Customer magazine by Putzmeister AG 71

Olympic stadium for those who like a challenge

Continuous concrete placingduring balanced cantilever construction of bridge

TELEBELT® in Ethiopia

M 20-4: more than 180 m working range

Upper Eastside Berlin –challenging logistics

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Content In brief

In brief

Change of Chairman of the Management Boardof Putzmeister AG

New world record in vertical pumping

Title story

Olympic stadium for those who like a challenge

On site

Towers in attractive location

M 20-4: Compact, flexible and 180 m reach...

Upper Eastside Berlin – challenging logistics

Pile builder work with concrete pump on crawler chassis

TELEBELT® delivers and places lean concrete

Continuous concrete placing during balanced cantilever construction of bridge

Practical tip

Neat solution!

Technology

What do the new BSA stationary pumps do?

PM iin focus

Putzmeister brings new painting centre into operation

M 32 in the Indian daily press

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New world recordin vertical pumping

The extreme high-rise concrete pumping atBurj Dubai continues to progress withoutc o mplications and entire ly according toplan. Shortly before this edition went topress (start of September) concreting of the149th floor in the central building core wascompleted using one of the three BSA 14000high-performance pumps. This correspondsto a pumping height of 550 m. The deliveryheight of 574 m, which was agreed betweenPutzmeister and the site management andpump operating company Unimix, is expect-ed to be reached in October.

In the meantime, this new record in high-rise concrete pumping has attracted theinterest of more than just the specialists. TV companies have also been reporting onthe spectacular construction site and night-time placing of concrete at external temp-eratures of nearly 40 °C. The FrankfurterA l l gemeine Zeitung, one of the leadingGerman daily and financial newspapers, re-ported on the concreting work at Burj Dubaiduring the "cooler" nighttime hours in anarticle entitled "The concrete takes half anhour to get to the top". Site reports about theBurj Dubai are available at the Putzmeisterhomepage www.putzmeister.de.

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Change of Chairman of theManagement Board of Putzmeister AG

Felix Selinger ta kes ch a rge of th ePutzmeister AG (Aichtal) Chairman of theManagement Board on the 1st August. Born-and-bred in Switzerland, he has been withthe company since 1999 and for the lasteight years led the subsidiary PutzmeisterIbérica, headquartered in Madrid, which hasenjoyed exceptionally dynamic growth.

Felix Selinger (49) is taking over from thep revious ch a i rman and speaker for th eM a n a gement Board at Putzmeister AG, Dr. Hinrich Mählmann, who will remainwith the company as a member of thesupervisory board. Felix Selinger has manyyears of experience in sales and marketingand his pro fessional commitment – inBrazil, Venezuela and Spain amongst others– have given him a considerable depth ofinternational insight. He is a multilingualgraduate in construction engineering whowas born in Bern and grew up in Zurich. Hecompleted further degrees at the Universityof Madrid and INSEAD (Paris) and has manyye a rs of pro fessional ex p e rience withmachines used in tunnelling and mining. As managing director of Putzmeister Ibéricabetween 1999 and 2007 he achieved an 8-fold increase in turnover of the PM sub-s i d i a ry, doubled pro fi tability (Ret u rn OnCapital Employed – ROCE), combined/merg-ed the wo rldwide Putzmeiste r t u n n e l l i n gactivities and has formed a sales alliancewith Sika® (Switzerland), a leading manufact-urer of chemicals for the building industryand shotcrete machines. In his new role,Felix Selinger considers the optimisation ofthe worldwide Putzmeister organisation tobe one of his most important tasks. Whileemployees at Putzmeister Ibérica will misstheir managing director who has lookedafter them for so many years, PutzmeisterAG welcomes the skill and knowledge thatthis new chief executive officer is sure tobring.

Burj Dubaialready over 550 m

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Title story

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Title story

As is generally the case in the run up to largesporting events, China has (almost) complet-ed the shells of many stadiums eleven monthsbefore the opening – however, work is stillunderway with a degree of urgency on theinterior finishings and infrastructure. "Beijinghas certainly progressed much further thanAthens had 500 days before the opening,"the Swedish IOC vice president GunillaLindberg noted at the end of March 2007,when comparing the progress of work withthe previous host of the Summer Olympics.However, only some of the 28 sporting eventswill take place and be decided in the Chinesec a p i tal. Shanghai, Hong Kong, Qingdao,Qinhuangdao, Tianjin and Shenyang are alsovenues for games at the 2008 OlympicGames.

Olympic stadium for those wholike a challengeIt is now only slightly less than a year before the opening of the Olympic Games in China (8th to 24th August 2008) and theplanned construction projects are well within schedule. While many excavators, wheel loaders and tippers have already leftthe six venues, truck-mounted concrete pumps are still driving to their "olympic jobs“. The following report provides an insightinto the comprehensive concrete construction measures using the town of Shenyang, one of the five venues of the upcomingOlympic football games, as an example.

New stadium with a legacy

A new football arena with an extremelychallenging architectural form, which willseat roughly 70,000 people, is under con-struction in Shenyang, the main town of thenorth-eastern province of Liaoning, at a costof 350 million Yuan (roughly € 34 million).The modern arena replaces the 16-year oldWulihe stadium and will take the samename, after the old stadium had been demol-ished. The people are already looking for-ward to the football games: ever since theChinese national team appeared here follow-ing their victory in the final round of theWorld Cup in 2001, the stadium at Shenyanghas been regarded as a lucky venue for foot-ballers in the People's Republic.

