The magazine by Putzmeister Concrete Pumps GmbH �9The magazine by Putzmeister Concrete Pumps GmbH �9Post

Hoover Dam Bypass Bridge – concreting at a height of ��4 m above the Colorado River

Dancing Towers on Hamburg‘s Reeperbahn – three long-reach boom pumps work in perfect coordination

The world‘s biggest stationary boom on the Bosporus M 6� placing concrete for oil production platform in Russia‘s Far East

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Content Content / worth knowing

Title story

Hamburg: Dancing TowersThree M 52 long-reach boom pumps used for the concreting of the foundation slab of the new St. Pauli landmark 4

On site

Hoover Dam Bypass Bridge – the story of a “modern marvel” Concreting at a height of 274 m above the Colorado River 10Russia: M 6� placing concrete for oil production platform„A single one-way ticket on the Trans-Siberian Railway from Moscow to Vladivostok“ 14Turkey: The MXKD 50, the world‘s biggest stationary boomSensational find from ancient Constantinople – Port of Theodosius discovered at the underground station in Yenikapı 18

50 questions

How does Putzmeister manage to be so ubiquitous?In each edition of PM Post we answer one of 50 interesting questions from the last 50 years of Putzmeister 16

In brief

Putzmeister Academy – Seminar brochure for 2011 �1Launching of the first dredger in China equipped with a Putzmeister KOS 25100 high-density solids pump �1Putzmeister at construction sites in India ��

Worth knowing

Exhibition dates / Interesting facts �

Photo credits �Imprint �

On the Reeperbahn at six in the morning…

History lesson: concreting at the Port of Theodosius

Dizzying heights: Hoover Dam Bypass

M 6�: 9,000 km rail journey to the Sea of Japan

Photo credits:

Unless indicated otherwise, all illustrations are copyright Putzmeister Concrete Pumps GmbH. 18: www.datenland.de · 22: hoover_dam_nevada_luft-aufnahme, Wikimedia Commons, licensed under Cre-ativeCommons license by-sa-3.0, Florian Arnd · 26: sea_of_okhotsk_map, Wikimedia Commons, licensed under CreativeCommons license by-sa-3.0, Norman Ein-stein · 27: cape tihii, Wikimedia Commons, Vihljun · 28: nivkh_men, Wikimedia Commons · 29: yuzhno sakhalin museum (5), Wikimedia Commons, licensed under Crea-tiveCommons license by-sa-3.0, Straitgate · 30: zametny island, Wikimedia Commons, Vihljun · 35: istanbul rapid transit map, Wikimedia Commons, licensed under Crea-tiveCommons license by-sa-2.5, Maximilian Dörrbecker

Imprint:

Editor:Putzmeister Concrete Pumps GmbHMax-Eyth-Str. 1072631 Aichtal · Germany

Editorial department: Volker Wehner, Petra MontagPutzmeister Concrete Pumps GmbH

Layout/DTP: Petra MontagPutzmeister Concrete Pumps GmbH

Print:Offizin Scheufele GmbH & Co. KGTränkestr. 1770597 Stuttgart · Deutschland

All rights and technical amendments re-served.Although content is checked carefully, we accept no liability for sites to which links are given. The operators of external web-sites are solely liable for their content.Some of the illustrations show special ma-chine variants and snapshots which do not always comply with the regulations of the Industrial Employers’ Liability Insurance Association.

© by Putzmeister Concrete Pumps GmbH2010 · Printed in Germany (3.51009)

Exhibition dates October – December �010

04. – 08.10.2010

Elektra Mining, Johannesburg/SA

27. – 30.10.2010

SAIE Bologna/Italy

22. – 25.11.2010

Big 5 Show, Dubai/UAE

23. – 26.11.2010

Bauma China, Shanghai/China

By the way… Did you know that for many years now, Putzmeister delivery cylin-ders have been hard chrome plat-ed? As standard!This is an important quality fea-ture and extends the service life substantially.

worth know

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“Two new dancers on Hamburg‘s Reeperbahn” Following the plans of architects Bothe Richter Teherani, the “Dancing Towers” project was begun in September �009 quite close to the Port of Hamburg. On the approx. 5,400 m² plot at no. 1 Ree-perbahn, two pitched high-rise buildings and a hotel complex are being built for around € 150 million. The contractor is Strabag Real Estate GmbH.

May �010 saw the second phase of con-creting the ground level with a volume of �,650 m³ of concrete. PM has had a look over the shoulders of those involved, who own four Putzmeister long-reach boom pumps (three in use plus one on stand-by) of the BSF 5�.�0 H type provid-ed by betonlift GmbH & Co. KG.

Placing such a large amount of concrete on a single day, even for the old hands of construction fi rm Ed. Züblin AG, requires some preparation in planning and consul-tation with the contractors. The concrete supplier is Holcim Beton & Zuschlagstoffe GmbH (Hamburg), the pumps are provided by betonlift GmbH & Co. KG and Sociedade de Construções, Lda (Lisbon) is responsible for placing the concrete. On this day, 5th May, work starts with the concreting con-cept for the bottom plate, which is subdivi-ded into six concreting sections. The follow-ing marginal conditions apply:

Max. plant capacity: 200 m³/h (four mobile concrete plants, each with 50 m³/h)Setting up three concrete pumpsHaving three construction crews at the ready

The site management prepares the concret-ing plan for each concreting operation.

