, regulates and limits, as required, the movements of the concrete
placing boom. EBC actively damps the
vertical movements of the boom, simplifies operation and supports safety during
concrete placement.
During construction of the power houses, two stationary PM placing booms distribute the concrete. One from a lattice tower, the other supported on tubular columns
(as shown here) (Photo: Alpine)
EPS (Ergonic Pump System)
Regulates the concrete pump control fully
electronically in the interest of optimised
delivery. Data, such as delivery pressure,
delivery rate of the hydraulic pump,
hydraulic pressure and many other
signals, is actively co-ordinated. With EPS,
the machine operator can assign and limit
the maximum desired pump pressure, for
example, (important for delivery lines,
whose compressive strength or wear condition is not known, or for “sensitive” formworks). Even switching over the transfer
tubes from one delivery cylinder to the
other is adapted to the current concrete
consistency and avoids “thuds”.
12
EOC (Ergonic Output Control)
Ensures fuel-efficient operation of the
concrete pump. The EOC automatically
regulates the optimal engine speed for
the respective delivery rate. This reduces
consumption, lowers wear and reduces
noise
The sensitive radio
remote control means
the boom tip with end
hose can be guided
accurately
Stationary boom grows to 55 m height
with lattice tower
An interesting interaction between truckmounted concrete pumps and stationary
concrete placing booms can be seen during
concreting of the power houses: The two PM
stationary booms with 32 m horizontal
reach are supported on a tubular column, or
on a lattice tower, which is extended to up to
55 m in height as the construction progresses. Via a special tube support system, the
delivery line is secured on the lattice tower.
It is supplied with concrete at the bottom
end by one of the BEKA truck-mounted concrete pumps.
silos, which are up to 70 m high, are constructed using the sliding formwork procedure. It is important when concreting with
sliding formwork that the concrete composition is adapted to the respective outside temperature and sliding speed. Dipl.-Ing.
Andreas Michnik, head of work preparation
at the construction site said: “As the concrete is placed round the clock here, but only
relatively small placement jobs are required, we work with a crane bucket. When
using pumps, the concrete would otherwise
set in the long delivery line!”
Both the outer walls of the four stair towers,
which are up to 120 m high, and the seven
Stiff concrete with increased strength
is the “daily bread” of PM pumps
6
EGD-RC (radio remote control
with graphical display)
With this ergonomic control system, all
EBC functions can be operated – even the
upper and lower limits of the working space can be defined, as well as the movement
of the rotating mechanism. On the display,
the machine operator receives additional
feedback and system indicators from the
machine, such as engine speed, fluid temperature, concrete pressure, delivery rate
and information on pressure and volume
limitations. The vibrator and end hose
squeeze valve too can be switched on and
off via EGD-RC.
13
PM 4276 GB
Power plant construction – Title story
14
The Telebelt ® conveyor belt can be telescoped several times and enables precision placement of material (Photo: Alpine)
15
16
Truck mixers pass the tamped concrete
and other bulk materials onto the Telebelt®
feed conveyor (Photo: Euro-Hochweit)
Filling the pit with the telescoping TB 130 Telebelt ® conveyor belt. The reach with this
model is 39 m (Photo: Euro-Hochweit).
TELEBELT® delivers dry tamped concrete
and bulk material
While you come across PM truck-mounted
concrete pumps at the power plant construction site in Hamm almost daily during
the carcass construction phase, most of the
Putzmeister Telebelt® TB 130’s jobs are completed by now. The TB 130 is a mobile conveyor belt system, which conveys unpumpable, pourable bulk materials into the site of
concrete placement via a telescoping conveyor belt. Typical materials include excavated material, hardcore, sand, humus, bark
mulch, granulate or extremely stiff, only
earth-moist concretes. Here at the power
plant construction site, the Telebelt ® – before
installation of the cleanliness layer and the
construction concrete – had conveyed dry
filling and tamped concrete (consistence
class F1) as well as sand and hardcore into
PM 4276 GB
the various pits. The building materials
were initially passed onto the Telebelt ® feed
conveyor either by truck mixers, truck tippers, mobile excavators or wheel loaders, in
order then to be transported up to 39 m
along the main telescoping conveyor belt
and distributed with precision. The belt
movements and the delivery rate are controlled by radio remote control, similar to
the control of the PM truck-mounted concrete pumps. Even a slanted raising or lowering
of the delivery belt is of course possible. The
actual installation performance of the TB
130 depends on the type of bulk material,
the construction site logistics, the waiting
times between the batches, etc. The Telebelt ®
is designed for an output of up to 270 m³/h
(max./theor.). ALPINE Bau Deutschland and
the subcontractor DÜCHTING hired the
Telebelt ® from Euro-HochWeit AG (Waltrop).
New coal power plant with exemplary
high efficiency
The two new power plant blocks of RWE
Power AG in Hamm-Uentrop will be fired
with coal and petrol coke. With an efficiency of approx. 46 %, the new two-block plant
will be one of the most modern and efficient
coal power plants in the world. Blocks “D”
and “E” should be connected to the grid by
the start of 2012, and blocks “A” and “B”
which have been in service since 1962/63
(output per 160 Megawatt) will be shut
down.
For more information, see:
www.rwe.com
www.alpine.at
www.bekabeton.de
www.euro-hochweit.de
www.wikipedia.de
7
High-rise construction
Clever boom solution
18
Even if space for truck-mounted concrete pumps is tight on construction sites –
there are solutions! So, for example, the
Berlin pumping service of Heidelberger
Beton, shows how a placing boom and
truck-mounted concrete pump can be set
up separately in the tightest of spaces in
the centre of the German capital and
nonetheless be operated together. Large
truck-mounted concrete pumps would
have no chance on this construction site.
