Customer magazine by Putzmeister Concrete Pumps GmbH 75
Transcription
Customer magazine by Putzmeister Concrete Pumps GmbH 75
Customer magazine by Putzmeister Concrete Pumps GmbH 75 French pumping service with modern machine fleet and additional business areas Evenly pumped with EPS – air-entrained concrete for avalanche protection PM 4114 GB Frankfurt's OpernTurm is growing with concrete pumps and a "climbing boom" Content 1 7 Foreword Current economic crisis an opportunity 3 Title story Frankfurt's OpernTurm is growing with concrete pumps and a "climbing boom" 4 Background Not seasick in the slightest 2 10 12 On site French pumping service with modern machine fleet and additional business areas 12 Pumps used on historical soil 15 16 Rotor pumps free-flowing cement screed – which can be walked on after 1 hour 3 Evenly pumped with EPS – air-entrained concrete for avalanche protection 18 BSA with crawler track for the pile foundation 21 22 Concrete pumps on target 18 Practical tip Too much pull? 20 4 Training Intensive training on the "real" model 2 23 24 PM 4114 GB Foreword Current economic crisis an opportunity 5 For months now, the global financial crisis has been shaking the foundations of the international banking and financial system. The precarious situation that many credit institutions have found themselves in has led to a restrictive financing policy felt by our clients as well as ourselves. The impact of the financial crisis has also affected the real economy. The construction industry is particularly affected, and has had to record weak downturns, in particular in the leading industrial nations. The recession in the USA and other important markets has not left our business untouched, and has led to significant adjustments in the organisation worldwide in line with market conditions. In addition to the negative economic development, 2008 has been shaped by our Chinese competitors settling directly in Europe. This will enable us to excel at new technologies and prove our superiority in terms of technology and service in a direct comparison. Imprint ■ Editor: Putzmeister Concrete Pumps GmbH, Max-Eyth-Straße 10, 72631 Aichtal / Germany ■ Editorial department: Jürgen Kronenberg, Layout and graphics: Friedrich Pippich, Putzmeister Concrete Pumps GmbH, Max-Eyth-Straße 10, 72631 Aichtal / Germany ■ Print: Druckerei Mack, Siemensstraße 15, 71101 Schönaich / Germany PM 4114 GB With the realisation of the global region concept, Putzmeister is well positioned to take on the new challenges: by means of forced implementation of the global region concept for sales and service, we are achieving an even greater proximity to the global markets and our customers. The global production concept enables an optimised production process that is based on the requirements of the relevant market. The global logistics concept acts as the third pillar in coordinating the global production concept. Without doubt, the current situation requires even greater effort from all of us. We will only succeed in traversing new paths if together our employees, partners and customers all revise their thinking. To achieve this we have to move together even more closely than in the past; together we will master the new situation. All in all, we should not see the current economic crisis as a threat, but as an opportunity. Potential regarding new markets and technologies are frequently not used to the optimum in times of economic prosperity. We are now being offered the opportunity to direct greater attention to these areas in order to emerge stronger from the current crisis – even if this may take us some time. I wish all of you and your families a Merry Christmas and a Happy New Year. Felix Selinger, Dipl.-Ing. Managing Director of Putzmeister Concrete Pumps GmbH 3 Title story Frankfurt's OpernTurm is growing with concrete pumps and a "climbing boom" Ed. Züblin AG is currently erecting an imposing high-rise project, the OpernTurm, in the centre of Frankfurt am Main at a breathtaking speed. Including its base plate, around 55,000 m3 of concrete will be placed in the 170 m tower. The main players in the speedy construction progress are, among others, Europe's largest truck-mounted concrete pump M 63-5, a stationary high pressure concrete pump BSA 2109 as well as a stationary boom MX-32-4, on newly developed tubular columns with a climbing system. The new construction of tower building and podium in front is located precisely opposite Frankfurt's Alte Oper, which is steeped in tradition, and will, once completed, blend harmoniously into the surrounding architecture. In the three basement floors, the OpernTurm has 580 car parking spaces, and approximately 67,000 m2 office and business space is rented over the 42 upper floors. The project developer is the American estate agency Tishman Speyer, which has already formed a striking image with the construction of the Frankfurt MesseTurm in the metropolis on the River Main. As the main contractor, Ed. Züblin AG is in charge of turnkey-ready construction work. Construction began in summer 2007 and is expected to be complete by the end of 2009. Massive base plate concreted with 5,660 m3 in 72 hours The order for concrete delivery, both for the base plate and for construction of the building itself, with 46 floors, was given to the concrete pumping service "Die Pumas". After extensive foundation work by Ed. Züblin Spezialtiefbau GmbH (in consortium), three truck-mounted concrete pumps from the pumping service situated in Lorsch with 42, 52 and 63 metre booms took on the task of concrete delivery for the base plate with a thickness of 3.0 – 4.5 m in July 2007. Due to the highly restricted space available, setting up the large boom concrete pump was far After 72 hours, the three truck-mounted concrete pumps have finished concreting the huge base plate, which is up to 4.5 m thick 4 PM 4114 GB Title story 7 from easy: while there was space for the M 42-5 and M 63-5 with one-side support on a makeshift ramp or on the very busy Bockenheimer Landstrasse, the third machine had to be set up on a specially-erected heavyload frame. Three consecutive days and nights were allocated for installing the 5,660 m3 concrete (strength class C 30/35). The Putzmeister M 63-5, the largest truckmounted concrete pump in Europe, alone delivered 2,000 m3 of the total volume within 24 hours without any problems. In consideration of performances at the neighbouring Alte Oper, a 20-hour break from concreting operations, which lasted several days, was accepted. It was thanks to finelybalanced concreting logistics that concrete was transported by truck mixers through the heavy inner-city traffic without any obstacles. 