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Title storyTitle story

Concrete Technology

In the case of the second phase described here, three different types of C30/37 con-crete are used. For the lower part of the fl oor and the diagonals, the maximum particle size is reduced to 16 mm because of the high density of the reinforcement (see the box). This ensures that the steel is coated with concrete on all sides. In the middle lay ers, the maximum particle size is 32 mm, and for the top layer, it is reduced to 16 mm again. From the point of view of concrete techno-logy, it is important to place the individual layers in such a way that concreting is al-ways carried out before the bulk concrete of the previously placed layer begins to set. This means that the bottom layer must still be processible when the next layer is being poured.

The concreted section has a surface area of 24.5 m x 42 m. For a concreting height of 0.5 m, the concreting volume is approx. 330 m³ per layer with a maximum com-ponent thickness of 4.52 m (1.5 m in the boundary areas) for the bottom layers. If one assumes an average output of 150 m³/h, approx. two to three hours will be required for concreting each layer. For the upper area, up to 550 m³ per layer and three to four hours workabil-ity time are set aside. This means that the workability time for the concrete supplied for the lower layers must be slowed to four hours, and fi ve hours for the upper layers – even once any change in location of the pumps has been taken into account.

The concreted section has a surface area of 24.5 m x 42 m. For a concreting height of 0.5 m, the concreting volume is approx. 330 m³ per layer with a maximum com-ponent thickness of 4.52 m (1.5 m in the boundary areas) for the bottom layers. If one assumes an average output of 150 m³/h, approx. two to three hours will be required for concreting each layer. For the upper area, up to 550 m³ per layer and three to four hours workabil-ity time are set aside. This means that the workability time for the concrete supplied for the lower layers must be slowed to four hours, and fi ve hours for the upper layers – even once any change in location of the pumps has

Pump

�Full support, feeding by two truck mixers at same time

Pump

�OSS (One side sup-port), 180° forwards working area

Pump

1OSS (One side sup-port), 180° forwards working area

betonlift Service truck with „caboose“

Stand-by pump

Mixture breakdown for the bottom plate bulk concrete

bottom area middle area upper area

Fresh concrete properties

Consistency F5 (58 ± 2 cm) F5 (55 ± 2 cm) F4 (53 ± 2 cm)

Workability time up to 6 hrs up to 10 hrs up to 2 hrs

Hardened concrete properties

Property class C 30/37 C 30/37 C 30/37

Exposure classes XC2, XC3 XC2, XC3 XC3, XD1

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neighbours, and therefore we need as many pumps as possible. So we have teamed up with betonlift to develop a very target-ori-ented, fair, good and safe solution. Because when placing large amounts of concrete as you see today, we really can‘t leave anything to chance. So, for example, we worked with betonlift to determine first of all the loca-tions of the three pumps (see fig. 7 and 9), restricted as we were by a very small set-up area, the maximum load on the supporting ground at the edge of the pit, and the access options for the truck mixers.”

p For some in St. Pauli, this early hour means hometime, but for the workers on the construction site, the day is only just starting: At half past 5 sharp, the first truck mixers arrive.

were able to provide full support there, and were able to load using two truck mixers at the same time. This enabled the P2 to reach a somewhat higher effective pumping rate per hour.”

An average pouring rate of 180 m³/h was assumed for the three pumps combined. At 2,650 m³, this meant a pumping duration of approx. 14 hours. Therefore, concreting was set to begin early, at 6:00 am. To save some

Franz Syrowatka from betonlift Hamburg adds: “To us it was clear that we would be using our Putzmeister 52 m booms; three in action and one as a stand-by pump with one machine operator to relieve colleagues dur-ing the day. The important thing for pumps 1 and 3 was the one side support, and that we have a working area of 180°. This was the only way that we were able to reach all corners of the area to be concreted. With pump 2, we had somewhat more space. We

Placing concrete - from a practical viewpoint

Laughing when asked what the greatest challenge for placing concrete is, project lead Silke Pförtner from Ed. Züblin AG ans-wers: “When you see the depth of the pit, the type of pit lining and the size of the area set aside for the construction site equipment, it soon becomes clear: There isn‘t actually any space for large machines. In addition, the hours allowed for concreting are clear-ly delimited because we have to respect our

t A fence reduces the street width by half: On one side, traffic can pass by unhindered, and on the other, the truck mixers control the M 5�, which is supported on one side. The one side support (OSS) for pumps 1 and � was crucial for their use in the tight space available.

q Don‘t push: Each truck mixer in the convoy is guided to the appropriate pump by the signaller. Pump � (far left) has a somewhat larger set-up area and can be fed by two truck mixers at the same time.