The comp a ny China No. 1 Const ru c t i o nBureau (Group) Co. Ltd. is responsible forthe construction of the new Wulihe stadium.Work started at the beginning of March2006, and completion is due by the end ofApril 2008. The concreting work started forthe first time in August 2006. The main con-crete supplier, Liaoning Taichen ConcreteCo. Ltd., delivered more than 60,000 m3 offresh concrete in less than five months. Dueto the tight schedule, Taichen used all threeof its Putzmeister BRF 42-4.14 H truck-mounted concrete pumps on the construct-ion site. An overall volume of 100,000 m3 ofconcrete is expected to be required for thenew stadium.

The stadium is supported by more than1000 massive concrete columns

The many components made of fresh con-crete include more than 1000 supports. Eachof these is over one metre in diameter and isburied in the ground to a depth of 16 m.These are in turn supported on cylindricalfoundations, each with a cross section of atleast four metres. The Chinese machineoperators require considerably less than 30minutes to set up the truck-mounted con-c rete pump including folding the boomin/out and retracting/extending the support– an impressive performance consideringthe on-site conditions.

However, even larger components are beingconcreted at the stadium in Shenyang. Forexample, the four massive bases that sup-port the loadbearing steel construction andwill later be covered with earth. To preventcracks forming in the component due to anuncontrolled increase in the hydration heat,the concrete manufacturer Taichen is in-stalling pipelines in the massive concretemountings th rough which cooling wa te rcirculates during and after the concretingwork. During pumping, particular care istaken to ensure that the concrete is notinstalled too quickly and that it is applied inseveral layers. Before the next concretingoperation takes place, the joints are filledwith a special mortar. Several days followingthe end of concrete installation the coolingwater is drained from the pipes – the pipesthemselves remain in the concrete base andsubsequently provide additional reinforce-ment.

Taichen is using its M 42 truck-mounted concrete pumps at numerous constructionsites in and around the Wulihe stadium

Concreting work is also carried out inNortheast China at sub-zero temperat-ures

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Heated buildings keep concretepumps and aggregates at the correcttemperature

The problem of achieving a uniform product-ion of heat during the concreting work isequally acute during the winter months onthe Oly mpic building site at Shenya n g .Ambient temperatures fall to -12 °C as earlyas December. In the north of China the oper-ators of concrete mixing plants have beenadapting to these conditions for quite sometime now – and Liaoning Taichen ConcreteCo. Ltd. is no exception: the Taichen mixingfacility includes a building with an area of2000 m2 and underfloor heating. The truckmixers and concrete pumps are kept in theheated building if they are not in use on theconstruction sites. This makes the warm-upp e riod for the machines considera b lygentler and faster.

Title story

The aggregates and water for the concreteb a t ches are heated to a te mp e ra t u re ofroughly 20 °C with steam at temperaturesof up to 80 °C prior to the mixing process inan enclosed, well insulated storage facilitythat covers an area of 10,000 m2. The use ofchemical aggregates (including set retard-ing admixtures) is also sometimes requiredin order to prevent frost damage.

Whereas the Taichen concrete works is onlyaround 30 minutes from the city centre andis not in danger of the concrete temperaturefalling too far in the icy winter months priorto pumping, other ready-mixed concrete com-panies in the north of China, where the ave-rage transportation times are two hours ormore, are faced with more acute difficulties.However, they have found a solution: in win-ter they wrap the drums of their truckmixers with thermal material. Although it is

likely that the insulating effect probablydoes not meet the specifications of the EUThermal Insulation Ordinance, it preventsthe concrete from cooling down too quicklyprior to placing.

A short introduction: Taichen – concrete manufacturer and pumpingservice

Liaoning Taichen Concrete Co., Ltd wasfounded in 2002. The company employsroughly 280 employees at both mixingfacilities in East and We st Shenya n g .Concretes with strength classes of C10 toC100 are manufactured. Around 1.5 mil-lion cubic metres of concrete are produc-ed annually. Taichen has rapidly becomeone of the biggest concrete suppliers inNortheast China and supplies numerousl a rge building sites in and aro u n dShenyang.

When choosing machine suppliers th emanagers of Taichen, a cost-aware, privatelyrun company, have a strong sense of whichare "good value for money" and which aresimply "cheap". This means that their fleetnot only includes Liebherr truck mixers with10 m3 capacity on Mercedes Benz chassis (acombination seldom found in China), butalso three Putzmeister truck-mounted con-crete pumps with 42 metre booms. In allprobability local manufacturers would be able to offer similar "more afford-able" construction machines but the price is not the only de-cisive factor when it comes to making investments in the

construction industry. In China, reliability,service and resale value of the machinesh ave now become imp o rtant decision-making factors. And, even as far away asNo rth e a st China, the products of th ethree German manufacturers are held inextremely high repute.

Information on Shenyang Shenyang, which has roughly 7 millioninhabitants, is an economic and culturalcentre in Northeast China and has muchto offer, and not just in terms of tourism.The town is also known for its whole-some regional cuisine. Here, you willcome across several restaurants offeringMuslim dishes or menus, including thep a rt i c u l a rly hot and spicy Szech wan cuisine. In the evening, the enormouskaraoke bars and western-style discosattract countless numbers of visitors.

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On site

Around 60 % of the total volume of concreterequired (roughly 45,000 m3) is being pump-ed. This task is performed by a BSA 2109 H-E that is connected alternately via deliv-ery lines to one of two stationary MX 32 Tbooms. The booms are mounted on 20 mhigh tubular columns and their workingrange effortlessly covers the various form-

The Sea Towers project has been under construction since May 2006 in Gdynia (Poland). The 36-storey complex consists of garagedecks, service areas, offices and apartments and, once completed, will be one of the most attractive residential locations near toa city on the entire Baltic Sea coast.

work sections. A C50 is used for concretingthe many ceilings and walls which meansthat the cross sections of the componentscan be kept relatively small. The Warsawbuilding company Modzelewski & Rodek, onbehalf of Porr (Polska) S.A., is responsible asthe main contractor for the execution of con-struction work on Sea Towers.