6 The M 63-5 works with one-side support from the roadside (Fig. Die Pumas) 8 (Fig. Die Pumas) PM 4114 GB A small ramp is enough to set up the M 42-5 (Fig. Die Pumas) 5 Titelstory Title story 9 The concrete pumping service also has stationary booms and pumps for large projects Concrete placing boom stands freely 16 m high on the tubular column without lateral guides In addition to a large fleet of truck-mounted concrete pumps (33 machines), the pumping service "Die Pumas" also has five stationary concrete pumps and seven stationary booms. This leaves the company in the best possible position to take on concrete delivery tasks for demanding high-rise projects. At Frankfurt's OpernTurm, "Die Pumas" are using for the first time the new Putzmeister tubular column system RS 850 with a simplified, automatic climbing system that carries the stationary boom with a reach of 32 metre. During construction of the OpernTurm, the stationary boom climbs upwards, in line with construction progress, not inside one of the building shafts but between the two cores, through holes in the floor. A tubular column and boom were installed after the third floor was completed, i.e. at the height of level "0" (ground floor). Since then, the concrete placing boom has stood freely, without ballast, on a tubular column 16 m above the last floor guide. Due to its higher position, the boom not only reaches every point of the floors, each of which are 1,800 m2, but also the formworks of the building cores, which are three levels higher. The stationary boom is connected to the stationary concrete pump by means of an approximately 80 m long ground line (DN 125). Later on, as the building height increased, the ground line was continued as a riser up to 170 m. Central constructional elements of the OpernTurm are two building cores, which will, when the building is complete, accommodate the stair wells, lift shafts and supply lines. During the building phase, the two cores are always two to three stories ahead of the floors. Both the two cores and the floors are made of concrete of strenght class "Die Pumas" associate Ingo Melzer C50/60 with a maximum grain size of 16 mm. The concrete batches, delivered from three mixing plants, are regularly monitored on the construction site by a laboratory. 10 11 Monitoring the concrete batches on the construction site Compact reinforcement (Fig. Tishman Speyer/Photographer: Klaus Helbig) 6 The BSA 2109 H D is connected to the 170 m hi delivery line PM 4114 GB Title story 14 12 From a higher position, the PM stationary boom also distributes the concrete to hard-to-reach parts of the ceiling formwork 15 New tubular column system automates the climbing of concrete placing booms The MX boom stands freely and without ballast on the tubular column, 16 m high 13 igh riser by means of an 80 m long horizontal PM 4114 GB The boom tubular column is held by four lightweight floor corner brackets. Each weighing approximately 35 kg, these guides can comfortably be carried to the next but one floor after the climbing procedure – heavy floor frames are not an issue with this system. In the Putzmeister RS 850 tubular column system, the climbing cylinders and locating bolts that are otherwise customary are replaced by integrated extending feet and the climbing system that is secured to the tubular column and also rises. With the new tubular column system, the delivery line is also no longer guided sideways along the column but integrated in the tubular column. When the floor is broken through, therefore, only one square opening is required. Let the placing boom climb one storey, set up the formwork, position reinforcement, concrete and strip the formwork after 12 hours – on average, one storey is completed every four days. Easy-to-move floor guides keep the boom tubular column laterally fixed 7 Title story 18 20 19 21 The RS 850 system – well thought out right down to the last detail New tubular column The RS 850 tubular column system comes with 3 m, 6 m or 9 m columns as standard, with standard pipeline lengths. Different tubular columns for setting up the boom pedestal and arm assembly are not required. The double M tubular column profile requires only one simple, square cut-out (1 m x 1 m) in the floors. When an adapter is used, existing booms can continue to be used with the RS 850 tubular column. 16 Automatic climbing procedure The climbing system integrated in the tubular column profile allows automatic climbing in the building. Once the climbing procedure is complete, the climbing cylinder is drawn upwards along the climbing bar, using a cable winch. Simple column connection Instead of the procedure common up until now, in which the tubular columns had to be laboriously screwed together, re-usable pins are now used in the RS 850 system. They can be simply inserted by hand and secured. 