Title storyTitle story

p Keeping an overview: Three booms, moving construction site cranes, constant changing of truck mixers – the construction site requires the utmost attentiveness from the machine operators.

time, the four concrete pumps were moved into place the evening before, which meant that all that remained to be done was to set up the machine supports and move the boom into its working position anytime from 5:00 am onwards. Around 5:30 am, the first Holcim truck mixer arrived from the plant approx. 15 km away, and shortly after 6:00 am, the first concrete started to flow. In total, there were 45 truck mixers constantly driv-ing to and fro, transporting the concrete to the “Dancing Towers”.

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t An army marches on its stomach: A hearty stew with sausages from the “betonlift canteen” and Portuguese fried chicken “à la Zucotec” provide new strength.

Concreting within tight reinforcement

Because in this area for concreting alone the reinforcement consisted of 776 t of steel, the meshing structure was so dense that specially marked concreting openings (d = 0.2 m) were planned in a 10 m x 10 m grid for inserting the end hoses (see fi g. 14). This allowed the boom to be mainly moved from point to point at lengthy intervals. How-ever, the machine operators could not take their eyes off the ball for a moment, because the interruptions caused by the frequent changes of truck mixers had to be agreed with the concreting team. In addition, the machine operators also had to keep the other placing booms and cranes within view, as they were moving at the same time. Not an easy job, when you consider that on this par-ticular day, work started around 4:00 am in the depot at betonlift, and that the construc-tion site had special permission to work un-til 11:00 pm, to be on the safe side.

Top planning combined with a good working atmosphere produces a high level of effi ciency

The working atmosphere and level of coope-ration on the construction site were remar-kably good. Contributing to this are very good organisation of processes and certainly the mobile combination of workshop and “caboose”, which Jürgen Bitsch from beton-lift Hamburg sends to the construction site to supply the team for such large-scale oper-ations (see fi g. 17). His explanation sounds quite simple:“When you require a lot from your team, you also have to provide some relief for them. And when you experience what the machine operators and many others have to put up with on the construction site, in cold and wet weather, then it quickly becomes clear that they really value a cup of coffee or a bowl of hot stew. It motivates them and refuels them

Title story

The Dancing Towers of St. Pauli

Soon to reach up to 85 m in height, the pitched “Dancing Towers” have already become the new symbol of the St. Pauli district. Combined with the inclinations in the buildings‘ structure, nocturnal il-lumination is meant to make it look as though the towers are dancing.

In addition to offi ces and a hotel, the “Mojo Club” will return to its former address of No.1 Reeperbahn. From 1993 it was an internationally renowned atten-tion in the nightlife scene of St. Pauli.

The towers are due for completion in summer 2012.

Webcam at the No.1 Reeperbahn construction site:

http://baustelle.strabag.at (various construction sites can be viewed)

Spectacular construction projects by architects Bothe Richter Teherani:

www.brt.de

Always worth a visit – the Hanseatic city of Hamburg

www.hamburg.de

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p Because of the extremely dense network of reinforcements, the workers can only feed in the end hose at the specially marked points.

t Working in the supporting ground: Zucotec workers are inside the rein-forcements while the bottom layer is being concreted.

for the next round of work. And because eve-ry construction site worker is welcome, we have a good reputation. It helps us particu-larly when, being far from home, there are problems from time to time. For example, a locksmith can be on hand quickly if necessa-ry, or people who can help to clear out a pipe fast if there is a blockage. In my opinion, we get back many times what we‘ve put in.”

Guten Appetit, or is that Bom Apetite?

The same must surely apply to the men from Zucotec, mostly Portuguese, who were responsible for placing the concrete inside the reinforcements, spreading it, venting and smoothing it. As a spicy aroma begins to

waft across the pit around the middle of the day, we cram into one of the site containers in search of the chef, who proudly presents two trays of fried chicken for his fellow Por-tuguese countrymen (see fi g. 16).

At around 9:30 pm, the last Holcim truck mix-er has been emptied, and even all 2,650 m³ of the top layer of fl oor concrete, with its tar-get consistency of F5, has been successfully placed. All that remained was smoothing, tidying up and cleaning. And when PM as-ked again the following day how the collabo-ration went, project lead Silke Pförtner and Franz Syrowatka from betonlift agreed: “The work was hard but was shared equally and ran smoothly.” ■

Title story

© www.datenland.de

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[Putzmeister America, October 2009] The Mike O‘Callaghan-Pat Tillman Memo-rial Bridge – better known as the Hoover Dam Bypass Bridge – is one of the most ambitious construction projects in the USA. With a span of ��� m between the twin concrete arches, once complete, it will be the longest in North America and the fifth longest concrete arch bridge in the world. Its apex reaches a height of ��4 m over the Colorado River. Stationary concrete pumps and placing booms from Putzmeister mastered the high demands of concrete pumping in this Colorado River bridge construction project.

