on site concrete - Mobil Baustoffe

Image: HOCHTIEF Construction AG
on site concrete
on site concrete
Experience
We have successfully completed an impressive array of projects and are able to
provide outstanding references. With our experienced team of specialists, we are
able to accept any challenge. We ensure we understand the needs of our clients and
are able to support them throughout the project.
Services
We are a service provider for the construction industry. We can offer an optimised
supply of concrete or other related building materials, such as annular gap mortar.
Our goal is to create quantifiable added value for the client and to make work easier
on site.
Quality awareness
We
We produce concrete and similar products in any grade and quantity as agreed
specialise in the production of concrete for large scale
with the client, anywhere in the world. Thanks to our technologies and experienced
construction projects such as tunnels, dams and
personnel, we are able to consistently achieve the agreed quality objectives.
similar major projects around the world. By keeping
pace with the special requirements of the construction
site, we design and build optimised mixing equipment
Goal
with harmonising logistic concepts.
We meet the requirements of our clients within the agreed framework of quality and
We
cost. We establish long-term partnerships with our clients, built on trust. We search
develop concrete mix designs that are adapted to
for new technologies in order to continuously improve product quality, within the
requirements and the availability of raw materials.
scope of our activities. Our aim is to offer an optimised supply of concrete to our
We build the required facilities for concrete
clients for the respective project.
production, operate them and dismantle them after
construction is complete.
We
can produce any quantity of concrete required
specified time frame.
Image: fotolia
by the client to the agreed quality and within the
Large volumes – outstanding performance
Complex logistics
A5 Y-section Vienna
In major projects, an appropriate logistic operation is of major importance. In publicprivate partnership (PPP) motorway projects for example, a wide variety of concrete
grades with highly variable volumes are required for individual constructions.
Bridge constructions and other civil engineering structures need different types
of concrete simultaneously and in large quantities. In addition to designing the
We delivered hourly volumes of 400 m³ of concrete at the PPP construction site for the A5 Y-Section
facilities and establishing the production sites, planning and managing the logistic
Vienna (Austria) with up to 100 mobile concrete trucks at any one time. We operated 5 concrete batching
chain is extremely important. After all, the right concrete has to reach the right
plants at 2 locations on the construction site. A dual batching plant with 2 x 3.33 m³ twin-shaft mixers
place at the right time. Computer-aided scheduling with vehicle status tracking via
was installed at one location. At the other location, another dual batching plant was set up with one
mobile phone or GPS has become a key component in the success of any project.
3 m³ twin-shaft mixer and one 2.25 m³ twin-shaft mixer. An additional mobile batching plant with a
3 m³ mixer was also set up and operated during the period of peak demand. The scheduling of all concrete
deliveries was coordinated by a single central office on this large site. The scheduling was carried out
in close co-operation with construction site management for the various parts of the site. The required
volumes and qualities were always available on time. We were able to prove, to the clients satisfaction
Images: Aerial photos: ARGE PPP Ostregion
that we not only accept such challenges but successfully manage them.
Project specific mixing equipment
Difficult Conditions
Our clients build complex structures that require considerable technical expertise.
Every project is unique, and requires tailor-made solutions. It therefore makes
sense to develop concepts for our clients that represent the optimum solution to
each specific problem. We do not offer standard concrete mixing equipment. We
plan, develop and operate concrete mixing equipment customised for each project.
Lötschberg Base Tunnel
We developed a concrete mixing plant for
underground operation at the construction
site
of
the
Lötschberg
base
tunnel
(Switzerland). This dual batching plant with
two 2.25 m³ twin-shaft mixers was designed
to fit the dimensions of the existing cavern.
A bunker silo for aggregate storage with a
capacity of more than 2,000 m³ was used
to achieve maximum reliability. Aggregates
were supplied by a conveyor belt that
transported the material directly via the
access tunnel into the bunker silo. With this
system we have produced approximately
700,000 m³ of concrete under extremely
difficult conditions to the full satisfaction of
Image: BLS AG
our client.
Complex concrete technology
Durability
Infrastructure projects such as tunnels or bridges are associated with considerable
effort and financial expenditure. This is why durability is increasingly emphasised
Nuremberg – Ingolstadt
in modern civil engineering, with intensive planning for the construction and
maintenance of structures. Durability is often estimated in advance, based on
calculations, and durability expectations in excess of 100 years have become
We produced over 1.1 million m³ of concrete
normal. Concrete assumes an important role in the field of civil engineering. By
for the construction of a section of the new
formulating concrete based on the exposure classes, structures of great durability
high speed railway between Nuremberg and
that require little maintenance can be constructed.
Ingolstadt. The construction of the new
railway link was divided into three lots.