17 8 PM 4114 GB Title story 22 In order to place the average of 100 – 120 m3 concrete in the ceiling formworks, the concrete workers need around three hours. To concrete a core (30 – 50 m3), one and a half hours. The stationary concrete pump at the base of the OpernTurm is operated by Matheo Placido, one of the most experienced "PUMA" machine operators. On top of the formwork, a specially-trained construction site employee controls the MX stationary boom by radio remote control. The two machine operators stay in contact by walkietalkies so that the output can be adjusted immediately. The boom and tubular column climbing process, which is largely automated, is also controlled by site workers. The climbing procedure from one storey to another, including placing the corner brackets, takes approximately 1.5 hours. Concrete is delivered right up to the top level by a ZX pipeline that is around 250 m long in total. This version is permitted for use with pressures up to 130 bar. In fact, the Putzmeister BSA 2109 H D in rod side operation at the Frankfurt OpernTurm "only" requires around 90 bar concrete pressure at delivery rates of 35 – 40 m3/h. When the floors are concreted, approximately 100 –120 m3 concrete is placed within three hours, high above Frankfurt 23 Technical data of the BSA 2109 H D Motor: 6-cylinder Deutz Drive performance: Stroke: 200 kW 2,100 mm Diameter of delivery cylinder: 200 mm Max. delivery pressure (piston side): Max. delivery output (piston side): Transmission ratio (piston side): 91 bar 95 m3/h i = 2.3 Max. delivery pressure (rod side): 152 bar Max. delivery output (rod side): 57 m3/h Transmission ratio (rod side): i = 3.8 Machine operator Matheo Placido stays in contact with the boom operator up on the floor by means of a two-way radio PM 4114 GB 9 Background Not seasick in the slightest speed on longer downward gradients ("throttle valve" principle). Since 22nd August 2008, the first M 70-5 large boom concrete pump has been on the American continent. This was preceded by careful planning and routine processing by PM dispatch, transfer to Bremerhaven on its own axis and a 3-week sea crossing. Meanwhile, the second M 70-5 will soon be ready for delivery from Putzmeister in Aichtal. It is also headed for an American concrete pumping service. Putzmeister processes almost all transfers of truck-mounted concrete pumps to customers abroad with the support of two or three renowned shipping companies. These transportation companies have the best contacts at the customs offices, liaison offices in the countries of destination and, with their experienced personnel, guarantee a reliable transfer of machinery. For the M 70-5 transfer, for instance, PM dispatch commissioned the shipping company Alfons Köster & Co. GmbH (headquarters in Hamburg). For noneveryday shipping tasks, the large logistics companies occasionally work together with specialised partners. This was also the case with the transfer of the M 70-5 from the Aichtal Putzmeister works to the roll-on / roll-off terminal (RoRo) at Bremerhaven. This part of the journey was overseen by the shipping company Gerber Transfer und Logistik GmbH (Munich). Some of their drivers are specially trained in transporting heavy loads on roads. For one thing was clear: a truck-mounted concrete pump with 52-metre boom and a gross weight of 48 t drives (and brakes) somewhat differently to a machine weighing almost 80 t with a 70-metre boom. Driver Hans Ott took it all in his stride, however: with decades of professional experience in heavy goods vehicle traffic and gross vehicle weights of over 300 t, he had done this more than enough times in the past. way bridge section between Würzburg and Fulda, prohibited for heavy goods vehicles over 44 t, had to be avoided. Travelling via Kassel and Hanover, the M 70-5 long-reach boom pump reached the pier in Bremerhaven after 816 km and 14 hours of travel time. We asked the driver Hans Ott whether the Kenworth C500B (10 x 6/4), which with 370 kW was not exactly "over motored", was not too slow for a tractor unit. "No", was the answer. "Even in the mountains around Kassel, with their steep, drawn-out climbs, we were still able to travel at at least 30 – 40 km/h." The experienced driver probably had to adapt on the downward gradients: while European manufacturers usually equip their trucks in this weight class with eddycurrent brakes or retarders as permanent brakes as standard, the Kenworth still has the traditional engine brake for stopping the On the subsequent three-week sea voyage on the "Cepheus Leader", the M 70-5 longreach boom pump was left alone. Sailing southwest, the huge transport ship crossed the Atlantic and headed first for the east coast of America and Florida's Jacksonville harbour. The civilian section of the Jacksonville harbour facility is the most important port of transshipment for vehicles in the USA. After a brief stopover, the journey continued through the Caribbean, and in mid-August the M 70-5, on board the transport ship, passed through the almost 82 km long Panama Canal, with its three lock installations. After a total of 8,635 nautical miles (approximately 16,000 km), on 22nd August the largest truck-mounted concrete pump in the world rolled off the ship in San Diego harbour (California) on its own axis in a wholly unspectacular manner – and without any sign of sea sickness: Welcome to America! 24 25 A 16,000 km sea journey On the loading ramp, the semi-trailer concrete pump adapts to the different levels (Fig. Köster) Different driving and braking behaviour Since the M 70-5 was designed for the American market, the machine required an official certificate of exemption for the transfer journey, on account of the special axle configuration. This certificate specified not only the course of the journey, but also offperiods in which the journey had to be interrupted (6.00 – 8.30 am and 3.30 – 6.00 pm). An accompanying vehicle followed the 10axle semi-trailer concrete pump at a distance of 50 m. A police escort was not required. The route took the vehicle directly north. The only time that the semi-trailer truck had to use non-motorway roads was when a motor10 For shipping on the "Cepheus Leader", a vehicle transporter 200 m in length, 32 m in width and with a capacity of 62,600 GRT, the concrete pump drove on board backwards over a loading ramp. This showed once more that the combination of tractor truck and air-sprung semi-trailer is completely manoeuvrable, even when the traffic area is on different levels. 