As was done 76 years ago, the Hoover Dam is again making its mark in history books. Crews are conquering an engineering feat of constructing the most technically challeng-ing bridge ever to be built in North Ameri-ca, the Colorado River Bridge. To help place concrete for this one-of-a-kind project, two Putzmeister placing booms and BSA trailer pumps are taking on the obstacles presented by the Hoover Dam surroundings.The bridge is part of the Hoover Dam Bypass project, will hover around 274 m above the Colorado River and run parallel to the dam. The bridge, with two lanes in each direction, is being built in an effort to alleviate traffic on U.S. Highway 93, which currently crosses the Hoover Dam to pass over the Colorado River.Because the highway is the major commer-cial corridor between Arizona, Nevada and Utah as well as on the North American Free Trade Agreement (NAFTA) route between

“For construction of the twin arches, we po-sitioned one trailer pump near the base of the Nevada arches and one on top of the arch footing in Arizona,” comments St. John. “A placing boom was also positioned on each the Nevada and Arizona side of the twin arches.”The separate placing booms and their pedes-tals were flown via crane to each of the twin arches for mounting on their specially-de-signed platforms.

The making of a “Modern Marvel”

Mexico and Canada, the traffic congestion (an average of 14,000 vehicles a day) caused by the existing highway across the dam, imposes a serious economic burden to the country.In addition, the traffic volumes, combined with the sharp curves of the highway near the Hoover Dam, create a potentially dan-gerous situation for Hoover Dam visitors and dam facilities. Once the Colorado River Bridge is complete, no through or truck traf-fic will be allowed on the existing roadway; only Hoover Dam visitors will be permitted.

Choosing the right system Obayashi/PSM JV, a joint venture of Obaya-shi Corporation and PSM Construction USA, Inc., the general contractor, began construc-tion on the 579 m long open spandrel deck arch bridge in early 2005.

Obayashi/PSM JV had its work cut out for them; the project included the pre-casting and erection of pier columns up to 91 m tall; construction of the twin, cast-in-place seg-mental concrete arch spans; and the installa-tion of temporary twin cable stays that have a 762 m span and are 101 m tall to support the arches during construction.

“We called Putzmeister right away to discuss the project and what our possible concrete placing solutions for this complicated pro-ject would be,” says Wes Pollnow, construc-tion manager of Obayashi/PSM JV. “We needed to know which solution would make the most sense and which would be most ef-ficient; they have a true complete systems

approach, helping us from the beginning of the project.The placing system they chose to maximize their concrete placement for the arch was MX 32-4 Multi and MX 36-4 Multi placing booms and BSA 2107 HP-E and BSA 2109 H-E trailer pumps.”

Overcoming the extreme

To date, Obayashi/PSM JV has pumped and placed about 10,000 cubic yards (7,646 m3) of concrete for the Colorado River Bridge.Jeff St. John, project manager of Obayashi/PSM JV, says the pump manufacturer helped their team determine how and where to mount the placing booms and position the trailer pumps for all portions of the project.

As a result of the blazing heat, and to prevent traffic problems, most of the concreting was carried out at night.

On site On site

Planned amounts of concrete and steel for bridge construction

69 N/mm2 concrete in the arches 6,499 m3

41 N/mm2 concrete in the pier columns and caps 6,395 m3

31 N/mm2 concrete in the bridge deck 4,193 m3

28 N/mm2 concrete in the footings and abutments 5,106 m3

21 N/mm2 concrete for column infill 1,575 m3

Reinforcing steel 3,765 t

Structural steel 3,084 t

Post-tensioning steel (permanent) 384 t

Post-tensioning steel (temporary) 680 t

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Quinn Concrete Pumping, Las Vegas

Quinn Concrete Pumping, Inc. (Quinn) of Las Vegas has also lent its services to the Colora-do River Bridge project. Quinn has supplied both pump operators and has provided their own Putzmeister equipment.“Quinn was on site quite early on in the project for the footing and arch foundation concrete,” notes St. John. “They are a great team to work with, very dependable. We ex-pect they’ll also be involved with placing the deck concrete as well.”

Most notably, Quinn’s M 42 and M 58 truck-mounted concrete boom pumps were on site back in 2005 to pump and place concrete for the Colorado River Bridge’s pier. The pier provides foundation for the vertical columns needed to support the arch of the bridge.

Hoover Dam Bypass Bridge

Owner/Developer: Federal Highway Administration/Washing-ton, D.C. · Arizona Department of Trans-portation/Phoenix, Arizona · Nevada De-partment of Transportation/Carson City, Nevada · U.S. Bureau of Reclamation · Na-tional Park Service · Western Area Power Administration/Lakewood, Colorado

Design Team: T.Y. Lin International/San Francisco, Cali-fornia · HDR Engineering · Sverdrup Civil, Inc.