The two high-rise towers are connected toeach other and located directly on the harb-our quay, not far from the city centre ofGdynias. Following their completion at theend of February 2009, the Sea Towers willbe 138 m high – the highest residentialbuilding on the entire Baltic Sea coast.

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Towers in attractive location

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On site

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On site

Examples of typical application areas areu n favo u ra b ly- l o c a ted or diffi c u l t - to - a c c e s sc o n st ruction sites on which concrete isrequired for renovation or finishings. Themachine operator can then reach the place-ment site directly with the 4-fold, incrediblyflexible 20 metre boom, even through smallroof windows and openings in walls andover and beyond obstacles. The operator canalso pump through the connected hose viathe hopper outlet and reduction pipe or ex-tend the boom pipeline using the deliveryhoses and pipe segments carried on the veh-icle. Incidentally, the Putzmeister M 20-4can also carry more than 166 m of hose andpipeline on board in mountings and contain-ers. When combined with the range of theboom this produces a net working range ofmore than 180 m (from the front bumper).

Boom as pipe bridge

Sometimes – as shown in the illustration onthe right – only a path width is available tosupport the truck-mounted concrete pump,with only softened agricultural land to theleft and right. Here, near Naumburg, the con-crete for the foundations of the overhead linepoles for Deutsche Bahn was being pouredusing a M 20-4 supplied by the HeidelbergerBeton pump service. In this case, the ma-chine could only be set up on the opposite

M 20-4: Compact, flexible and 180 m reach...Although in production for less than 18months, considerable quantities of theM 20-4 ZR "allrounder" concrete pumphave already been produced. The machineconcept (compact design, extremely flex-ible "quadruplet" boom with 3.9 m un-folding height, hose and pipe storage onrequest) is popular not only in Europe,but also in Japan and the USA.

side of the embankment where the machineoperator found a carriageway which was only3.5 m wide. As the compact 2-axle model re-quired a space of 2.6 m to the rear and 3.4 min front for support it was quickly ready forpumping. The boom also served on this con-struction site as a tubular bridge to whichthe additional delivery hoses that led to thefoundations were connected. In order not tointerfere with the train services, the deliv-ery line was laid under the railway tracksthrough the platform body in an empty pipe.

With additional hoses into basement

A n other exa mple, from the town ofHelmbrechts in North Franconia where thetextile processing company Knopf’s Sohn isextending its warehouse capacities. To dothis, a large amount of renovation work isrequired in the basement of a buildingwhich includes the concreting of variousfoundations and beams. There is space avail-able in the narrow area between the build-ings to set up a larger truck-mounted con-crete pump. However, it is almost impossibleto slip the boom into the lower building level

and roll out the single arm segments usingother machines. To reach the bottom form-work in the rear area, machine operatorMatthias Wolf places the tip of his M 20"quadruplet" boom on the ground and re-places the end hose with two reductionpipes. The tapering is initially from 125 to100 mm, and then from 100 to 65 mm in thesecond stage. The four delivery hoses eachwith 4.5 m length are connected and theconcreting work can start.

Larger truck-mounted concrete pumpscould also set up here. But would theyhave enough space to bring the placingb o o m i n to its wo rking position onceunfolded?

Concrete installation in a basement

M 20-4 used during construction work on a bridge in Japan

Where others would have to admit defeat, the M 20-4 comes into its own: here the machine is supported on a narrow path, theplacing boom is guided up the railway embankment and passes with additional hoses under the platform bed

Two M 20-4 on American constructionsites

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Practical tip

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Technology

Following their presentation on the worldsbiggest construction machine trade fair andthe overwhelming positive response amongstcustomers, the BAUMA machines were soldout on the spot. In the meantime, they arenot just providing reliable service in Europe,but also in the Middle East and overseas.These were preceded by a comprehensivete st series as decisive innovations we retaking place under the smart hoods. Take theelectronic pump control (EPS), for example:the required pumping volume or maximumdelivery pressure can be adjusted via thecontrol cabinet display. It only requests thepower that is actually required to pump therelevant quantity of concrete which resultsin noticeable fuel savings.

Or take the current diesel engines thatc o mp ly with the TIER3 sta n d a rd: th e i rreliability under all operating conditions

What do the newBSA stationary pumps do?Let's refresh our memory: the modern design of the new generation of stationary PM concrete pumps presented at the BAUMA is not only convincing in terms of its appearance. The machines with their new control and their economic, emission-optimisedengines are well ahead of their time.

had to be ensured prior to the start of seriesproduction. Is the machine capable of hand-ling full loading during pumping operati-ons? Is the cooling output sufficient even inextreme external temperatures? Does thecontrol of intake and exhaust air need to beoptimised? To which value could the soundpower level be reduced? All these points –and many more – were investigated underrealistic operating conditions.

The new plastic hoods on the other handneeded to be investigated to determine theirimpact resistance, temperature resistanceand elasticity. All products passed the testswith flying colours. However, the machineswere only dispatched once a large numberof test reports had been evaluated and thefinal precision adjustments had been made.

The sponge ball is completely satur-ated with water and pushed intothe hose ...

… and pushed to the other end of the line with the customised"push-in device"

Machine operator Wolf prefers to use a cylindrical wash-out pig made of spongerubber to clean the boom pipeline

The hose guides on the flatbed of the M 20-4 are located at shoulder leveland can be comfortably reached

A gentle kick with the foot is all it takesto engage the front support leg in itsdrive position

To ensure that the boom line is also thor-oughly clean following use with concrete, in-stead of inserting the standard sponge ball,machine operator Wolf opts to insert a cyl-indrical sponge pig made of the same mater-ial through the boom tip into the deliveryline. He then pumps in reverse: "Once re-verse pumping is complete the inner wall isas clean as a whistle again!"