17
Andreas Keiser, Heidelberger Beton
The PM Multiboom with a reach of 24 m usually sits on a truck-mounted concrete pump – here,
however, “for a change”, it sits on a self-climbing tubular column (Photo: Heidelberger Beton)
In the centre of Berlin, one of the most prominent construction gaps is currently being
closed: Not far from Alexanderplatz, as an
architectonic eye-catcher, the “KönigstadtCarree am Alexanderplatz” is being constructed as the new north gateway to Berlin’s
most famous square. Heidelberger Beton,
north-east concrete pumping division, is concreting the upper stories with a Putzmeister
MXR Multiboom, which can be separated
from the truck-mounted concrete pump.
together with Berger Beton on behalf of
Dresdner Industrie- und Wohnungsbaugesellschaft mbH has supplied the readymixed concrete. During the pumping work,
there has been a special feature, which
Andreas Keiser, deputy division manager of
Heidelberger Beton GmbH, describes as follows: “From the 9th floor, we were no longer
able to work with our truck-mounted concrete pumps due to a lack of space. The access
street in front of the construction site and the
inner yard were simply too narrow. Instead,
we removed the placing boom (MXR 24) from
the truck-mounted concrete pump and had
the boom climb upwards hydraulically on an
18 m high tubular column in the course of
the construction.” A securely laid riser then
supplies the respective highest story with
concrete via a high pressure pump.
Lack of space requires separate solution
At the junction of Mollstrasse and OttoBraun-Strasse, the construction works for a
71 m high office block with 21 floors, flanked
by a doctor’s clinic and a hotel, have been
underway since 2007. Heidelberger Beton
19
By means of a riser, the boomless truck-mounted concrete pump with MXR Multiboom is now connected to the highest floor (Photo: Heidelberger Beton)
8
Multiboom for mobile and
stationary use
The MXR Multiboom was developed by
Putzmeister for pumping services which
place particular value on a flexibly deployable machinery fleet. For if the carcasses
become so high than they can no longer be
reached by the boom of a truck-mounted
concrete pump, the 4-arm multiboom together with adapter can be removed from the
truck and set up on a tubular column. This
means the truck-mounted concrete pump
placing boom becomes a stationary boom,
which is either firmly installed on a tubular
column with cruciform base or – as here at
the “Königstadt-Carree” construction site –
moves from floor to floor as the construction
progresses with the help of an automatic
climbing system. Between the concreting
works, the Heidelberger Beton pumping service deploys the carrier truck with the concrete pump on other construction sites.
During these times, concrete delivery is carried out using pump tubes or pipelines – the
truck-mounted concrete pump, which now
no longer has a boom, carries 60 m of such
pipes with it on board.
For more information, see:
www.deutsches-architektur-forum.de
de.wikipedia.org
PM 4276 GB
Bridge construction
21
Long-reach
boom pump
at the Unstrut
valley bridge
As part of the Deutsche Einheit transport projects, Deutsche Bahn AG is working full speed ahead on completion of
the new InterCityExpress (ICE) line from
Leipzig/Halle to Erfurt (VDE rail no.8).
This is also part of the planned transeuropean high-speed network from Berlin
to Verona. PM long-reach boom pumps
with flexible 5-arm technology carry out
concreting work during bridge construction at heights of nearly 50 m.
20
5-arm booms are simply more flexible: Here are two Putzmeister M 52-5s, which not
only reach high, but with their arm (“flyer”), also reach horizontally across the formwork
In addition to three tunnels, the route also
requires six large bridge constructions, one
of which is the Unstrut valley bridge, which is
currently under construction. At a length of
2,668 m and a height of up to 49 m, it is the
second longest railway bridge in Germany.
The structure consists of a chain of 580 m
long, jointless and bearing-free framework
bridges. The pre-stressed concrete box section, with approx. 5 m construction height and
14 m width, is split into 46 sections. The
bridge superstructure is supported by 41
piles in a 58 metre pattern as well as by four
reinforced concrete arches. The customer is
DB Projektbau GmbH, and construction is
being executed by a consortium of Alpine
Bau Deutschland AG, Leipzig/Halle branch
PM 4276 GB
(management) and Berger Bau GmbH, Berlin.
The concrete pump services are being provided by the Putzmeister customer concrete
delivery union, Raßnitz.
Quintuplet booms use net reach even in
high-rise construction
During our visit at the start of September, the
pre-stressed concrete box section (trough) was
being concreted at the first bend. To place the
concrete accurately in the reinforcement at
this height, a long-reach boom pump with the
necessary vertical reach is required. As shown
on the photo, this is only possible with flexible
5-arm technology. Truck-mounted concrete
pumps with 4-arm placing booms with the
same reach would have to have been removed
again without having achieved anything.
Stefan Klöpfel, managing director of BFU said,
“We are working on both sides of the bridge
superstructure with two Putzmeister M 52
quintuplets, because these machines can
unfold their last boom arm over the formwork
even at such a height.”
The superstructure between the bends is concreted using a launching gantry and the associated formwork. On the lateral brackets, two
stationary placing booms with 24 m reach
have been set up on the launching gantry.
They are also supplied by truck-mounted concrete pumps.
For more information, see:
www.db.de
9
High-rise construction
22
PM elephants in the land of the
Russian bears
View of the old and new Moscow. In the centre of the picture, on the right-hand side of the Moskva River, is Lomonosov
University. On the opposite riverbank, some new “Moscow City” buildings.
For many years, Putzmeister was represented in Russia “only” via a sales office.
But for four years now, the PM elephants
have been represented by a subsidiary:
PM RUS. The reason for opening a dedicated branch in the largest country on
earth is the high economic growth that is
expected in the BRIC countries (Brazil,
Russia, India, China) in upcoming years.