General Contractor, Concrete pump supplier and concrete ready mix supplier: Obayashi/PSM JV, a Joint Venture of Oba-yashi Corporation and PSM Construction USA, Inc./Boulder City, Nevada

Concrete pump sub-contractor: Quinn Concrete Pumping, Inc./Las Vegas, Nevada

Additional concrete ready mix suppliers: Casino Ready Mix/Las Vegas, Nevada · Sil-ver State Materials/Las Vegas, Nevada

Equipment: Obayashi/PSM JV: Stationary concrete pumps BSA 2107 HP-E and BSA 2109 H-E, placing booms MX 32-4 Multi and MX 36-4 Multi Quinn Concrete Pumping: M 42 and M 52 truck-mounted concrete pumps

In order to avoid the intense heat and avoid traffi c congestion, most of the concrete place-ments occurred at night. Once the placing booms and trailer pumps were in position, they were ready to step up to overcome the 38 °C weather, while pumping and placing the notorious, harsh Nevada concrete mix up 85 m and out 162 m. “All of the concrete mixes used for the arch were advanced concrete mix designs using harsh aggregates,” says St. John. “Liquid nitrogen has been used extensively for pre-cooling of the concrete in order to reduce the temperature the concrete reaches during cu-ring.”

For the arches, a high-strength 69 N/mm2 concrete mix was used, and for the columns and pier caps a high-strength 41 N/mm2 mix was used. Early in the project the concrete mixes were provided by Casino Ready Mix and Silver State Materials (now a part of the CalPort-land Company), however in late 2007 Oba-yashi/PSM JV began operating their own concrete batch plant for the arch and deck concrete, and will continue to make their own until the project is complete.“Even with the combination of the heat and the harsh mix, the trailer pumps were able to easily maintain a continuous concrete fl ow, at a timely pace, up to the placing booms so it would not clog the pipe system in the extreme conditions,” comments Pollnow. “In addition, the S-valves on the pumps had no problem gulping down the tough concrete mixes.”

The trailer pumps are able to provide a smooth, more controllable output of concrete because of each pump’s free fl ow hydraulic technology. Both pumps have a fully adjust-able volume control to allow very slow pump-ing while retaining full concrete pressure.The pumps have been outputting around 12 m3/h due to the job site’s extraordinary environment conditions.

“The pumps really provided that extra muscle we needed to push the concrete up and out to its fi nal destination, and in fact, both trailer pumps have the capability to pump concrete up to 244 m high. Also, the capabilities of the placing booms helped im-mensely to reach the exact point of concrete placement for each segment of the twin arches. Again, because of the unconvent-ional setup, we really needed dependable booms, and they did not disappoint.”

p Each state had a stationary concrete pump: one in Nevada and one on the Arizona-side of the Colorado River.

t The airy workplace for the placing booms

The Hoover Dam – interesting and intriguing

Concrete on a huge scaleThe Hoover Dam was constructed as an arch gravity dam between 1931 and 1935 with a height of 221 m and a crest width of about 14 m. The base width is 201 m. Approximately 2.6 million m3 of concrete was used in the construction of the dam. The dam was not cast as a single piece but, instead, was created from a large number of individual trapezoidal concrete blocks that were 1.5 m in height. Each block con-tained a series of pipelines through which the cool water circulated. As a result, the heat that is produced as the concrete sets is conducted away at a considerably quick-er rate. Without this measure, the concrete would have taken approximately 105 years to cool!

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Boulder Dam? Hoover Dam?Originally started as the “Boulder Dam” project, the dam was renamed to “Hoo-ver Dam” at the beginning of the offi cial construction phase. At this time, Herbert C. Hoover was standing for re-election as president. Despite linking his name to this construction project, which created many thousands of jobs during the Great Depres-sion, Hoover lost the election. In 1933, the dam was again called Boulder Dam, but 14 years later, and ever since, the dam was again called Hoover Dam.

The metropolis of gambling grew as the dam grew The town of Boulder City was built spe-cifi cally to house workers involved in the construction along with their families. How ever, gambling and alcohol were prohi-bited in Boulder City. It was therefore only logical for workers to use their free time to make the pilgrimage to the small desert settlement of Las Vegas, 50 km away. Bars and Casinos started to emerge in no time.

Las Vegas without electricity? Unimagin-able! However, a curious fact is that at the time when the electricity purchasing rights from the hydroelectric power station at the Hoover Dam were being negotiated, the desert city‘s mayor at that time rejected any purchase, saying “Las Vegas will ne-ver have more than 5,000 inhabitants”. As a result, Las Vegas currently only receives about three percent of its annual electrici-ty demand from the nearby Hoover Dam hydroelectric station.

On site On site

“The 58-meter boom pump was positioned atop a cliff’s edge on site, and used its full boom length to place concrete into the hop-per of the M 42 which was situated in a gorge below on another cliff,” says Pollnow. “The M 42 then stretched its boom to pump and place the concrete to its fi nal destination. The equipment setup and performance was truly remarkable.”

As of October 2009, Quinn has placed about 3,823 m3 for the Colorado River Bridge pro-ject and about 80 percent of the bridge was complete. The remaining work on the pro-ject includes erecting the precast spandrel columns, installing tub girders, casting the pier caps, the deck, then the barrier walls and approach slabs.Concrete placement is anticipated to be com-plete during summer 2010, with the bridge opening for public use in November 2010. ■

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On site On site

Russia – vast country, long journey: 9,000 km by train to the site

In March of this year, a brand new M 6�-6 travelled over 9,000 kilometres on the Trans-Siberian Railway from Moscow to Vladivostok.