In his view it is sensible and also consider-ably easier, to clean longer line lengthsusing compressed air. The remaining tasksthat must be carried out by hand such aspushing the hoses into the magazine andfolding in the front support by applying alight pressure with the foot have been partof the machine operator Wolf's routine forsome time now.

The new BSA 1003 with cutting-edge technology and superb design (Photo: Hövemeyer)

Important operating data are recordedduring the continuous test

The display in the control cabinet showsimportant information on the currentpumping operation

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Neat solution!

Although the M 20-4 by BPD Vogtlandis equipped with a compressor, themachine operator Matthias Wolf cameup with a special solution for cleaningif only a few 65-type extension hoseswere to be connected: "That can bedone faster and more easily!“ He andhis colleagues at BPD Vogtland carry areinforcement rod which is roughly 5 mlong (14 mm diameter) on board. A disc(roughly 50 mm in diameter) is weldedcentrally to one of the ends. Once thehose line has been detached from theboom tip and the individual couplingshave been opened, he places the hoses,which are still full of concrete, parallelto one another on the ground. Themachine operator then pushes a wetsponge ball into one of the flanges andquickly pushes it forwards using thereinforcement rod. The inside of thefirst hose is clean within seconds, theremaining th ree delive ry hoses arethen cleaned immediately.

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On site

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On site

Five buildings are under construction atUpper Eastside Berlin which is located inthe central district at the junction of Fried-richstraße and Unter den Linden. Köster AGis erecting an ensemble of buildings onbehalf of MEAG on the site of a former hotelto accommodate many classy retail outlets,offices and apartments on a gross floor areaof 40,000 m2. The client is Münch e n e rRü ck ve rs i ch e rungs AG. The anticipate dcapital expenditure is around € 200 million.

While the architecture of the multi-storeybuilding complex with its green courtyardwill blend harm o n i o u s ly with the liste dstructure of the neighbouring row of houses,the logistics of the construction site pre-sents considerable challenges, particularlyat present during the shell constructionphase. The area is bounded by three busyroads and is also directly adjacent to an oldbuilding. This means that there are virtual-ly no free areas available on which to storeconstruction materials or operate construct-ion machinery.

Long-reach boom pump in Berlin: OSS support required for every other job

Our pictures were taken when concretingthe 70 m x 70 m floor slab, which is beingfabricated in nine sections and is 1.3 m thick.On this day alone it was necessary to installan overall volume of 1,000 m3 of concrete,using a M 52-5 long-reach boom pump madeby the concrete pumping division of LichtnerBeton (Velten, near Berlin) and a combinat-ion of stationary pump BSA 2109 H-D andstationary boom MX 32-4 T. In order to avoido b st ructing building site operations andtraffic as much as possible, the machineoperator Mario Schillinger set up his 5-axlevehicle in the one-side support position.This meant that the machine only requireda support width of roughly 7 m at the frontand 6.45 m at the rear with the boom fullyex tended to the side. Machine opera to rSchillinger commented, "When working in

Upper Eastside Berlin –challenging logisticsThe new building complex, Upper East-side Berlin, is under construction in aprime central location in the German cap-ital. More than 30,000 m3 of concrete isbeing installed by Putzmeister long-reachboom pumps and stationary pumps aswell as a stationary PM placing boom inan extremely confined space.

the city, it's almost certain that for everyother job I will only be able to support myl o n g - re a ch boom pump on one side.Construction sites inevitably require con-crete pumps with large boom reaches butthe available space is so incredibly tight!“

BSA pumps from the direction of the Boulevard

The construction company Köster AG hasjust about room enough to set up a station-ary concrete pump on the opposite bound-ary of the construction site area, located onB e rlin's famous Bouleva rd Un ter denLinden, and charge it with truck mixers.This machine is a BSA 2109 H-D connectedto the stationary boom MX 32-4 T via a ZXdelivery line. The pump line initially drops18 m vertically into the pit and is then laidhorizontally for a distance of 70 m.

Stationary boom climbs through the slabs

The stationary boom is mounted on a tub-ular column which is 10 m high and is init-ially supported on the foundation via a cruci-form base. The column will subsequently beextended by adding a 6 m section. As con-struction progresses, the tubular column,together with the boom and supported bytwo hydraulic lift cylinders, can climb up-wards through the roughly 1 x 1 m wideopenings in the two basement floors andseven upper f loors. The tubular columnsand boom are guided during this procedureby three floor frames. The concrete pipelineis mounted on the tubular column andclimbs with the tubular column; supplement-ary pipes can easily be used if required.More than 30,000 m2 of concrete will bedelivered to the construction site by fivemixing installations of the Zementwe rkBerlin and Lichtner-Dyckerhoff consortiumover a maximum distance of 15 km.

Manufacturer takes over service for rental machines

The stationary boom and the stationarypump were hired by Köster AG from thePutzmeister branch in Berlin (Basdorf). Thestaff were given thorough instructions whenthe new machines were first set up. Duringthe construction phase, the PM employeeswill subsequently also carry out the neces-sary inspection and maintenance work onthe boom and pump.

Machine operator Mario Schillinger

Client with financial clout

M E AG MUNICH ERGO AssetManagement GmbH (Munich) is thei nve stment manager of Münch e n e rRück und ERGO Versicherungsgruppe(group of insurance companies). MEAGis an inte rnational orgnisation withunits in New York and Hong Kong and,in addition to managing the group'sown money, does business with part-n e rs outside the Münch e n e r- Rü ckgroup. MEAG manages inve st m e n t sthat are currently valued at around €184 billion, around € 13 billion of thisis in property.

€€Without OSS, the M 52-5 long-reach boom pump could not have been used on thisconstruction site. In the background: the stationary MX 32 placing boom.