HOCHTIEF Construction AG built the 18 km
long middle lot as general contractor. We
delivered concrete for three railway tunnels
with a total length of about 15.5 km including
the accompanying emergency exits, as
well as for bridges and civil engineering
structures in the middle lot. Our concrete
technologists developed special concrete
mixes in close cooperation with the client.
The concrete mix designs were examined
by a Deutsche Bahn expert and approved as
suitable. The durability of the concrete was
calculated, resulting in a lifespan of more
than 100 years across the board. Finally
the concrete mix designs were approved
for use by Deutsche Bahn and the Federal
Railway Authority. In order to lower the
core temperatures of mass concrete, some
of the mix designs contained less cement
than the minimum quantity specified by
the standard. The reduction in fine material
was offset by adding fly ash. This resulted in
tremendous cost advantages.
From the initial offer phase to the final
installation
of
concrete
components,
specially trained and experienced concrete
technologists were available. This ensured
that our client not only received high quality
concrete, but the best concrete for the
Image: Construction AG
purpose.
Tunnel lining segments
Project-specific
development
Tunnel boring machines (TBM) are increasingly used in modern tunnel construction.
The high level of mechanisation in tunnelling is making tunnel construction safer
and more precise. Tunnel lining segments, which usually represent the finished
tunnel without any additional components, constitute the most important
part of the tunnel. The concrete segments are assembled into a ring by the TBM,
guaranteeing the stability of the tunnel. Using a special steel formwork, the tubing
sections are made of steel-reinforced concrete which conform to the highest
standards in terms of accuracy.
Finnetunnel
We successfully produced 48,000 tunnel
lining
segments
tolerances
for
with
the
extremely
low
construction
of
Finnetunnel for Deutsche Bahn. In doing so,
we exceeded the planned performance by up
to 40%. This allowed our client to complete
tunnelling work for the two tunnel sections
within the given timeframe. We have also
developed special concrete mix designs with
our concrete technologists. With the support
of an external concrete expert, the need for
coating the segments which is normally
required by the German standard could be
eliminated. This also helped to reduce costs.
According to the client, our production of
the tunnel lining segments for Finnetunnel
has shown a quality never seen before in a
Images: Dirk Brzoska
comparable timeframe.
Preparation of aggregates
Everything
from a single source
Aggregates are the primary ingredient of concrete. This means aggregates not only
have a significant impact on concrete quality, but they also have a major influence
on the price. With many tunnel constructions, our know-how enables us to turn
some of the excavated materials into aggregates for concrete production. For other
projects, or in case of tunnel construction where the excavated material is not
suitable, producing project-specific aggregates rather than acquiring them on the
market may also be advantageous. In order to do so, corresponding deposits must
be found and processing facilities need to be installed.
Neuhaus gravel plant
At our gravel plant in Neuhaus (Austria) we
have established a production facility for
aggregates. We therefore have the know-how
required for the project-specific preparation
of aggregates. Combining the preparation of
aggregates and the production of concrete
under one roof has an invaluable advantage.
This is the only way to eliminate a key
interface that can lead to quality problems.
By combining the production of aggregates
and concrete from a single source, we
provide optimal quality at the best possible
Images: E. Zier
price.
Complex logistics
Concrete by rail
Gotthard base tunnel
Railway transportation poses special challenges for many construction sites. In
some cases raw materials are supplied by rail, in other cases concrete is transported
by rail. Railway transportation always requires sophisticated logistics and facilities.
For this reason we prepare individual concepts that represent the optimum solution
for each project in cooperation with our suppliers and clients. We hold the required
At the Amsteg and Erstfeld sections of the Gotthard base tunnel (Switzerland), we organised the
knowledge and have established outstanding contacts, not only for developing
delivery of cement by rail. The required rail wagons were parked on dedicated “cement tracks”. The
concepts, but also for their technical implementation. Whilst doing so, we involve
cement was then blown directly into the cement silos of the batching plants through long pipes. Due to
our clients at all stages integrating their specific requirements and knowledge.
large storage capacities and precise co-ordination between the supplier and our qualified personnel, the
construction sites were continuously supplied with concrete. The concrete was also transported by rail.
Tunnel trains were loaded using special mobile concrete hoppers. It was possible to load the train from
2 mixers, each with a capacity of 3 m³, simultaneously. The loading system, including train shunting
yard, was developed by us in cooperation with our partners. Here the fully automatic cover lifting device
deserves a mention. The transport hoppers of the concrete trains were closed with covers. Our system
automatically recognised the cover, released the latches, removed the cover and put it aside while
concrete was loaded. After loading, the automated system replaced the cover and latched it. Thanks to
our know-how and dedication, we were able to make a significant contribution to the success of the
Images: AlpTransit Gotthard
construction project for the longest tunnel in the world, the Gotthard Base Tunnel.