And despite the economic difficulties,
which have seriously affected Russia like
other countries, there are still some
interesting large-scale projects here –
albeit delayed.
pumping fleet. The head of pumping on the
construction site Alexandr Salmatov explains to us that the short distance between
mixing plant and construction site means
that concreting with this project can be
achieved during the day. It is otherwise normal in the Russian metropolis to carry out
large-scale concreting operations in the
period after the evening rush-hour.
23
Large-scale residential complexes as a
routine job
Don-Stroy has handled many large-scale projects such as this over the years. This is why
the use of the stationary concrete pumps on
this construction site is nothing unusual.
Alexandr Salmatov merely points out that
one BSA 14000 is being used for two residential towers. His company has relied
exclusively on Putzmeister for many years
for quality reasons. And with great pride he
says: “We rarely need the Service department, because we know the machines so
well that we are able to carry out maintenance work and repairs ourselves.
Nevertheless, the Putzmeister engineers are
always dropping by, and we discuss with
them alternative solutions for meeting the
various requirements involved in high-rise
pumping.”
The high-quality residential complex Losiniy
Ostrov Eco Park is situated on the northeastern outskirts of Moscow and borders on
the Losiniy Ostrov National Park. The project, which was started in 2006 and will provide approx. 100,000 m² of living space, is
being managed by the construction company Don-Stroy. It consists of five high-rise
buildings with up to 30 stories and approx.
100 m height of construction. Don-Stroy is
working on the various construction phases
using a total of three BSA 14000 stationary
concrete pumps and five PM MX 32-4 climbing booms. PM truck-mounted concrete
pumps with M 36-4 and M 42-5 placing booms
are also involved in pumping a total volume
of approx. 35,000 – 40,000 m³ of concrete.
Alongside six concrete plants and 40 truck
mixers, Don-Stroy has a comprehensive range of construction machines with its own
10
Carcass of one of the high-rise buildings
in the Losininiy Ostrov Eco Park
For concrete placement, Don-Stroy relies exclus
for high-rise construction
PM 4276 GB
High-rise construction
25
On the day of our visit to the construction
site, no pumping operations were being
carried out, and so there was time for an
interview with the M 42 machine operator
Gennadiy Loginov:
PM: How long have you worked as a machine
operator with concrete pumps?
GL: I started 10 years ago and I have operated
all of the PM pumps that Don-Stroy has.
liked my previous machine with trunk
system. It however had a 4-arm boom. In
certain situations, there are more benefits
to the 5-arm machine with its greater
manoeuvrability.
PM: This is a M 42-5 from 2008. You say
you have already pumped 80,000 m³ with it.
What do you think about this machine?
GL: It pumps just as reliably as all other
Putzmeister pumps. However, I especially
PM: A great deal of information is shown
on the graphic display of the control cabinet. How do you use it?
GL: I have not yet had any fault displays.
This is certainly because we were instructed well in how to use the machines and
we keep to the maintenance regulations.
What I use is the operating hours meter and
the ECO switching.
26
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27
29
A PM service car in the Moscow traffic
24
“Moscow City” is an entire complex of
modern high-rise buildings
Stationary boom and pumps
for the “Moscow City” project
ively on Putzmeister concrete pumps – even
PM 4276 GB
“Moscow International Business Centre
(Moscow City)” is a building project in the
Russian capital, the planning of which dates
back to 1992. “Moscow City”, as it is known
for short, is a completely new district in the
city that is being erected on the left bank of
the Moskva River only 5 km away from the
Kremlin. The total cost of the project is esti-
mated at US $12 billion (approx. € 8.6 billion). On completion, numerous companies
and office buildings will be located here,
among them the spectacular and also architecturally demanding high-rise buildings.
Completion of the entire complex is not
expected before 2012.
11
High-rise construction
30
Mercury Tower: pumping height of 320 m
The 380 m high Mercury Tower is one of the
skyscrapers in “Moscow City” that will later
attract everyone's attention. The 70-floor
high-rise has been under construction since
2005. As the lead construction company,
Rasen Construction – a member of the
Turkish Soyak-Holding – has been commissioned with the project. To deliver the, for
the most part, high-strength concrete to a
height of 320 m, Rasen Construction is
using three stationary Putzmeister BSA
14000 HP D concrete pumps. The concrete
is distributed in the floor and wall formworks using three MX 32-4 T stationary
booms that each sit on 20 m high tubular
columns and climb upwards in the building
shafts hydraulically. PM engineers had
developed solutions especially for the
Mercury Tower, so that the slewing radius of
the boom ballast beams could be individually set to the construction site requirements.
At Mercury Tower, three large BSA 14000 concrete pumps and three MX 32-4 stationary booms undertake concrete placement
31
High-rise building for the
Moscow City Council (308 m)
In the immediate vicinity of the Mercury
Tower, a new, 308 m high tower for the
Moscow City Council (Tower of Moscow Government) is being constructed. Similarly, the
building contractor MonArch is completing
numerous concreting tasks using Putzmeister technology: a stationary BSA 2109 HE
concrete pump for delivering concrete, a horizontally slewable RV 10 rotary distributor,
and two stationary MX 32-4 T booms.
32
Model view of Mercury Tower
12
The high-performance BSA 14000 SHP D pump won recognition during high-rise concrete pumping at the Moscow Federation Tower
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High-rise construction
33
Federation Tower: high-strength
concrete up to a height of 360 m
The building complex “Federazija” (Federation Tower) is being erected on behalf
of the investor Mirax Group and is also
one of the technically and architecturally
demanding building construction projects in “Moscow City”. The “Federazija”
project consists in essence of two towers
with heights of 243 m and 360 m
(440 m when the antenna is fitted later).