The BSA 2109 H-D delivers concrete tothe stationary boom from the edge of

the excavation pit via a ZX delivery line

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On site

The special feature of this concrete pump isthe crawler track which sets it apart fromthe familiar stationary concrete pumps andmachines mounted on a trailer chassis. Thiscrawler track makes the BSA mobile on theconstruction site and its set-up site can bechanged – by the machine operator of thepile-driving machine via remote control –according to the requirements. The pumpquantity and the maximum required deliv-ery pressure can also be limited and addit-ional important information read off viaradio remote control, e.g. the quantity ofconcrete pumped per pile and per day. Thenumber of piston strokes also provides anindication of the concrete filling level in thepiles.

Piles made of ready-mix concrete

The piles which are cast on-site from freshconcrete are suitable for a wide variety offoundations for structural elements. Thismethod has countless benefits.■ High daily output possible owing to fast

installation and effective work progression■ Pile lengths can be easily adapted to vary-

ing ground conditions■ Reinforcement can be made to measure■ High loadbearing capacity of the pile is

made more effective by compressing theconcrete when vibrating out the ram pipe

■ An ideal foundation installation method inbuilt-up areas due to the relatively lownoise emissions and shaking in the sur-rounding area.

Putzmeister has three of these concretepumps on crawler chassis in its range forthe concreting of bored or displacementpiles or for jobs to be carried out away fromsurfaced roads. The small BSA 1005 DRF issupplied with a rubber or steel crawler trackand the extremely powerful BSA 1409 DRFand BSA 1412 DRF models are suppliedwith a steel crawler track. Rubber bufferswhich are used in the crawler chain meanthat these machines can also be used onasphalted surfaces without increasing ope-rational wear and tear. In addition to theradio remote control with information dis-play, the crawler track BSA control cabinetis also equipped with the familiar EGDmodule (Ergonic® Graphic Display) installed

on other PM concrete pumps. This displaysa large amount of additional data on itsmenu interfaces, e.g oil temperature, opera-ting hours, possible faults, etc.

The machine operator operates the con-crete pump with the aid of the radio re-mote control. The current machine datacan be called up via the display

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On site

Work on the foundation for the new centralwarehouse in south west Switzerland isbeing carried out by specialised companieswith many years of experience. Due to theground conditions it was decided that thepiles should be installed to a depth of 35 m.

During this procedure steel pipes with steelcovers on the bottom ends are driven intothe ground by a ram with a ring vibrator. Assoon as the required depth has been reach-ed, the inside of the pipe is lined and rein-forced using a stocking made of geotextilematerial. High-quality ready-mix concrete isthen poured in and the pipe is vibrated backupwards. During this procedure, the steelcap remains at the bottom and is "lost“ inthe ground. As the vibration oscillations aremainly applied in the advance or withdrawaldirection, only minimum shaking occurs inthe immediate vicinity. To reduce pressurepeaks and friction forces on the shaft duringthe placement on this construction site whenpassing through the sand and silt layers, thecompany Eggstein further developed andused a combined vibration-jet method withlow-pressure rinsing.

Around 3 m3 of high-quality concrete arerequired to fill a single pile. The concrete isdelivered by truck mixers to a PutzmeisterBSA 1412 DRF concrete pump which is con-nected to the pile ram via a hose (DN 125)roughly 50 m long. The effective contact between the concrete, stocking and earthmeans that the piles subsequently have ahigh shaft friction and loadbearing capacity.The concreting of one pile takes roughly 45minutes to complete.

Pile builder work with concrete pumpon crawler chassisA consortium made up of the companiesEggstein (Kriens, CH) and Hilti & Jehle(Tirol, A) has been constructing a total of7,500 re a d y-mix concrete piles sinceNovember 2006, using a heavy-duty pilefoundation machine and concrete pumpon a crawler track. The foundation workis necessary in order to turn 100,000 m2

of soft alluvium into solid, load-bearingbuilding ground for a new Aldi distribut-ion centre in the Swiss town ofDomdidier (Freiburg Canton).

BSA 1412 DRF with steel crawler track in action during bore pile filling operation (Photo: Eggstein AG/Schmid)

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GAFARSA II1954

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On siteOn site

The Gafarsa reservoir in Ethiopia has beensupplying the capital city, Addis Ababa,with drinking water for over 60 years. Whenit was brought into operation in 1944, thestone dam was only 9 m high and had awater capacity of 1.5 million m3. In an initialexpansion stage in 1954 the stone dam wasraised to a height of 15 m thus raising thestorage volume to 6.5 million m3 (Gafarsa II).The reservoir is located at an altitude ofmore than 2,500 m, roughly 25 km to thewest of Addis Ababa and has been connect-ed to the town via a pipe system since 1952.

A further expansion phase has been under-way at the dam since April 2007 (GafarsaIII). The water supply and disposal author-ities in the Ethiopian capital awarded thecontract for this work to the Water WorksConstruction Enterprise (WWCE), which hasits headquarters in Addis Ababa. The reserv-oir now not only supplies the populationwith drinking water, it is also used for irrig-ation of agricultural land. To increase thecapacity of the reservoir, the 250 m longstructure needed to be heavily reinforcedwith concrete and the height of the crownhad to be increased.

Slump only between 1 and 3 cm

The initial plans to install the concrete witha mobile pump and placing boom were soondiscarded. The reason for this was that themass concrete or tamped concrete normallyused in the construction of dams, also refer-red to as RCC (roller-compacted concrete),with its low cement proportion and a slumpof 10 – 30 mm, is so stiff that it can no long-er be sucked in by piston pumps. In addit-ion, the aggregate size of 65 mm and aboveis not suitable for pumping through pipeswith 125 mm diameter. Due to its consist-ency, the concrete cannot be delivered bytruck mixers.