Speed
High cost-effectiveness
Even in a relatively static business such as the production of ready-mix concrete,
speed can be of crucial importance. In the event of short-term requests or bottlenecks
in deliveries to construction sites, solutions have to be found quickly. With our own
pool of equipment and an excellent network of partners and suppliers, we are able
to provide equipment that meets the project requirements without delay.
All our batching plants are mobile. Depending on the plant size and layout
installation varies between a few days and a few weeks. Due to our long experience
we understand the needs of our clients, especially in terms of the valuable
construction time and we always react accordingly.
Berlin and Munich airports
For the Berlin Schönefeld airport, a large-scale construction project, we installed a concrete mixing
plant with a 3 m³ mixer. It was ready for operation in only two weeks. Due to this rapid response the
tremendous peak requirements of the construction site were reliably met. With the help of our expertise
and experienced specialists, we were able to achieve maximum results in a minimum amount of time.
Speed counts.
We also supplied high quality concrete for the construction of terminal 2 at Munich Airport. At peak
times we produced more than 4,500 m³ of concrete per day from 4 batching plants. The concrete
Images: Munich Airport
produced by us has enabled the expansion of Munich airport.
International experience
European know-how
Borders are being eliminated through global competition and technical know-how
is in demand around the world. Today many international companies are facing new
challenges in foreign countries. With confidence in reliable partners that hold the
corresponding technical expertise, demanding challenges are mastered together.
Further to our traditional core markets in Central Europe, we are also engaged in
Azerbaijan and Qatar. We have also supplied or supported construction sites in
Bulgaria, Hungary and Myanmar. With our technical expertise and flexible personnel,
we are in the position to produce concrete at any site around the world where
Image: MBS
sufficient security is assured. We are supported by a network of system engineering
and raw material suppliers. With consultation, planning and understanding of the
M6 – Hungary
requirements, we are able to consistently offer the optimum solution.
We have supplied concrete to one of the largest hydroelectric generating stations
in Europe, the Tsankov Kamak generating plant in Bulgaria. Our concrete made a
major contribution towards ensuring that the arch dam with a height of 130 meters
Background image: Copyright
Image: MBS
Image: MBS
Image: Aerial photo:
ARGE PPP Ostregion
Image: MCQ
can now securely hold the 111 million m³ of stored water.
Ras Laffan – Qatar
A5 Y-section – Vienna
Yewa Dam – Myanmar
Tsankov Kamak – Bulgaria
Innovative cooling system
Green concrete
In regions where the climate is hot, concrete usually has to be cooled. Flake ice
or nitrogen cooling systems are frequently used for this purpose. These cooling
methods are inefficient and consume a lot of energy. With these standard cooling
processes, the cement paste is cooled, but due to temperature equalisation with
Experience in Qatar
the aggregates, warms up again significantly after a short period of time. Therefore
the concrete is not cooled effectively.
We have developed our innovative cooling
system to meet market requirements in
We have developed a cooling system that cools coarse aggregates in a water bath
Qatar. The system was developed to supply
with very high effectiveness. This also allows concrete with a low water/cement ratio
the Ras Laffan port facility. With consistently
to be produced at consistently low temperatures. Especially in case of low water/
positive client feedback, we are the only
cement ratios and the requirement for high cooling rates, flake ice systems reach
company in Qatar able to deliver concrete
their limits, since the theoretically required addition of ice exceeds the allowable
during the day that meets the requirements
water volume. The system can also be used to assure temperature equalisation
during the hot summer months. Our
throughout the year. In addition, our cooling system makes a significant
system is suitable for all regions where
contribution towards conserving energy and therefore carbon emissions, and can
concrete must be effectively cooled. For
contribute to successful participation sustainability programmes. This makes our
other climates the system can be modified
system an integral component of our “Green Concrete” initiative.
to heat concrete to a very accurate level.
Furthermore, it is well suited for all projects
that have to or want to collect credits
according to international evaluation criteria
in sustainability programmes such as LEED
(Leadership in Energy and Environmental
Designs, USA) and QSAS (Qatar Sustainability
Assessment System, Qatar). For most largescale projects, cooling with our system is the
most economical alternative.
Air
Our research and development efforts
45°C
have resulted in an innovation that allows
concrete to be cooled effectively and
economically. This improves virtually all
concrete characteristics, for example the
consistency becomes more even and concrete
Cement
Aggregates
10 –20 mm
90°C
40°C
Aggregates
0 –10 mm
40°C
Water
30°C
additives are more effective. This represents
Gas
true progress thanks to experience gained in
Ras Laffen, Qatar.
cold
Water
Images: MCQ Photographic Permit DS/152/2010/10/2192.3
30°C
10°C
8°C
21°C
63°C
Frequently asked questions
Influence of w/c ratio changes
Batching plants:
Maximum concrete output per hour depending on truck mixer
size and batching time.