Lead contractor for the construction of
the eastern tower is the China State
Construction Engineering Corporation;
the contract for the western high-rise
building was given to the Turkish building contractor Ant Yapi.
Even during the winter months, extreme
strength class C80/90 concrete will be
pumped at the Federation Tower. Despite
high-wearing concrete mixes, two Putzmeister high-performance BSA 14000
SHP D concrete pumps have proven
themselves here over pumps made by
other manufacturers (they were removed
long ago). Incidentally, the PM machines
are identical in design to the ultra-high
pressure concrete pumps that were used
in the record-breaking high-rise pumping at Burj Dubai (606 m). While the top
PM 4276 GB
34
floors are reserved as an observation deck,
restaurants and a fitness club with swimming pool, there are 30 floors of office space underneath that are reserved for the
Russian WTB-Bank – it is providing 50 % of
the investment for the Federation Tower. In
addition, a luxury hotel will take up a large
number of the floors in the higher tower.
The construction costs of the “Federazija”
skyscraper are estimated at € 390 million.
For more information, see:
www.soyak.com.tr
www.rasen.com.tr
de.wikipedia.org/wiki/Moskau_City
www.mirax.ru/content/33/Default.aspx
en.wikipedia.org/wiki/Federation_Tower
Construction of the Federation Tower
is already very advanced
13
Service
The same applies in Russia:
“PM expertise near you”
36
With 142 million inhabitants, the Russian Federation is not only an economically interesting market, but, with its
west-east expanse of over five and a half
thousand miles and an area of over 17
million km², also very far-reaching. The
biggest country in the world stretches
across eleven time zones and, east of
the Urals, has just a sparse road and rail
network, and yet good flight connections. We spoke to Jürgen Drensek, the 56
year-old After Sales manager of PM RUS,
to find out how the Putzmeister After
Sales department deals with these conditions, and how it organises support for
customers and their machines through
to the far east.
Arrival in the provinces: Thanks to good flight connections, the Russian PM service
technicians in this vast country can get (almost) anywhere very quickly
35
Service manager Jürgen Drensek and
Andreas Milow, managing director of PM Rus
PM: And what is a normal case?
JD: In addition to the headquarters in
Moscow, we now also have two service
support bases in St. Petersburg and
Krasnodar. If the site of use is less than
800 km from one of these sites, we go there by car or with the night train. Distances
of over 800 km are really only possible by
plane.
Here in Moscow, we have almost all commonly used parts in stock. If spare parts
are needed for a job, these are sent to the
customer first. Then, depending on the job,
extensive tools may be needed. It is not
always that you find the right equipment
at the construction sites or in the local
workshops. And then, coordinated with
the arrival of the parts, the service technician starts to make his way. For
Vladivostok, this can mean: departure in
the evening at 6 pm in Moscow, then eight
and a half hour flight and eight hour time
difference. Arrival the next morning at
10.30 am local time and direct departure
to the construction site.
37
PM: Mr. Drensek, you have many years of
experience in service for construction machinery in various regions of the world. What
is special about the service business in
Russia?
JD: The main thing to note is the vast
distances. In order to keep costs as low as
possible, we always try to solve problems
initially by telephone. Our customers often
have their own local workshops and are able
to help themselves given the right instructions.
PM: And what happens if this is not enough?
JD: Then we always ask again, to prevent a
repeat of a situation some time ago during a
service deployment in Vladivostok: At that
time, we had to fly 6,500 km because of a
depressed emergency shut-down button on
a M 36 truck-mounted concrete pump …
Certainly an exception, but these things do
happen.
14
Training on the new BSA “far off the beaten track”
PM 4276 GB
Service
38
St. Petersburg
Moscow
Krasnodar
Vladivostok
The Russian Federation extends across eleven time zones and measures over five and a half thousand miles from east to west
PM: … that’s certainly not easy for the service
technicians?
JD: No, especially due to the physical strain.
But we have a good team of willing people,
who we have trained ourselves. Most of
them were themselves truck-mounted concrete pump drivers before. We then trained
them in PM technology and gradually introduced them to the more challenging service
work. Unfortunately, there is no apprenticeship training in Russia like there is in
Germany. Training here is very theory-oriented and the practical part has to be performed in the businesses.
PM: Does that not cost a lot?
JD: Yes, of course, and above all, you need a
few years to do it. But our customers expect
a high-quality service package from Putzmeister and attest to it again and again
through the trust they put in our service.
39
Construction site preparation in the
middle of nowhere
PM 4276 GB
40
View of the dispatch area of the Russian PM subsidiary
15
Excavation
41
In three days and two nights, several truck-mounted concrete pumps concrete the huge bottom plate of Tower 185 at the same time
Pumping for all you’re worth ...
The Frankfurt pumping service “The Pumas”
pumped 15,056 m³ of concrete within 68
hours in the second section of the huge
bottom plate of the new Tower 185 in
Frankfurt using four large boom truckmounted concrete pumps.
To do this, a M 63-5, a machine with a 58 m
boom and two M 52-5s were set up on two
sides of the pit. In the course of the concreting, the end hose of one of the two M 52s
was extended with pipelines, which were
connected to an easy to use, hydraulically
controlled placing boom with a 20 m reach.
The working range of this boom could be
extended again, if necessary, through coupling with a mechanical rotary distributor
RV 10. Three weeks before, the first section
of the bottom plate was already cast with
5,660 m³ concrete. The concrete was supplied by the Sehring and Waibel ready-mix
concrete plants.