The customer – Stroitel’nyi Aljans – is cur-rently using this long-reach boom pump 180 km away in Nakhodka, a port city on the Pa-cifi c coast of the Russian Far East. Together with its older brother – an M 44-5 that was manufactured in 1996 and that Stroitel’nyi Aljans acquired second-hand from Japan in 2004 – the M 62-6 is concreting the base of a large oil platform.

t Well lashed – in Moscow, the M 6�-6 commences its long journey to the far east with the Trans-Siberian Railway.

q In the port city of Nakhodka, the M 6�-6 and M 44-5 together are pump-ing a total of 55,000 cubic metres of concrete for an oil platform.

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Sakhalin – Сахалин

Sakhalin – affectionately named “the wild dishevelled animal” in the language of the indigenous people – is 948 km long and be-tween 27 and 160 km wide and is situated to the north of the Japanese island of Hokkaido in the Pacifi c.

With 650,000 inhabitants, this is Russia‘s biggest island and only 3,150 of these inhab-itants belong to the indigenous groups of the Nivkh, Nani, Orok and Evenki. They live self-suffi ciently, as fi shermen, as herdsmen or by collecting wild plants. Ceded to the Russian Empire in 1875, the south of the island was ruled by Japan from 1905 until 1945. The few remaining indige-

nous people were forced to leave their home-land and travel in the direction of Hokkaido. Since the 19th century, the island had been used as a penal colony for Russian prisoners. The inhabitants who live there today – ex-cept for those who immigrated as a result of the raw materials boom – are descendants of the former forced labourers.

With approximately 175,000 inhabitants, the island‘s capital Yuzhno-Sakhalinsk is the largest city on the island. However, most of Sakhalin is made up of largely untouched boreal forest or mountains and has a popu-lation density of 6.2 inhabitants per square metre – half as much as in Norway.

Sakhalin is currently trying to fi nd a balance between becoming an ambitious economic region and nature resort, between tourism ambitions and the threat of damage to the environment.

q (from left to right) Cape Tihii (“Quiet Cape”) in the Sea of Okhotsk · Nivkh hunters in their traditional dress · The state museum in Yuzhno-Sakhalinsk provides evidence of the former Japan-ese reign · The island of Zametny in the Tihaya Bay

Vast oil and gas reserves in the Russian Far East

An area just off the coast of the island of Sakhalin in the far north-east of Russia is said to contain the largest untapped re-serves of oil and gas in the world. In oil alone, it is estimated that there are 13 bil-lion barrels in this area. The Arkutun-Dagi fi eld – part of the Sakhalin-1 project and the future site of use for the GBS that is currently under construction in Nakhodka – is located only a few kilometres off the coast of Sak-halin. The US oil company Exxon-Mobil is investing about 12 billion US dollars in the development of the three oil and gas fi elds (in total), amounting to the largest direct investment by a foreign company in Russia to date. Approximately 13,000 jobs have been created (directly and indi-

This GBS – Gravity Based Structure – con-sists of a concrete slab that has an area of approximately 100 x 127 m and is 13 m thick and on which four shaft towers – 25 m in dia meter and 41 m high – will be erected. The complete structure will be concreted on land and will then be towed by ship to an oil fi eld just off the coast of the island of Sakha-lin and, from there, it will be lowered to the seabed at a depth of 35 m. The client is the Norwegian company Aker Solutions.

In total, the two Putzmeister pumps will place 55,000 cubic metres of concrete before the end of 2011. ■

www.sakhalin.ru/engl/Information about Russia‘s largest island (engl.)

www.sakhalin1.com/en/Information about the oil and gas development of Sakhalin-1 (engl.)

www.waytorussia.netWritten and researched by the locals, “Way to Russia” is a very popular inde-pendent guide to Russia online (engl.)

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rectly) from the development of these raw material reserves and the tax revenue for the region has doubled. The island has the highest proportion of foreign nationals of all the Russian regions and an above-aver-age share of English-speaking Russians.

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Nakhodka

Arkutun-Dagi oil and natural gas fi eld

Sea of Okhotsk

China

North Korea

Sakhalin

Hokkaido

Kuril I

slands

KamchatkaPeninsula

Russia

Arctic Ocean

Pazifi c Ocean

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50 questions 50 questions

? We‘ve picked 50 questions from over 50 years of Putzmeister and given the answers some serious thought.

From now on, we‘ll be featuring one question in each new edition.

The company · Question 9

How does Putzmeister manage to be such a global presence?Putzmeister promises “Competence near you”. This is a bold claim for a com-pany whose customers are dispersed all around the world. It‘s a claim that Putzmeister lives up to with modern communications technologies, a dense service network and the best possible relationships with distribution partners in every corner of the globe.

Since Putzmeister sold its fi rst machine abroad, the company has gradually opened up one world market after another. Peter Dörr was an instrumental part of this pro-cess. Since 1984, the 67-year-old has travel-led the Near East and the countries of Asia in order to sell machines made in Aichtal. And his record is a successful one.