Low w/c ratio
High w/c ratio
High compressive strength
Low compressive strength
Low porosity
High porosity
Low shrinkage
High shrinkage
No bleeding
High bleeding
Loading 9 m³ of concrete into a truck mixer
30 sec
45 sec
60 sec
90 sec
Liebherr 2.25 A-R/DW
76
68
60
49
Liebherr 3.0 AR/DW
88
79
71
59
Concrete cooling
Per m³
Loading 6 m³ of concrete into a truck mixer
Mixing time
30 sec
45 sec
60 sec
90 sec
Liebherr 2.25 A-R/DW
51
45
40
33
Liebherr 3.0 AR/DW
59
52
47
39
European cements: EN 197-1:2000
300 kg
10.1 K
- 1K
Water
165 kg
3.7 K
- 1K
Aggregate
2,000 kg
Cement type
CEM I
Portland cement
Portland slag
cement
CEM II
CEM III
Image: E. Zier
CEM IV
CEM V
CEM I
CEM II/A-S
CEM II/B-S
Portland silica fume
CEM II/A-D
cement
CEM II/A-P
CEM
II/B-P
Portland pozzolana
cement
CEM II/A-Q
CEM II/B-Q
CEM II/A-V
CEM II/B-V
Portland fly ash
cement
CEM II/A-W
CEM II/B-W
CEM II/A-T
Portland shale
cement
CEM II/B-T
CEM II/A-L
Portland limestone CEM II/B-L
cement
CEM II/A-LL
CEM II/B-LL
Portland composite CEM II/A-M
cement
CEM II/B-M
CEM III/A
Blastfurnace slag
CEM III/B
cement
CEM III/C
CEM IV/A
Pozzolanic cement
CEMIV/B
CEM V/A
Composite cement
CEM V/B
Ggbs
Silica
fume
natural
tempered
high
silica
high
chalk
Burnt
shale
K
95-100
80-94
65-79
S
6-20
21-35
D
-
P
-
Q
-
V
-
W
-
T
-
L
-
LL
-
0-5
0-5
0-5
90-94
-
6-10
-
-
-
-
-
-
-
0-5
-
36-65
66-80
81-95
18-30
31-50
-
-
-
Guideline only - for full information please refer to the relevant standard.
6-20
21-35
-
-
-
6-20
21-35
-
11-35
36-55
18-30
31-50
6-20
21-35
6-20
21-35
-
- 1K
Filler
Portland
cement
clinker
80-94
65-79
80-94
65-79
80-94
65-79
80-94
65-79
80-94
65-79
80-94
65-79
80-94
65-79
80-94
65-79
35-64
20-34
5-19
65-89
45-64
40-64
20-38
1.6 K
or
Cementitious material
Pozzolana
Fly ash
b
Results in a lower
fresh concrete
temperature of
Cement
Mass as percentage of cementitious material
Designation of the
27 cement products
Cooled down
by
6-20
21-35
-
-
-
6-20
21-35
-
-
Ice added
7.6 kg/m³
- 1K
Liquid Nitrogen
7-13 kg/m³
- 1K
Limestone
6-20
21-35
-
-
6-20
21-35
-
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
0-5
Estimation of fresh concrete temperatures and core concrete temperatures
Components of concrete
Cement
Quantity
Temperature
Temperature
Temperature
Temperature
350 kg/m³
90°C
90°C
90°C
30°C
Aggregates 0/10
900 kg/m³
40°C
40°C
40°C
40°C
Aggregates 10/20
1,100 kg/m³
40°C
40°C
10°C
10°C
Water
150 kg/m³
Fresh concrete temperature
+ Heat of hydration
= Temperature of concrete in the centre of an aggregate app.
30°C
-2°C
8°C
8°C
43 °C
35°C
27°C
21°C
85°C
78°C
69°C
63°C
Choosing the right maximum aggregate size
Minimum
element
width /
thickness
Minimum
concrete
cover
Nominal
concrete cover
to achieve
minimum
concrete cover
Minimum
distance
between
rebar
Maximum
aggregate
size
m
mm
mm
mm
mm
1.0
100
120
1)
63/125
0.25
30
50
37
32
0.15
20
35
27
22
0.10
15
25
20
16
0.05
10
20
20
8
Development of heat in components with different fresh
concrete temperatures:
90°C
Guideline only
1) For walls 2 times max aggr. size, for slabs 3 times max aggr. size
80°C
Fresh concrete temperature
Mixing time
70°C
60°C
50°C
43°C
35°C
27°C
21°C
40°C
30°C
20°C
0°C
0h
12h
24h
36h
48h
60h
Erlenweg 1
A-9463 Reichenfels / Austria
Tel.: +43 43 59 21 20 0
Fax:
+43 43 59 21 20 15
Mail: [email protected]
www.mobil-baustoffe.com
Graphic : www.zierdesign.de
Mobil Baustoffe GmbH
Image: HOCHTIEF Construction AG
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