16
Over 20,000 m³ for the bottom plate
The planned 185 m tall high-rise building
with 50 stories is being built in Frankfurt’s
new Europa quarter between the main train
station, the trade fair site and the banking
quarter. Tower 185 essentially consists of a
multi-storey underground car park, a horseshoe-shaped base building and two highrise halves with aluminium-glass facade,
which enclose a glass centre section. The
investor is Vivico Real Estate. It commissioned Hochtief Construction AG with completion of the entire carcass. The pit was
created in advance by Züblin Spezialtiefbau
GmbH. The project is being financed by a
bank consortium with a credit volume of
EUR 254 million. Construction of the bottom
plate started in March 2009 and the base
building is to be completed by autumn 2010.
Completion of the construction work in the
50th story is planned for the end of 2011.
New double-walled pipes (130 bar)
with x-times extended service life
Both for the concrete pumping service and
for Putzmeister, Tower 185 is of interest for
another reason. For “The Pumas” also have
the order to concrete the basement floors,
the base building and the two high-rise
towers. And for the first time, double-walled,
up to 130 bar pressure-resistant pipelines
with ZX couplings are going to be used for
high-rise concrete pumping in the towers.
Double-walled delivery lines have already
been being used on PM truck-mounted concrete pumps for a long time to extend the
service life (and thereby to reduce the conversion costs and downtimes), but only in
a version limited to 85 bar pressure. For
stationary use, the high-strength, doublewalled delivery lines offer the advantage of
being able to withstand pressure up to 130
bar for as long as it takes until the inner layer in the pipe is closed. This means there is
PM 4276 GB
Background
42
Significant construction progress after
just six months
no need for regular replacement of the
highly stressed delivery line pipes immediately next to the concrete pump at highrise construction sites. For this first section of the pipeline is subject to the greatest
level of wear and the highest pressure.
Wear experience with these delivery lines
will be reported in one of the next issues of
PM Post.
The speed of the work on this project is
clear from a comparison of the two photos.
The two pictures were taken at an interval
of less than six months.
For more information, see:
www.vivico.de
www.diepumas.de
www.baunetz.de/Meldungen_Baubeginn_
fuer_Bueroturm_in_Frankfurt
The Committee for European Construction Equipment (CECE) has indicated
that, at the start of 2010, the new EU
Directive 765/2008 will enter into force. Based on this ordinance, the customs authorities at the EU external borders, will inspect in detail if the
construction equipment intended for
import actually meets the European
safety requirements, with effect from
the start of the new year.
The reason is that for years, many construction machines – e.g. from Asia – have
been sold in Europe, even though they do
not meet the safety requirements in accordance with EU standards. According to
the German Association of Machine and
Plant Engineering (Verband Deutscher
Maschinen- und Anlagenbauer (VDMA)),
one of the members of the CECE, this not
only distorts competition, but also leaves
potential purchasers in the dark about the
resulting significant risks. The German
Association of Machine and Plant Engineering (VDMA) considers these risks to
include an increased risk of accident,
significant uncertainty in legal and liability questions after accidents, quality and
guarantee problems as well as
downtimes and fines.
But not only the illegal sale
of machines is a thorn in
the eye for the CECE.
Another aspect is the
labelling obligation
of non CE-compliant construc-
tion equipment, which are shown at trade
fairs or open-house exhibitions, for example. The CECE is turning to dealers, construction companies, insurance companies
and banks. For although it is forbidden to
sell machinery that does not conform to
the EU guidelines within the European
Union, these products may be exhibited at
trade fairs provided they are labelled
accordingly. Obviously, these labels have
been omitted, however. So, for example,
random testing at INTERMAT, the big
international construction machinery fair
in Paris in April 2009, showed that the
machines in question were not adequately
labelled or had no labelling at all. In the
interest of the customer, CECE together
with the trade fair organisers will therefore ensure in future that the manufacturers
meet their obligation to label their products.
This is why the CECE is speaking out
against these illegal imports and supports
the stricter import controls for construction machinery.
By implementing qualification measures,
the CECE wants to ensure that the EU authorities responsible for customs and market monitoring are able to check compliance with these standards.
For more information, see:
www.vdma.org
www.cece-eu.org
Photo: Scholz/VDMA
43
EU imposes stricter
inspections on imported
construction equipment
44
For tight concreting deadlines, the
supply must flow efficiently
PM 4276 GB
17
Technology
45
The M 47-5 in practice –
e.g. in Marseille harbour
The office tower and future headquarters of CMA CSM in the old harbour of
Marseille is being constructed near
the quays, from which loads are taken
from the containers of the international logistics service provider. After
completion of the building core, in
which approx. 40,000 m³ concrete has
been placed, it is the turn of the
surrounding smaller structures.
There, during our visit, a Putzmeister BSF 47-5.16 HLS was
being used. We took the opportunity to talk with Christophe
Adelaide (CA), who has been
employed in sales for the pumping service Maxi Pompage
(Groupe ISP) for many years.
The M 47 “quintuplet” is really flexible again: Concrete placement from the outer end of the reinforcement to directly above the
machine
18
PM 4276 GB
Technology
46
The additional 5th arm and its hinge
increase the flexibility, number of applications and net reach of a truck-mounted
concrete pump (top). Due to a lack of
manoeuvrability, a 4-arm boom is much
more difficult to slip into buildings. It
may have to give up on attaining its net
reach, depending on how great the
distance is.
the structure and the shorter individual
arms allow for a more direct path to the site
of concrete placement. This is pure geometry (see top graphic).
PM: And how does the machine operator cope
with moving five boom arms?
CA: Operation of the quintuplet is easy from
the outset. We were relatively confident of
this because we have already had many
years of good experiences with the M 42-5.
It helps that only two joysticks are required
to move the five arms.