26 Specialist in unusual transportation: driver Hans Ott View of the Kenworth driver's cab PM 4114 GB Background 27 The M 70-5 travels at speed even on rural roads (Fig: L. Franke / Köster) 28 After a 16,000 km sea voyage, first arrival at San Diego harbour PM 4114 GB 11 On site French pumping service with modern machine fleet and additional business areas In the small, northern French town of Hazebrouck, approximately 40 km south of Dunkirk, the construction company Eifrage TP Nord (Wattignies/Lille) is currently building a rainwater storage basin with a capacity of 10,000 m3. Their customer is the municipality of the township numbering 21,000 inhabitants. The basin, sunk 12 m deep, has a diameter of approximately 35 m and will relieve the strain on the town's sewage system after heavy rainfall. It is only worthwhile to use truck-mounted concrete pumps with a large working range and flexible boom technology here. The order for pumping approximately 1,100 m3 concrete for the basin wall, base plate and eight columns that will later carry the reservoir cover went to the concrete pump operator Transports Samyn from Arques, 20 km away. The company's first Putzmeister truck-mounted concrete pump M 47-5, only a few months old, provides the best preconditions for civil engineering, namely sufficient reach and highly-flexible boom kinematics in the 5-arm boom. M 47-5 in civil engineering with EBC boom damping The machine stands, correctly supported, directly in front of the concrete circle that contains the rainwater storage basin, and today will concrete the connection between the base plate and the basin wall (52 m3). To do this, the machine operator, Bernard Battel, has to drive the boom tip in an arc of 35 m diameter at a depth of 12 m. During this process, the end hose is either within the reinforcement or constantly approximately 20 cm above it. Since the M 47-5 is equipped with EBC boom control, Mr. Battel can switch on additional damping for the placing boom using the radio remote control. 29 Machine operator Bernard Battel 12 Wide, deep and across columns – the M 47 "Quintuplet" adjusts flexibly to construction site conditions, even in this rainwater storage basin PM 4114 GB On site 31 100 m delivery line on board – concrete pressure can be limited with EPS The M 47-5's flatbed offers ample space for additional delivery pipes But the machine is also at home on construction sites of very different scales. This is clear from some specifications given by customers. For instance, in France, the 35 t 4-axle vehicle (DB 4144) was loaded to 41 t permissible gross weight and fitted with additional brackets as well as support cradles for further delivery pipes. It total, Transports Samyn's M 47-5 can now carry up to 100 m pipelines (DN 100) on board. The computer-aided electronic pump control stands the machine operator in good stead when ensuring that concrete pressure in the delivery line installed on the ground does not increase too much during pumping operations. For the EPS system not only offers a considerably quieter pumping process with correspondingly lower fuel consumption in comparison to conventional control systems, it also allows concrete pressure to be limited. To do this, the rotary selector on the radio remote control can be used to specify the maximum pressure required. This value is also shown in the display and can be changed at any time. 30 PM 4114 GB 13 On site 32 Supplying concrete and other building material for 25 years Safety taken seriously The degree of seriousness with which the issues of safety and employee training are taken at Transports Samyn is exemplary. For instance, before a new concrete pump operator can take over his machine, an experienced colleague accompanies him on the construction site over a period of several weeks. Thus, it is taught not just in principle but also in practice how the PUMI® or truckmounted concrete pump is safely supported or the required distance from power lines is kept. Naturally, cleaning the delivery line and pump is also taught "on the object". Moreover, in Francois Gruwe, Transport Samyn has an employee who, in addition to his everyday work in the office and warehouse, takes charge of complying with safety-relevant aspects in the company, on the vehicles and construction sites. The company Transports-Samyn has been in existence for 25 years. It was founded by Patrick Samyn, who quickly earned a good reputation as a transportation company for concrete and other building materials in northern France, shortly afterwards setting up his own concrete pumping service. In 2001, Damien Cousin took over the company, including all employees. Meanwhile, the workforce has grown to 47 persons, including Cousin's wife Aurelie. The vehicle fleet has almost doubled in the past seven years. Alongside other trucks, Samyn now has 15 truck mixers, 12 PUMI® truck mixer concrete pumps and 13 truckmounted concrete pumps. The company is distinguished by one special feature: some of the Samyn truck mixers, both PUMI® and truck-mounted concrete pumps, can be rented without machine operators, instead being driven by internal personnel. Mr. Cousin considers the main area of operation for Transports Samyn to fall within a radius of a roughly two-hour car journey around the company headquarters in Arques. For this reason, drivers frequently do not return to company premises in the evening, instead taking the concrete pumps home with them. This saves both time and fuel. The machines are then cleaned on the premises of one of the concrete plants that work with Transports Samyn. Damien Cousin, the "patron" of Transports-Samyn 33 Quick parts delivery Damien Cousin has routine maintenance work and repairs performed in his own, well-equipped workshop. If wear parts are required for the Putzmeister concrete pumps that are not in stock in his own warehouse, these can be supplied quickly. "Parts transport from Putzmeister France's central warehouse in southern Paris to us takes only around three hours – I can live with that", says Mr. Cousin in an interview. In addition to the rapid-response customer service, Mr. Cousin rates the constantly expanding Putzmeister range of technical innovations above all as positive, currently, for instance, the "Follow Me" boom control by movement of the end hose. Mr. Cousin operates smaller construction sites with his truck mixer concrete pumps, like the rotor PUMI® 24.67 Q shown here 14 PM 4114 GB On site 34 Pumps used on historical soil The Mount Washington Hotel, which became known in 1944 as the Bretton Woods conference venue, is currently being expanded into a wellness area. During the construction work concrete is delivered into the individual formwork sections by a Putzmeister BSF 36.16 H. 35 36 The plan is to