Telescoping belt can be positioned horizontally and with an approachangle of 30°

Putzmeister proposed that the constructioncompany WWCE use the mobile and tele-scoping TELBELT® TB 110 belt conveyor forthe transportation and placing of the build-ing material. TELEBELT® is an on-board mult-iple-telescoping conveyor belt system ontowhich the material is transferred by a feedconveyor, e.g. by tippers or wheel loaders.

Three models (TB 80, TB 110 and TB 130)with a horizontal reach of 24 m, 32 m and38 m re s p e c t i ve ly are available in th ePutzmeister range. The machine operatorcan move the conveyor belt horizontally andalso tilt it up to an angle of 30°. All kinds ofbulk materials can be transported on theTELEBELT® transport belt which is roughly45 cm wide – dry or lean concrete mixes,sand, chippings, gravel and hardcore, andalso topsoil, turf and substrate for landsca-ped roofs. Typical areas of use are in civilengineering, dam construction and railwayplatform construction as well as gardeningand landscaping. The TELEBELT® machines

TELEBELT® deliversand places lean concreteThe construction of dams for the safesupply of water to the population and foragriculture is a tradition in many count-ries. In Ethiopia, where water suppliesare relatively plentiful, the constructionof simple dams and surround of smalllakes has been carried out by the statea u th o rities since 1895. Howeve r, th edams constructed must be solid and alarge quantity of concrete is required toe n s u re that large re s e rves of wa te raccumulate. In view of the large quanti-ties of material required, it is easy tounderstand that the building materialsused must be as inexpensive as possibleand also adapted to the conditions. Thismeans that less cement (also to minim-ise the build-up of hydration heat) andonly a low proportion of sand and fineaggregate must be used – but with a con-siderable amount of oversized grain. Asc o n c rete pumps are not suitable fo rthese extremely lean mixes, Putzmeisteroffers an alternative delivery system aspart of its range.

Dams not only used as a source of drinking water

E thiopia is not just expanding th ecapacities of its drinking water reser-voirs. Countless numbers of new damsand hydraulic power stations are beingplanned with the aim of increasing thepower supply in the country to threetimes its current level of around 790MW within the next four years. Expertsestimate that the enormous power pot-ential in the country to be harnessedusing water is in the region of at least30,000 MW. Whereas today only 5 % ofthe population outside the capita lAddis Ababa is connected to the powers u p p ly, it is planned that by 2010around 50 % of Ethiopians will haveaccess to electricity supply. In addition,the economy (processing industry, agri-culture and service sector) has beengrowing at annual rates of between 6 %and 9 % since 2002/03 which is result-ing in an increasing need for electricity.

are mounted on 2, 3 or 4-axle chassis and –in contrast to belt conveyors on heavy RTchassis (RT: rough terrain) – are fully roadcompatible. These machines have a deliveryrate of 275 m3/h (max./theor.) and are there-fore extremely powerful. They are widelyused in North America.

At the Gafarsa dam the TELEBELT® is set upat various points in the immediate vicinityof the base. Dumper trucks transfer earth-moist concrete to the feed conveyor using afeeder hopper; the material is transferredfrom here to the transportation belt itself.The additional concrete layer is transferredstep by step to the existing dam wall start-ing from the bottom and working towardsthe top and is compressed with a roller. Dueto its range of 32 m and the variable posit-ioning angle the working range of the tele-scoping conveyor is extremely adaptable tothe building site conditions.

GAFARSA III2007

GAFARSA I1944

This picture was taken during instruction in the use of the TELEBELT® TB 110 on aneighbouring construction site (Photo: Brändle)

Schematic representation of the multi-stage expansion of the Gafarsa dam

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In the northern part of the Czech Republic,the town Chomutov has become a nationalconvergence point for traffic in the past fewyears. A four-lane bypass is currently underconstruction in order to relieve the congest-ion in the town centre. It joins a dual carriage-way that connects the indust rial site saround Chemnitz in Saxony to the Czechcapital, Prague. One section of this motor-way is in the form of a bridge over the riverHacka which is 336 m long and a few kilo-metres north of Chomutov. A consortiumconsisting of the construction companiesMax Bögl a Josef Krysl (leading) and SMPwas entrusted with the task of completingthe 17 million-€-project by the Czechhighways agency.

Previously unheard of: high-rise delivery of concrete by pump

As both construction companies in the con-sortium previously had no experience withhigh-rise concrete pumping using stationarypumps, the initial plan was to install theconcrete using a crane bucket. However, theneed to maintain a continuously high con-crete quality in the construction elements ofthe bridge and the increasing pressure as

regards costs and deadlines also had to betaken into account. Following intensive dis-cussions and sharing of advice th ro u g hmutual cooperation between colleagues atthe head office of the group of companiesMax Bögl (Ne u m a rkt i.d.OPf.) andPutzmeister, the managers of the consort-ium carrying out the construction workwere ultimately convinced by the proposalto deliver the concrete by means of pumpingand opted to venture into this area of techn-ology which, for them, was previously un-charted territory. Any further reservationswere finally dispelled through intensive,skilled training and inst ruction of th emachine operators.

60 m high columns

The bridge is supported on three foundat-ions, each supporting two pillar slabs. Dueto the craggy supporting ground the consort-ium opted for a raft foundation for whichmore than 2,500 m3 of concrete was instal-led during the course of the ground replace-ment. In addition, around 1,700 m3 of con-crete was used for the foundations them-selves.

The consortium used hydraulic climbingformwork to construct the pillar slabs whichare up to 60 m high in five metre stages. Thetwo slabs of each column are connected toeach other at the top by the hammer head

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Continuous concrete placing duringbalanced cantilever construction of a bridge

Sophisticated bridge structures can also be built with relatively little effort using con-crete pumps and concrete distribution machines. The best example of this is theHacka viaduct in the Czech Republic, which was handed over to the clients at the endof June 2007 after only two years of construction work.