PM: Mr. Adelaide, how long have you had the
M 47-5 and how do you like it?
CA: This large boom was added to our mobile concrete pump fleet, which consists of 28
machines including three PUMI®s, in summer 2008. The M 47 has pumped 10,000 m³
to date. We are very happy with the machine, above all with the 5-arm placing boom.
PM: What is special about it?
CA: I compare the boom with 4-arm alternatives from the 40 m class. Above all, the
extraordinary manoeuvrability of the five
arm boom is impressive. With this, you can
often compensate for a few metres more
reach of a larger machine in the 50 m class.
Simply because you can fold out closer to
47
PM: A propos remote control. Since Bauma
2007, a display for indication and operation
of certain functions has been integrated. How
do you use this?
CA: The machine operator’s first focus is on
the machine, the boom and the man at the
end hose. He only looks at the display in
exceptional situations. So, for example, he
can read the speed of rotation if he no longer
hears the engine running, check the field
strength if the radio link cuts off or can see
how much charge is still left in the battery.
This provides safety. In addition, there are
important on/off functions for the agitator,
vibrator and others, which we use less often.
PM: The machine also has EBC, the computeraided boom control.
CA: Yes, although its use depends highly on
the individual method of operation of the
machine operator. One colleague may not
always switch it on because he prefers to
control the boom directly. Others would take
advantage of this opportunity, such as relief
staff, who don’t work with the machine
every day.
Christophe Adelaide (left) in a meeting with a service technician from Putzmeister
France and the machine operator of the M 47-5
PM 4276 GB
PM: You mean, you don’t take advantage of
the damping effect of the EBC?
CA: But you would have to admit that the
M 47-5 stands or pumps very quietly anyway. Although – the higher the pump output, the more important damping becomes.
Then we can always switch over, so that the
boom remains quiet even during a high placement and can be guided safely by the man at
the end hose.
19
Technology
Growing within its niche –
the Roline pump concept
49
Anyone driving onto the yard of Thomas Catherin Transport SARL in Montluel near Lyon
will look across to the fleet of around 15 closely parked lorries belonging to the small
haulage and pumping service provider. The office and materials store of the family firm
are housed in containers. Jean Marc Catherin, who built up the company on his own
initiative, tells us in his quiet, friendly manner why he changed from the PUMI® truckmounted mixer pump two years ago to become the first in France to invest in a Roline
concrete pump.
“I had four truck mixers, eight tippers and a
PUMI®. This was similar to what many others
had to offer, which meant I didn't really stand
out from my competitors. That’s the background to why I was interested right from the
start in the Roline machine concept. With
this small, highly manoeuvrable machine, we
can undertake a wide variety of pumping
tasks economically, fast and sometimes even
more simply than with a large truck-mounted
concrete pump. Add to this the fact that the
20
machine costs a lot less, both in terms of the
initial investment and the running costs (e.g.
fuel consumption). And so I was sure I was
doing the right thing when I ordered the first
machine from Putzmeister in mid-2008...
Of course, at first we had to familiarise our
customers with the Roline – that always takes
a little time and effort. But then we began to
gain our first experiences of pumping concrete with the system, in swimming pools,
cellars, terraces behind houses and in inac-
10:05
No supports are required with the
RoLine. Work can begin as soon as the
reducer pipe is connected.
PM 4276 GB
Technology
50
The RoLine concrete pump is designed
in such a way that it can be conveniently filled from the truck mixer, and the
delivery line can be laid out
48
10:12
Easy loading and unloading of the 3 m delivery hoses and couplings
51
10:18
The concrete work for the terrace is performed by the client with friends under their
own management. They also help with laying out the delivery pipes and hoses.
52
53
Technical data RoLine
Pump
R 60
Delivery rate (max./theor.)
Delivery pressure
58 m3/h
25 bar
Hopper volume
10:25
Filling the cement slurry to start
pumping
PM 4276 GB
400 l
Overall length/width
6.4 m/2.0 m
Support
not required
10:40
The DN 75 delivery hoses are easy to
handle
54
21
Technology
55
11:10
56
11:15
As soon as the first square metres of the terrace have been
concreted, the hoses – from back to front – are cut off and
emptied over the reinforcement
cessible narrow alleys. It all went so well that
we already have a second machine. It is not
our intention to compete with the large-scale
boom pumps; on the contrary, we limit our
activities to concreting work where pumping
is easily carried out with a rotor or 75 mm
diameter delivery lines and hoses. These
After cleaning, the hoses are immediately stowed away
lines can be easily laid over a length of up to
3 m without any problem and can still be
moved by hand when concreting reinforcements, even when filled with concrete. Of
course they are not suitable for pumping
coarse grain concrete, but we have successfully used them for grain sizes of up to
20 mm. We cannot achieve really high pump
outputs with the rotor, as the output is in
theory limited to a max./theor. of 58 m³/h.
But on smaller building sites, slower, continuous pumping is often more appropriate
and more efficient than going full speed ahead and then having to hold back. Our working
57
11: 40
To clean the line, the rotor pump sucks
the wet sponge ball back
22
12:15
Finally, the hopper and pipes are cleaned. Dismantling and cleaning are completed
after just 40 minutes.
PM 4276 GB
Technology
The RoLine is the ideal concrete
pump for smaller construction
companies and for applications in
house and apartment construction.
• Almost no concrete residue in the
system:
– The customer receives the concrete volume he pays for
– Quick and easy cleaning
• Jolt-free pumping process
• Low hopper filling height
• Light delivery line
– Safe operation up to 25 bar pump
pressure
– Light and simple handling and
fast readiness for operation
• Quiet pumping
• Delivery rate is infinitely adjustable,
forwards and reverse
• Even delivers difficult to pump
material
• Quick and easy cleaning
• Low wear:
The rotor hose is the only wear part
of the pump and can be replaced
very quickly
• Easy maintenance
• Putzmeister Service near you
methods are therefore economical for both
sides – for our customers and for ourselves.”