open the extensive plot, with its modern, landscaped swimming area by the turn of 2008/2009. During the winter months, the Bretton Woods area is primarily visited by cross-country and downhill skiers. At warmer times of the year, the Mount Washington Hotel, above all the rambling and well-manicured golf course, is a focus for guests. While the name Carroll, a small town in the US state of New Hampshire that is home to around 700 inhabitants, is hardly well known, much has been written around the world about the southeastern district of Bretton Woods with its Mount Washington Hotel, for some time. This is because the imposing hotel, built in 1902, was the venue for the Bretton Woods conference (1st – 23rd July 1944). The decisions made here led a little later to the formation of the World Bank and the International Monetary Fund – institutions that, on the one hand, even today play an important role in the international economic system but on the other, also face criticism from opponents of globalisation. M 36-4 carrying out concreting work in Bretton Woods (Fig. Brinkmann) PM 4114 GB 15 On site Rotor pumps pourable cement screed – which can be walked on after one hour Many pump operators are presumably aware that rotor pumps can deliver not only concrete but also liquid screed. Liquid anhydritebased screed (i.e. containing gypsum) is widespread, particularly in France, due to its easy workability for constructing floors in residential and industrial construction. In the meantime, the cement screed suitable for external and damp areas has also been – mark you: in pourable form – delivered by truck-mounted concrete pumps with rotor systems. 37 A typical construction site situation for this is displayed by these photographs from a Paris suburb. Here, the concrete pumping service Inter Service Pompe (ISP) which operates across the country is using a Putzmeister pourable concrete pump BQF 28-4.80 from its fleet to cast the shared terrace in the inner courtyard of a semidetached house with pourable cement screed. With its 4-arm, 28-metre boom, the dimensions of the machine are more than sufficient for this kind of job. A total of 16 m3 material is required for the outer area, which is approximately 90 m3. The substructure consists of a concrete ceiling of an underground car park. Once the 8 m3 batch from the first truck mixer has been pumped quickly into the inner courtyard at the semidetached house construction site, operations stall. The second truck mixer is clearly in a traffic jam and does not appear for another half an hour. In the meantime, the concrete pump operator has swung back the boom and begun pumping the pourable cement screed in a circle, with the end hose over his own hopper. This is because he knows the mixture breakdown, which, among other elements, contains a maximum grain size of 8 mm, 300 kg/ m3 cement and a setting accelerator: although the material is nothing special to look at (consistency of pea soup), it has to be processed very quickly, as the screed will set after only an hour, allowing the ground to be walked on. The Putzmeister BQF 28-4.80 is equipped with a rotor pump. The delivery system is largely the same as the rotor, as is known from the rotor PUMI®. With a delivery output of 80 m3 /h (max./theor.), the rotor unit in the truck-mounted concrete pump is, however, significantly more powerful than that on the PUMI®. Looking over the new 2-storey building from the street – with the 28-metre boom, the BQF rotor concrete pump has a considerable working range 16 PM 4114 GB On site 38 Overview of screed types A basic distinction is drawn between screeds based on cement and those based on anhydrite, both of which are available in different quality grades. While traditional screed (bonded by cement or gypsum [anhydrite]) does not pump due to its stiff, thin consistency but can only be delivered using compressed air (Putzmeister Mixokret system), liquid screed based on anhydrite and cement is well pumpable and easy to process. Due to its particularly even pumping characteristics, screw conveyor pumps, as well as rotor pumps, are mainly used to deliver this material. If a truck mixer does not come and the concrete threatens to set, only one thing helps: pumping in a circle (i.e. into your own hopper) The machine does, however, have all the benefits that characterise a rotor pump ■ very quiet in operation ■ continuous, interruption-free delivery ■ even the smallest concrete volumes can be pumped ■ pump system and concrete hopper can be emptied almost completely after use – meaning that there is no concrete residue to dispose of ■ easy to clean 39 But anhydrite liquid screed with gypsum as a binding agent does not have only benefits. For instance, this material is not suitable for outside structural elements (balconies, terraces, garages), or rooms with high air humidity (bathrooms, shower rooms, swimming pool areas). Due to the relatively high water content, floors made of anhydrite liquid screed cannot be walked on or bear load until considerably later than floors constructed from traditional cement screed. Cement-bonded liquid screed is, therefore, an alternative for floor construction in outside or wet areas. It contains Portland cement as the binding agent and is laid floating or sliding, as with synthetic resin cement screed (binding agent: resin coated special cements). PM 4114 GB 17 On site Evenly pumped with EPS – air-entrained concrete for avalanche protection Klosters is erecting an avalanche protection gallery at a height of 1,800 m in the Swiss Canton of Graubünden. The standard EPS equipment for the stationary concrete pump BSA 1003 D stands the machine operator in good stead when air-entrained concrete is to be delivered, as this equipment can limit the maximum delivery pressure precisely. Despite frequent concreting operations, the firm manages to avoid any disruption to railway services on the Klosters-Davos route. By creating a gallery on another section of track, the Rhaetian Railway is eliminating a possible source of danger that can, in some Alpine regions, lead to repeated accidents due to landslides and avalanches after heavy precipitation. The construction site for protecting