Asked about the secret of his success, Dörr doesn‘t take long to fi nd a response: “You have to be interested in people. Of course, you also need a good product. But interper-sonal relationships are crucial. If you want to be successful in a foreign country, you need to have distribution partners there who are prepared to nurture these relationships and will be there for their customers 100 percent.”

Hoang Minh Hung is one of these distribu-tion partners. The 47-year-old represents Putzmeister in Vietnam. “He‘ll bend over backwards for us and his customers when-ever it‘s necessary,” says Peter Dörr. When Dörr fi rst met Hung back in 1993, Hung had no capital. What he did have, however, were intimate and trusted ties with many poten-tial customers, and he was convinced by Putzmeister products. Dörr gave Hung a mo-ped. They would dash through Hanoi and Ho Chi Minh City, sometimes even side by side, to visit customers and deliver spare parts.

p Since the 1990s, Putzmeister concrete pumps have even serviced Vietnamese construction sites.

q A Putzmeister stationary concrete pump on the way through the streets of Hanoi.

“In Vietnam, we started out as a tiny opera-tion. We sold our fi rst machine at an agricul-tural trade fair,” recalls Dörr. Hoang Minh Hung turned out to be a born entrepreneur. In 2001, he employed a technician for the after-sales service and set up a small spare parts warehouse in Hanoi. His company, Minh Hoang & Co, now has 20 employees and two offi ces in Hanoi and Ho Chi Minh City.

Many Putzmeister distribution partners all over the world can tell a similar story. “These partners have grown with us. This results in very close and resilient relation-ships,” says Dörr.

A close network of specialists

Putzmeister has mostly been blessed with a lucky touch when it comes to the selection of distribution partners. The worldwide ser-vice and distribution network of Putzmeister

subsidiaries and dealers is now present in more than 100 countries. The headquarters in Aichtal and the regional subsidiaries of-fer support in the form of service engineers, training specialists and a team of service technicians.

Together, they ensure that Putzmeister cus-tomers always receive competent advice, are effi ciently supplied with spare parts and can depend on a speedy and reliable after-sales service, no matter where in the world their machines are put to use.

In many cases, Putzmeister service tech-nicians do not even need to visit the site. Thanks to modern telecommunication tech-nologies, they can often diagnose and rectify fault causes easily from their PC.

This is how Putzmeister continues to guar-antee “Competence near you” worldwide. ■

q In Vietnam, the motto is “even the smallest moped has room”.

q Hoang Minh Hung (�nd from left) with his family and the partners of Putzmeister: Friedemann Bornträger (�rd from left), Peter Dörr (�nd from right) and Johnson Ong (far right)

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Our Putzmeister Partner in Vietnam:

Minh Hoang & Co. 4� Pham Huy Thong · Hanoi

Mr. Hoang Minh HungTel: +84-4-��1�950Fax: +84-4-��1�95� E-mail: mhc-hanoi@hn.vnn.vn

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MXKD 50 at the centre of an archaeological sensation

The construction of a new, state-of-the-art transport interchange is supposed to be un-derway here, in Yenikapı, on the European side of the Bosporus: a major rail transit station to serve the 15-million metropolis of Istanbul. When the ground was broken back in 2004, nobody thought that the project would be set back by the discovery of an im-portant transport hub from Constantinople‘s past.

First of all, the excavation of the pit for the new, 21st century subway station on the Marmaray tunnel line unearthed a series of ancient walls. As it turned out, these belong-ed to an important Byzantine trading port, a transport hub of the “global world” dating back to around 400 AD. The “Port of Theo-dosius” – named after the last ruler of the Eastern Roman and Byzantine Empire – con-tained the remains of, to date, more than 30 ships, the largest single discovery of ship relics anywhere in the world. Among them were four Byzantine dromons, the oldest warships ever to have been discovered. They must have been sunk around 1000 AD.

What was a great moment for archaeology (Yenikapı is the largest urban excava tion and one of the most signifi cant fi nds in Tur-key) has caused developers to suffer serious time delays and, of course, to incur enor-mous costs. Yenikapı is situated on the southern shore of Istanbul‘s old town on the Sea of Marma-ra. With the future construction of its major rail transit station serving the “Marmaray” undersea tunnel under the Bosporus strait, Yenikapı is intended to offer passengers a means of changing from overground to un-

MXKD 50 and BSA �110 HP D concreting the underground rail station in Yenikapı / Istanbul

derground trains. Originally, a new region-al train station had also been planned in order to connect suburban commuter traf-fi c to the East-West network. However, this aspect of the project had to be changed: such is the importance of the ancient port, the local heritage trust decided that it would have to remain exactly where it is.

q Discovery site of one of the wooden ships

In February �010, the time had fi nal-ly come: an MXKD 50 on a 15 m lattice tower and a BSA �110 HP D stationary concrete pump began concreting the Yenikapı railway station.