New components for
high-pressure resistant
delivery line system
In order to be able to shut-off a delivery
line even in narrow spaces or to be able
to switch between different inlets and
outlets of a transfer tube in the highpressure ZX delivery line system,
Putzmeister has developed new components for use on construction sites.
Some of the incentive to do this
stems from committed PM customers.
There is not space on all construction sites
for a large hydraulic gate valve or a separate hydraulic power pack. In light of this, the
new, manually operated hydraulic gate valve GVHM 2/2 130 was developed. The device is approved for a concrete pressure up to
130 bar, so that it can even be integrated in
concrete lines for high and far placement.
Due to its compact dimensions (set-up area
approx. 26 x 26 cm, height 106 cm) the
gate valve is, however, also suitable for use
on narrow construction sites, such as in
tunnels.
58
The heart of the Putzmeister scissor pipe
RS 0.76 ZX is an internally developed, axially rotatable coupling for the high pressure Zentrifix delivery line system ZX 5.5”
(approved up to 130 bar). Unlike the otherwise rigid ZX pipe connections, this construction allows, for the first time, a rotating – but at the same time completely tight
– pipe connection in Zentrifix high pressure lines. This manoeuvrability is necessary,
for example, if a concrete pump supplies
two delivery lines alternately via one transfer tube. Or if you switch from one transfer
tube outlet to another during cleaning. As
the line has to move to the side during the
sliding process of the transfer tube and ZX
couplings to date do not allow for any angle
of deviation, in the past the SK coupling
designed for smaller loads had to be used.
The new, mechanically much more stable
scissor pipes and their couplings in ZX
design now allow for much safer work with
transfer tubes.
59
The new GVHM 2/2 shut-off valve,
authorised up to 130 bar
12:20 Finished!
60
The high-pressure
scissor pipe for the
ZX system
PM 4276 GB
23
Tunnelling
61
Transport of the Putzmeister shotcrete manipulator SPM 500 over a mountain pass at an altitude of nearly 3,500 m
63
Shotcrete placement in 32km
long high mountain tunnels
In Western China, at an altitude of 3,380
m, two parallel railway tunnels 32.6 km
long are currently being driven through
the Guanjiao mountains. It is the longest
tunnelling project that has ever been
undertaken in China. Putzmeister technology was commissioned to secure the
excavation under extreme conditions
using wet-shotcrete.
The spectacular structure is being constructed in a mountainous region that is difficult
to access, and is set to replace the older
Guanjiao Tunnel (length 4 km) currently in
use and situated 300 m higher, but which is
only accessible via very windy access roads.
Thanks to the perfectly straight route
through the mountain situated at a lower
altitude, journey times will be shortened
considerably, and fuel savings will be significant as each train will have three diesel
locomotives at the front. The sections of the
new Guanjiao Tunnel have been
designed for train speeds of up
to 160 km/h.
62
The construction site accommodation is
tightly packed
Technical data for the
shotcrete system SPM 500 PC
Working height of the telescopingsprayer arm SA 14:
4.5 –16 m
Delivery rate of the double piston
shotcrete pump:
4 – 30 m³/h
Volume of the
additive tank:
1.000 l
Delivery rate of the additive
metering unit:
30 – 700 l/min
Compressor output:
9 m³/min.
Volume of the water tank:
Power cable:
195 l
50 m
(100 m optional)
Operation of
pump and boom: cable remote control
(radio remote
control optional)
Drive output of the carrier truck, including with 4-wheel steering, all-wheel
drive, rotating driver’s cab
75 kW
The Chinese machine operator familiarises himself with the remote control of the SPM 500 PC
24
PM 4276 GB
Tunnelling
64
Old tunnel:
Length: 4,010 m
65
And it’s back to
work again after
an oxygen shower
Overview of the main Chinese
rail routes (Fig. China Rail)
New tunnel:
Length: 32,605 m
The map shows the winding course of
the old, 300 m high route section and
the position of the two new, significantly longer, single lane tunnel pipes
(Picture courtesy of China Railway
16 Bureau Group)
Inhabitants of Xining in
typical traditional costume
66
67
Concrete wet spraying machine with
special spray arm kinematics
Initially, a Putzmeister SPM 500 PC concrete wet spray manipulator will be used to
secure the excavation. In late 2009 a second
machine of the same type will be put into
operation on the construction site. The allwheel-drive and all-wheel-steered concrete
wet spray systems have a concrete pump
which delivers an extremely even supply of
shotcrete via hydraulic control. The shotcrete is applied with a highly mobile spray
nozzle in combination with special spray
arm kinematics. The hydraulic parallel guide of the front telescopic spray arm makes it
possible to automatically keep the complete
telescopic spraying arm with nozzle in a
horizontal position – regardless of the angle
of the first boom arm.
Chinese site personnel before the commissioning of the PM shotcrete machine
PM 4276 GB
25
Tunnelling / Excavation
Faster to Tibet
Low temperatures and “thin air”
take their toll
The tunnels form part of the transportation
route (814 km) inaugurated in 1984 connecting Xining, capital of the Qinghai Province,
and the city of Golmud situated further
west. From 2000 to 2005, the railway line
was extended by 1,142 km from Golmud to
Lhasa, capital of the Tibet Autonomous
Region (“Tibet Railway”). The China Railway
16 Bureau Group is commissioned with building over 17.3 km of tunnel – more than half
of the entire Guanjiao Tunnel Project. The
two single-track tunnels 40 m apart will be
driven up from all four entrances to create
an excavated cross section of approx. 90 m².