the railway track is located only a few kilometres north of the popular holiday resorts of Davos and Klosters. The construction costs are estimated at CHF 2.7 m. (approx. EUR 1.8 m.). In order to construct the 90 m long Seehorn avalanche gallery (7 m wide, 8 m high) all components will be concreted using a concrete pump, and even the 61 double-sided slanted concrete supports will be manufactured on site. The gallery has a longitudinal gradient of 2.5 % and, due to the small curve radius, a transverse gradient of 6.4 %. Due to the limited space available and the trains running at 20-minute intervals, particular care has to be taken with the logistics of the construction site. Air-entrained concrete prepared homogeneously in the mixing trough The construction site equipment directly next to the railway track includes a small concrete mixing and pump installation. The pre-mixed gravel components (0 – 32 mm) are delivered by truck and transferred to a compulsory mixer with a tipping trough. The exact quantities of cement, plasticising admixture and air-entraining agent are added in this mixer. With the air-entraining agent, the construction site reaches a pore volume of approximately 4.3 % in the concrete. The tiny air voids are required in order to create numerous small air chambers in the cement paste, which provide space into which the freezing water can expand at winter temperatures. This increases the 40 A glimpse of how the construction site is set up: The tipping trough (right) in its vertical position transfers the gravel additives into a compulsory mixer (covered with a sheet here), in which the aggregate is prepared with water, cement, plasticising admixture and airentraining agent to form concrete. Underneath that is a double-shaft additional mixer, which transfers the concrete batches to the hopper of the BSA 1003 D. 18 PM 4114 GB On site 42 component's frost resistance. After being mixed for 90 seconds in the compulsory mixer, the concrete and its additives are intensively homogenised once again in a double-shaft pre-mixing trough with a 3 m3 volume, which transfers the concrete in equal doses to the hopper of the BSA 1003 D. Concrete pressure always under control While delivering air-entrained concrete using a rotor pump may be problem-free (a maximum pressure of 25 bar may apply, depending on the system), caution is necessary when a piston pump such as the BSA 1003 D is used: for instance, at higher concrete pressures (up to 80 bar is possible with this pump type) the air voids in the concrete are compressed and thus destroyed. In consequence, the concrete would no longer be frost resistant and the component would have to be torn down again. Putzmeister stationary concrete pumps have clear advantages here, due to Ergonic® pump control (EPS): with EPS the maximum pressure required can be set precisely. This is practical not only for pumping concrete with air voids, but also if the pipeline's wall thickness (i.e. its compressive strength) is unknown. Over the course of the 62 concreting operations between July and October 2008, the BSA 1003 D delivered concrete outputs of 15 m3/h at pressures between 19 and 24 Gallery construction has the same longitudinal and transverse incline as the 61 concrete columns on the valley side 44 bar. It manufactured foundations, guide walls, back walls, supports and floors for the gallery, concreting sections of 15 to 150 m3. During this time, the length of the delivery line (DN 125) reached up to 130 m. At two points, the pipeline had to pass under the railway embankment, in consideration of the client's strict special requirements. In total, the BSA 1003 D delivered 1,900 m3 air-entrained concrete (C25/30, exposition class: XF4) for the Seehorn avalanche gallery, with 36-40 cm spread and a relatively low W/Ceq value of 0.42. Measuring device to determine the air void contents 41 Information on the Rhaetian Railway The Rhaetian Railway (RhB) is a narrowgauge railway company in the Swiss Canton Graubünden, founded in the year 43 1888. The RhB has a rail network of total 384 km in length, with a track width of 1,000 mm, made up of eight regular stretches of track and one motorail connection. Every year, the Rhaetian Railway transports 9.7 million passengers. The RhB's rolling equipment includes 80 locomotives, 391 passenger carriages and 743 goods wagons. With 1,270 employees, the company generates revenue of approximately CHF 296 m. (approx. EUR 197 m. (all figures from 2007). A significant part of the business profit is spent on ensuring the safety and on renovating routes, including the 582 bridges and 114 tunnels, as well as on modernising the machine fleet. In summer 2008, the technically and scenically spectacular RhB rail route between Thusis and Tirano (Albula/Bernina) was designated a UNESCO World Heritage Site. The work does not interfere with rail traffic PM 4114 GB 19 45 Practical tip Too much pull? Pipe brackets on placing booms play a "bearing role", since, on stationary booms and truck-mounted concrete pumps, they connect the delivery line to the outrigger. But it is important to make sure that pipe bracket clamping strips are not fastened too tightly! At Putzmeister, a pipe bracket design in which delivery pipes are usually clasped and held by a pipe clamp before and after the coupling has been proving its worth for years now. The bracket is made of a flexible steel clamping strip and a steel pipe rest as a counterpart. With this design, the actual holding powers are deflected to the boom by to the way in which delivery pipes are secured. This is because the clamping strip pivots react highly sensitively if tightening torques are too great. In extreme cases, this could even cause strips to crack. This is added to by the dynamic loads of the placing boom, which lead to additional forces on the clamping strips. Stress distribution in the area of the pipe bracket when the clamping strip is very tight means of a pipe holding pipe welded securely to the pipe rest. The trend seen in recent years towards greater boom lengths, reduced material thickness (in the interests of saving weight) and, on average, ever greater concrete pressures requires increased attention to be paid However, if the screw tightening torque is too great, this will also have detrimental effects on the wear and weight optimised twin pipes. These double-walled delivery pipes are now part of the original equipment for most Putzmeister truck-mounted concrete pumps and repeatedly baffle concrete pump operators due to their longevity. However wear-resistant twin pipes may be, if the clamping strip is tightened too much, cracks may appear in the inner pipe. Cracks in twin pipes are usually harmless, however. But if the inner pipe becomes so distorted that gaps appear, the cracks will be eroded at this point and increased wear will occur. 