The concrete transfer area of the BSA stationary pump is protected from the weather. The gate valve with hydraulic power pack can be seen in the backgroundon the right – this also changes over when moving to the other column.

The delivery of concrete to 66 m heightis made via ZX delivery lines that aredesigned with a particularly tight formfit at the collars. The lines are fastenedto the pillar slab.

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Interesting PM gate valve systems

As a basic rule. Putzmeister distinguish-es between manually ("M") and hydraul-ically ("H") operated gate valves anddiversion systems. Gate valves as wellas diversion valves were used duringthe construction of the Hacka viaductand were controlled hydraulically. Thetype designations for the GVM 2/2 flatgate valve and DVH 5/2 diversion valveare derived from the expressions ("GateVa lve Manual" and "Dive rsion Va lveHydraulic"). The first digit provides anindication of the overall number of hop-per openings (for inlet, outlet andcleaning), the second digit refers to thenumber of switch positions. In generalthis refers to the number of outlets –however, the switch positions can alsorefer to the number of outlets plus cutoffpositions.

Concrete pump or crane bucket?

Situations certainly arise on site fromtime to time where it makes goodsense to carry out concreting workusing a crane bucket – for very smallamounts of concrete in components inunfavourable locations, for example.However, as rough calculations willmake clear, it is more economic to de-liver concrete using a pump on thekind of high-rise construction sitesdealt with in this article. On this con-struction site a maximum of 5 or 6crane cycles are possible per hour (fillbucket, lif t bucket to above 65 m,d i s ch a rge and dist ri b u te concrete ,lower bucket). While the pump torqueof the crane in the area of the hammerhead permits the bucket to be filled toa volume of roughly 1 m3 (around 2.4tons), the working load of the cranereduces from initially 0.5 m3 concretein the 5th section to much less in the10th section as work on the super-structure progresses. If, for the pur-poses of this example, we assume anaverage transport volume of 0.7 m3

per crane cycle, the calculated instal-lation performance is roughly 4 m3/h.This would mean that one concretingcycle for the superstructure (requiredquantity of concrete 180 – 200 m3)would only be complete after 45 – 50hours. A stationary concrete pumpsuch as the BSA 1407 D which has amax./theor. delivery rate of 70 m3/hwould normally not pump this valuein practise (e.g. because the concreteis not delivered continuously by thetruck mixer or because the deliveryrate must be reduced due to the dens-ity of the reinforcement). But even ifthe machine was only to pump at 25 %of its possible pumping quantity, thei n stallation perfo rmance would bemore than 17 m3/h, i.e. more than 4times the quantity achieved using thecrane bucket. As the precise wages ofthe personnel who are not occupiedd u ring the crane cycles and th eacquisition and operating costs of theconcrete pump including gate valveand diversion valves are not available,we wish to end the model calculationhere.

which is used as the starting point to createthe superstructure using the balanced canti-lever construction method. The superstruct-ure is executed as a single-cell box section22.3 m wide which reaches a height ofroughly 6 m above the columns and tapersin the middle of the field to roughly 2.6 m.

BSA changes between two set-up sites

While it was still possible to concrete thelowest of the three columns and its super-st ru c t u re using tru ck- m o u n ted concretepumps, the consortium used a stationaryPutzmeister concrete pump for the two highcolumn const ructions and corre s p o n d i n gsuperstructures. The BSA 1407 D was set upat the bottom in the valley and connected tothe placement site on the superstructure viavertical ZX delivery lines fastened to the pillar slabs. The BSA was operated in tand-em with a GVH 2/2 gate valve from the baseof each column alternately. The machineswere parked in weather-resistant shelterswhen concreting during the cold wintermonths. The service work was undertakenby Peva – t he PM agent for the CzechRepublic in Prague, 90 minutes drive fromthe site.

Hydraulic gate valves ensure even balance

The concreting of the superstructure start-ing from each hammer head in the valleyand hillside direction was carried out in 10sections and at four to five metre intervals.The placing of concrete in the lower area ofthe box section was relatively time consu-ming. This is because time and again theconcreting hose needed to be fed into thenpulled out of the ceiling formwork. In con-trast, the concreting work at the top on thec e i l i n g / floor slabs pro gressed qu i ck ly.

Between 180 and 200 m3 of concrete werepumped during every cycle. During this pro-cedure the concrete workers – under thes u p e rvision of site manage rs Ro st i s l avLeskovsky and Petr Holy – took particularcare to ensure that the superstructures onthe hill and valley sides respectively wereconcreted at uniform intervals of one hour.

To achieve this without a large amount ofexpenditure the consortium connected theZX riser to PM diversion valve model DVH5/2 on two of the three hammer heads. Thediversion valves as well as the ZX deliverylines have the advantage that their connect-ion points (joints) are designed in such away that they are completely tight and rigid-ly engaged. This prevents "bleeding" of theconcrete from the pipework, thus preventingencrustation which could lead to blockages.

The gate valve and diversion valves wereswitched over hydraulically by remote con-trol, which meant that the concrete could bedirected to the pipework on the valley or hillside at the push of a button. Flexible extens-ion hoses were subsequently coupled tohorizontally routed line runs. These wereeasy to handle and could also be fed throughthe reinforcement and ceiling formwork intothe lower part of the box section. A total ofaround 15,000 m3 of concrete was required

for the superstructure. This was a C35/45with 22 mm maximum particle size and acement proportion of 400 kg/m3. One morething should be mentioned – the deliverylines were thermally insulated from themiddle of December 2006, the concrete wasdelivered with heated aggregates to thepump and the freshly concreted segments ofthe superstructure were covered with insul-ating material to prevent them from coolingdown too quickly.