Progress will be made both with the use of
tunnelling machines as well as with drilling
and blasting techniques. As part of tunnelling operations – once excavated and with
the calotte strengthened with shotcrete –
the walls and base are built moving a few
meters at a time. The construction costs for
the new Guanjiao Tunnel come to 2.5 billion
RBM (approx. € 250 million). The construction time is estimated to be 53 months, and
completion is planned for 2012.
At temperatures as low as –36°C and atmospheric pressure reduced by one-third, the tunnelling operations at an altitude of 3,380 m
put a strain on workers and machine opera68
tors. Typical symptoms experienced by site
staff include shortness of breath, exhaustion, headaches and nausea. In case of emergency, there is oxygen equipment available
at the construction site.
The compressor output of the spray gun at
this altitude is still at 100 % (the result of air
volume times pressure remains constant),
and the low static pressure has an effect on
the suction in the shotcrete pump, at least in
theory. However, at a maximum delivery
rate of 30 m³/h, this loss in output cannot be
detected in practice.
Of course, the low temperatures are a problem (the annual average is below 0° C) –
especially during the winter months. This
also results in the formation of ice in the
tunnels. This means that the shotcrete
aggregates are stored in such a way that
they do not freeze, and that the additive and
water for the concrete batches and for
cleaning purposes “free-flowing”…
For more information, see:
www.crcc.cn
www.qh.xinhuanet.com
The gradual conversion of the walls
and base, which follow the
calotte tunnelling, is clear to see
BSA pumps concrete
S.O.B. piles in Trinidad
On the Caribbean island of Trinidad, three
stationary BSA concrete pumps pump
2,000 drilled piles for an enormous bottom plate, on which the modern La Brea
720 MW gas turbine power plant is being
constructed. The client for this $ 708
million project (approx. € 480 million) is
Trinidad Generation Unlimited (TGU).
Completion of the power plant is not
planned before July 2011.
69
A BSA 1005 D delivers fine concrete to
the augured pile device
26
During the five-month foundation work, the
three Putzmeister BSA 1005 D were connected to the top car of the drilling apparatus via
a flexible hose and pipework system. The
foundation piles, which are up to 14 m deep,
are produced as screw conveyor cast in place concrete (S.O.B.) piles. With this process,
an endless screw conveyor with a liner is
sunk under constant rotation and almost
without displacing any ground. As soon as
the desired depth is reached, the BSA
pumps pump the concrete down through the
liner. At the same time, the drilling apparatus pulls the drill upwards without rotating.
A reinforcement basket is then driven into
the concrete-filled hole.
At the La Brea construction site, the specialists of Züblin Scandinavia A/S (Denmark)
and Züblin Spezialtiefbau GmbH (Stuttgart)
concrete the reinforced S.O.B. piles with a
diameter of 60 cm. The main contractor of
70
For the S.O.B. piles, reaching down to
14 m, augurs the height of houses are
required
the project is the Danish construction company E. Phil & Sons.
PM 4276 GB
Power plant construction
Food for the Telebelt ® –
Bulk concrete for dam project
71
The Telebelt ® TB 130 while placing concrete at the Braamhoek dam
The Ingula pumped storage power station will be the first hydroelectric power
station to be built in South Africa for
almost 20 years to cater for future electricity requirements. A mobile Telebelt ®
telescopic conveyor capable of conveying concrete batches with aggregate
53 mm in diameter and a low cement
content will be responsible for transporting the bulk concrete (RCC) to the
location.
The construction site is located in KwaZuluNatal, a province along the East coast of
South Africa that is home to almost 10 million inhabitants. The new pumped storage
station will consists of two reservoirs situated 4.6 km from one another with a difference of altitude of 470 m and connected by
a hydropower tunnel. The access tunnels
and the turbine house will also be located
underground.
The construction of two dams will be required
to create the water reservoirs. The 480 m
long, 49 m high Bedford dam will be constructed from rock and encased in concrete
and the lower Braamhoek dam will be 330 m
long, 39 m high and built from compressed
bulk concrete containing coarse aggregate
(roller-compacted concrete – RCC).
PM 4276 GB
72
24 hours a day,
7 days a week
A Putzmeister Telebelt ® TB 130 will be used
to transport and distribute bulk concrete
containing aggregate with a maximum diameter of 53 mm at the Braamhoek dam site
as well as concrete with other consistencies
(a total of more than 100,000 m³). The
machine is the first mobile telescopic belt
conveyor ever used in South Africa and is
frequently used around the clock, seven
days a week on the site.
The concrete mixing plant is just 500 m
from the dam construction site and has a
capacity of 120 m³/h. The RCC contains
a reduced cement share and must be integrated at a temperature of exactly 23°C. The
summer months are much warmer, especially during the day, and so the RCC process
water is cooled to 4°C in a separate cooling
system prior to mixing.
The owner of the Telebelt ® is Concor – a company that belongs to the Braamhoek Dam
consortium. The consortium of the companies Concor Roads and Earthworks, WBHO
Roads and Earthworks and Silver Rock had
previously won the contract against international competitors. The construction work
began in November 2007 and is due for
completion in 2012. When the Ingula power
station is commissioned in 2013, it will
The telescoping conveyor belt can be
guided accurately over the reinforcement
generate a turbine output of 1,332 MW,
making it the largest pumped storage power
station in South Africa.
73
Truck mixers load the Telebelt ® feed
conveyor. The insulation of the mixer
drum is also clear to see, as it protects
the cooled concrete from the high
ambient temperatures
27
Less Wear · Longer Service Life · Greater Economy
The New Generation
Proline 67
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PM 4276 GB