46 For this reason, Putzmeister recommends reducing the screw tightening torque on clamping strips in order to relieve the strain on pipe brackets and delivery pipes. If the tightening torque is reduced on the clamping strip, the pipe is fixed significantly more flexibly in its bracket than it was previously, since minimal pipe movements in the bracket can be made without any great resistance. This prevents secondary bending and relieves clamping strips, delivery pipes and pipe brackets. In practice, this means that tightening torques can be lowered to 15 Nm when new pipework is initially assembled (including new clamping strips). If a torque wrench is not available, the following procedure is recommended: 1. Without increasing your effort, tighten the clamping strip screws until the clamping strip is resting against the pipe and you feel increased resistance when you turn the wrench. 2. To reach the required screw tightening torque of approximately 15 Nm, turn the nut on a free-moving thread one full turn (360°). If the thread is stiff, 1.5 turns (540°) are advisable. A reduced tightening torque on the clamping strip relieves clamping strips, delivery pipes and pipe brackets 20 PM 4114 GB Practical tip BSA with crawler track for the pile foundation In September, considerably earlier than planned, the Spezialtiefbau consortium (Ed. Züblin AG and Bilfinger Berger AG) completed the contracted foundation work for the future Rhine Gallery in Ludwigshafen. A significant amount of this rapid construction progress was due to a Putzmeister concrete pump on a crawler track, which manufactured hundreds of drilled piles using the screw conveyor in-situ concrete procedure (SOB). 47 chain-driven, heavy piling device even on unsecured terrain. The two machines were connected by means of an approximately 22 m long hose line that was connected to the auger on a pipeline with flexible connection hoses (DN 125). Drive commands, steering and operation of the concrete pumps were performed via radio remote control. The relatively high pump output (max. 120 m3/h) was not required in continuous operation when the drilled piles were concreted, but was frequently beneficial during the first phase of hole filling when relatively large volumes of concrete had to be installed quickly. Meanwhile, many civil engineers prefer to use self-driving construction site concrete pumps to fill the drilled piles, and for good reason. This is because, in contrast to truckmounted concrete pumps, a crawler track BSA does not have to be supported, and can begin work on the next hole within a very short period of time. In addition, when constructing pile foundations, concreting with this machine is much safer as it does not require such precise coordination of movements between the two machines: the danger of the drilling apparatus suddenly pulling on the end hose, and therefore on the placing boom, is also excluded (result: the truckmounted concrete pump tips over). And, in comparison to concreting with a delivery pipe, the placing output with a concrete pump is considerably higher. Both on crawler trucks, the heavy augured pile device and the concrete pump can also be used to their full extent "off road". A hose line creates the connection between the two machines Of the 580 concrete piles, the Spezialtiefbau consortium manufactured 510 (between 90 and 120 cm in diameter) out of screw conveyor in situ concrete. The average daily output was between 12 and 13 SOB pillars. The remaining 70 piles are concreted in the usual way with a delivery pipe. In total, approximately 9,000 m3 concrete (C25/30) was required for the pillar foundations of the Rhine Gallery. 48 The new shopping centre, which later will have 120 retail outlets, is being built on a 10 hectare plot in Ludwigshafen, on the former Winterhafen site, which was filled in in 1957. To ensure that the planned Rhine Gallery will stand on firm ground, its 400 m x 80 m base plate is being erected on numerous reinforced concrete pillars, which are placed in a precise grid. Before the 15.5 to 21 m deep holes are sunk, any existing obstacles in the building ground were eliminated by means of fragmentation drilling. To manufacture the SOB pillars, a heavy piling device was used to PM 4114 GB screw a hollow stem auger in the prepared building ground. Once the target depth was reached, concrete was delivered under pressure using the bore of the endless auger in the hole. In this process, the drilling apparatus pulled the auger upwards without rotating it. Once the auger and the drilled material accumulated on the surface had been removed, a reinforcement cage was shaken onto the freshly-concreted pillar. The holes were filled with concrete by a Putzmeister BSA 1412 D RF pump on a crawler track. The machine is equipped with an off-road chassis so that it can follow the The machine operator controls the selfdriving concrete pump 21 On site 49 Concrete pumps on target Since January 2008, an extensive building complex has been under construction directly on the start and home stretches of the Nürburgring. During concreting operations, it is good to observe the ever-changing Putzmeister truck-mounted concrete pumps such as the popular models M 24-4 and M 36-4, the compact M 46-5 and M 52-5 or the imposing M 58-5 and M 62-6. With their 5 and 6-arm booms, the long-reach boom pumps, which extend over walls, can reach even inconveniently-situated formwork sections. 