DVH 5/2

GVM 2/2

To be able to concrete the reinforcement in the lower section of the bridge hollowsection, the end hose must be passed through several holes in the floor

In the background (on the left) the riser penetrates the bridge superstructure andbranches into two pipe runs laid horizontally. A transfer tube makes it possible toswitch over the flow of concrete immediately from one side of the balanced canti-lever construction to the other.

The two site managers Petr Holy (left) and Rostislav Leskovsky

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PM in focus

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Putzmeister intends to use the new paintingc e n t re to speed up the th roughput ofmachines and plants considerably. The newcombined painting and drying line (57 mlong, 10 m wide, 8 m high) can be used asone, or operated as three individual paintingcabins each of 19 m in length. And last butnot least, the cabin roof can be opened alongits entire length to take future developmentsinto account where a particularly large plac-ing boom may need to be fully extended andpainted inside the plant.

A special ventilation system was requiredfor the painting cabin due to its size. Theventilation zones move with the paintersalong the concrete pumps and booms. Tomake this process automatic the paintersare "sensed“ by laser scanning which meansthat the ventilation zones travel round thevehicles and components to be painte ddepending on the movements of the person-nel. In practice, this means ideal workingconditions for the team and automatic energysavings of 50 % when compared to convent-ional technology.

The painting cabins at the complex – whichwas constructed in record time (under con-struction for only 15 months including found-ation work and internal finishing) – fall wellbelow the limits defined by stringent regulat-ions governing solvent emissions and theremoval of solid particles. The cabins aredesigned in such a way that paints contain-ing even fewer solvents such as very highsolid and water-soluble materials can beused in future. The heating and drying iscarried out by environmentally-friendly gas-fired surface burners with an efficiency ofmore than 99 %. A high proportion of theenergy used is recovered via a heat ex-changer.

Working platforms that can be moved threedimensionally make it possible for the paint-ers to reach all areas of the truck-mountedconcrete pumps and placing booms whilstmaintaining an ergonomic body posture.They can operate the equipment themselvesby hand and foot controls.

The new painting centre is integrated into aspacious hall complex which is 17 m highand has roughly 4,900 m2 of floor space. Allnecessary work for the painting preparationis carried out here (grinding, masking, seal-ing of welded seams, etc.) protected from theelements. A modern drying off and washingbay amongst other facilities is accommodat-ed within the new building. Both have theirown areas for preparing the extended boomand truck superstructures for painting aswell as spacious staff rooms. A roofed man-oeuvring space is connected to the enorm-ous building, covering an area of roughly1,000 m2.

Putzmeister brings newpainting centre into operationPutzmeister AG has invested in the region of 17.3 million € to set up a new state-of-the-art painting centre which was brought into operation at the beginning of August.The new building was constructed to accommodate the annual growth in productionof concrete pumps and booms which has now risen by between 20 % and 30 % .

Overall, the new PM painting centre will notonly accelerate the throughput times, it willalso further improve the quality of the paint-ing work. This means that, following thec o nve rsion of its production facilities athome and abroad, Putzmeister will also haveincreased its capacities in the area of surfacetreatment by 100 %.

Prior to painting, all machines are thoroughly cleaned from a working platform thatcan move three dimensionally

Several truck-mounted concrete pumpscan be accommodated in the paintingand drying cabins

Paint booth LK1 Paint booth LK2 Paint booth LK3

Paint booth LK4

Flash-off area ventilation

TR60 dryer

Wash hall

Paint store

Small parts preparation area

There is plenty of space in the new hall for preparation of the base structures and booms for painting

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PM in focusPutzmeister AG, Max-Eyth-Str. 10, D-72631 AichtalPSdg, Deutsche Post AG, Entgelt bezahlt, E 60458

All rights and te chnical details subject to alte ration · The illust rations show special mechanical equipment and snapshots in practice on const ruction sites, which do n ot always correspond to the regulations of the Indust rial Emp l oye rs’ Liability Insurance Association · © 2007 by Putzmeister AG · Pri n ted in Germ a ny (3.50709RR)

This edition of the "Sandesh" dailypaper from the Indian federal state ofGujarat recently reached the PM posteditorial. The newspaper is published in Gujarathi, one of the many languag-es of India which is particularly wide-spread in the north west of the country. With a daily circulation of700,000 copies, "Sandesh" is one of the ten most widely circulated daily papers in India.

The caption under the lead photo roughlyt ra n s l a ted reads: “Const ruction wo rk onnational road no. 8 in the area of Vankaneris progressing at a rate of knots. While con-struction of this motorway is in progress, arailway bridge is also under construction.Modern construction equipment is beingused to speed up the work.”

The photo shows a PM truck-mounted con-crete pump (model BSF 32.09 H) manufact-ured in Turkey. The machine is mounted ona 25-ton chassis by the Indian truck manu-facturer Ashok Leyland. An independentpower unit with 118 kW output has been in-

M 32 in the Indian dailypress

stalled on the flatbed to drive the concretepump and boom hydraulics. This is a Deutzdiesel unit with a torque characteristic thatis desirable for industrial machines. Theo p e ra tor of the concrete pump is th eNagarjuna Construction Company Ltd (NCC)w h i ch has its comp a ny headqu a rte rs inH y d e rabad (fe d e ral sta te of AndhraPradesh). NCC recently placed an order for asecond BSF 32.09 H with Putzmeister. Thework for the truck superstructure of the

X unit (i.e. base structure with support,placing boom and core pump) on the Indianchassis was carried out in July – the machinewas handed over to the customer just a fewdays later. In addition, since December 2006the Nagarjuna Construction Company hasalso been operating a stationary PM con-crete pump model BSA 1404 D, in tandemwith a RV10 rotary distributor in the capitalcity, New Delhi.

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