50 From the set-up site beyond the 350 m long wall, the PM long-reach boom pump M 62-6 can comfortably reach the formwork sections for the new "world of adventure" at the Nürburgring For around € 25.5 million, the carcass of a "world of adventure" is being erected opposite the grandstand on the legendary race track in the Hocheifel region. Among other elements, the project includes an underground car park (700 parking spaces), a "boulevard", on which automobile manufacturers and accessory suppliers will give presentations, an arena for 3,500 guests, an "event hall" with capacity for 1,800 people and the "Welcome Centre". The leisure time facilities will be rounded off with a gocarting track and a roller coaster. In addition, a new, modern grandstand is to be built with 5,000 covered seats as well as a "business lounge" for 600 guests. The order for the 350 m-long building complex has been assigned to the Nürburgring consortium (Ed. Züblin AG, Max Bögl Bauunternehmen GmbH & Co.KG and Fritz Meyer GmbH). 22 Around 60,000 m3 of ready-mixed concrete will be delivered by the mixing plants of KANN Beton GmbH & Co. KG, Beton Union Rhein-Ahr GmbH & Co. KG as well as CityMix GmbH for this major project. With the truck-mounted concrete pumps used, the supply association is able to rely on its own fleet, to a certain extent. Thus, Beton Union is once providing its 21-metre PUMI® and truck-mounted concrete pumps with 27, 28 and 34 metre booms, and KANN Beton a 24-metre PUMI®, a M 24-4 and a M 36-4. In addition, CityMix is ordering its M 36-4 as well as the new M 46-5 to the Nürburgring. If, however, greater horizontal reach and boom flexibility is required, the long-reach boom pumps M 52-5, M 58-5 and M 62-6 owned by BEKA Betonpumpen-Service GmbH will be ordered to the construction site. Practically all of the machines are also consistently in use for the construction of the neighbouring "Congress & Motorsporthotel Nürburgring". An additional 20,000 m3 of concrete will be delivered here. Work on the new 4-star hotel began at almost the same time as the laying of the foundation stone for the "adventure world" along the start/home stretches. On completion, the classy 160room lodgings will also have a helipad and direct access to the grandstand. PM 4114 GB On site 51 53 Attractive world of motor racing Completed in 1927, the Nürburgring with its 89 left and 85 right-hand bends, inclines up to 27 % and a length of almost 23 km was, until 1977, a regular venue for the Formula 1 Race – "Grand Prix of Germany". After several serious accidents, however, the track was made off-limits for the Grand Prix sport. After its first reconstruction (1983), with provision for extensive safety measures, the ring, surrounded by beautiful countryside, has been used for motor racing once more since 1984. This M 36-4 is concreting the base plate of the neighbouring "Congress & Motorsporthotel Nürburgring" 52 In the meantime, the legend of the Nürburgring has become a brandname product. More than 300 races, leisure time, incentive and music events are held here professionally every year. The circuit includes both a Nürburgring racing driver school and a course in driver safety training. Approximately two million people attend the numerous events every year, or take advantage of the leisure facilities all around the famous race track. Due to growing interest, the offer has now been extended from the coming year, for that is when the "Leisure and business centre Nürburgring 2009" project, costing a total of € 215 million, is to be started up. Training for the 5th run of the long-distance championship at the Nürburgring PM 4114 GB 23 Putzmeister Concrete Pumps GmbH, Max-Eyth-Str. 10, 72631 Aichtal PSdg, Deutsche Post AG, Entgelt bezahlt, E 60458 Training Intensive training on the "real" model With an attractive range of programs on offer, the Putzmeister Academy has started its training season 2008/2009. The many courses available have different areas of focus and are directed towards, among others, concrete pump operators with little practical work experience and experienced machine operators who want to refresh or enhance their knowledge, as well as operations managers, fleet scedulers and workshop managers. 54 Since the Putzmeister trainers not only impart theory but also want to undertake practical work with seminar participants "on the real thing", Putzmeister has installed two complete training pumps in the training rooms. These are "real" truckmounted concrete pumps without the truck chassis, and are driven by an electric motor. This kind of practical work on fully-functioning models allows participants to carry out all necessary set-up work, for instance, and receive direct training in troubleshooting. The two training concrete pumps are also equipped with additional sensors. These record all of the important data for concrete pumping operations, such as main pump high pressure, low pressure, charge pressure, control pressure, accumulator pressure and volumetric flow rate, as well as the pump control system's electric control current. This data is transmitted to a PC by means of a CAN bus system. The computer visualises the measured values obtained and presents the information accurately in the form of virtual pressure gauge displays. These displays are shown to all seminar participants in enlarged format as projected images. By preparing the visualisation in a didactical manner, the seminar leaders can illustrate complex processes and dependencies in the hydraulic systems of Putzmeister concrete pumps. One of the "real" concrete pumps with an image projection of all important parameters – an example of practice-oriented training at the Putzmeister Academy 55 In the meantime, practical modules both on the training pumps and on the "right" truckmounted concrete pumps have become an integral part of any course for machine operators and mechanics at the Putzmeister Academy. For more information, call +49 (0) 7127 599-586. All rights and technical details subject to alteration · The illustrations show special mechanical equipment and snapshots in practice on construction sites, which do not always correspond to the regulations of the Industrial Employers’ Liability Insurance Association · © 2008 by Putzmeister Concrete Pumps GmbH · Printed in Germany (40812Ma) 24 PM 4114 GB