This is the only station of the new Marmaray tunnel line being constructed using the cut-and-cover method. Its bottom surface mea-

ISTANBUL

Historic city center

Yenikapı

Sea of Marmara

Bosporus

Marmaray

tunnel section

sures approximately 300 m long and 35 m wide. For the concreting of the foundations, it was divided into a total of 29 sections. Each section – approximately 10 x 35 m and 2 m thick – is being concreted mono-lithically in multiple layers of 40 cm. Each layer contains some 120 m3 concrete, which produces an average of 650 m3 for each of the 29 sections. .

q While some go to work with heavy machinery, others require rather more delicate tools, such as a trowels and brushes. In the foreground are unearthed fragments of the ancient harbour wall.

t Pipeline fastenings in the horizontal section ZX 1�5/5”-1�0 bar

Technical data BSA �110 HP D

Output up to 102 m3/h

Concrete pressure up to 220 bar

Engine 330 kW Diesel

Delivery cylinder Ø 200 mm

Stroke 2100 mm

On site On site

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In brief

Putzmeister Academy Seminars �010/�011

Launch of the fi rst dredging boat in China with solids pumpKOS �5100At exactly 9:09 am on 6th June, 2010, the ship “Guohai I” (Chinese Sea) was named and launched at the port of Rongcheng (in the province of Shandong) in an offi cial ceremony.

This dredger from the Chinese manufac-turer Guohai Meister (a co-operation part-ner of Putzmeister Solid Pumps GmbH) is the fi rst dredger that has integrated a KOS 25100 piston pump and transports the sludge in a closed pipeline. The dredging sludge can be pumped across longer distances using a lower wa-ter content and this accelerates the pro-cess of land reclamation considerably.

q Many representatives from the Chinese regional government and industry representatives took part in the offi cial naming ceremony of the “Guohai I”. (4th from the right) Gerhard Schäffer from PSP

q The huge stationary boom at the start of foundation concreting. In the background are the tunnels of the future underground line.

Five set-up sites are planned for the MXKD 50, which will all enable it to reach each point of the foundation area. This means that it will have to be relocated four times. The boom anchor set is located in the centre of the reinforcement of one of the foundati-on sections. As the boom foundation needs to have a certain amount of strength before subsequent anchoring can take place, a defi ned workfl ow has been planned for the

p Hydraulic gate valve GVHM �/� con-verted for installation in a vertical line

p The hopper of the stationary concrete pump is cleaned under high pressure, and cleansing water is then pumped through forwards.

concreting of the individual positions. When each section gets its turn is absolutely cru-cial to avoiding unnecessary waiting times in the re-siting of the lattice tower. The concrete mix is particularly challenging. Despite a strength class of “only” C40, the high additives content makes it awkward to pump. These additives are necessary because the concrete must be able to withstand a high groundwater pressure.

In total, the concreting time of the subway station (foundations, walls, shafts, etc.) is es-timated to take 15 months to complete. ■

On site

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Our seminar brochures for 2010/2011 (German language), containing dates and information about courses and training, will be sent out by post in October.

In our seminar brochures for different target groups, we de-monstrate what is important: preventing accidents, increas-ing effi ciency and lowering costs.

Find out about the current dates for the next “season”, sign up in good time and reserve your customised company semi-nar.

If you have not yet received your copy, then please contact us by e-mail: akademie@pmw.de

Putzmeister Academy Seminars �010/�011

43

Our seminar brochures for 2010/2011 (German language), containing dates and information about courses and training, will be sent out by post in October.

In our seminar brochures for different target groups, we de-monstrate what is important: preventing accidents, increas-

�� PM 4307 GB PM 4307 GB ��

In brief

Essar Oil Refi nery in Jam-nagar: Four truck-mounted concrete pumps in action

Putzmeister at construction sites in India

p Teamwork: Three M �6 and the new M 4�-5 are placing 1,400 m� of concrete

Climbing booms and stationary pumps at the Ruby Mill Tower in Mumbai

Ruby Mill Tower

Once complete, the Ruby Mill Tower will be 185 m in height and have 34 levels (four of which are parking areas). The to-tal usable area of 78,000 m2 will mostly be used as offi ce space.

The building was designed by the New York architects FxFowle, analysis and design was carried out by LERA and the Indian company Vascon Engineers un-dertook the construction of the building.

Construction commenced in 2007 and the building should be complete by the end of 2010.

Concreting data

Concrete Compressive type strength

Slab M 40 > 40 N/mm2

Column M 50 > 50 N/mm2

Inner wall M 50 > 50 N/mm2

Slump measure (ø) 140 mm

Concrete delivery pressure 200 – 220 bar

Essar Oil

The Essar Oil Refi nery in Vadinar/Jam-nagar in the state of Gujarat lies on India‘s west coast, ideally located close to the oil-rich Gulf states. It is one of the largest refi neries in the world.

The Indian conglomerate, Essar Group, is active in the fi elds of steel, oil and gas, energy, communication, transport/logis-tics, construction and raw materials.

In brief

Essar is using the fi rst Putzmeister M 42-5 in India to concrete one of the largest re-fi neries in the world at Jamnagar in West India. Together with three of the eight M 36 pumps from the fl eet, the “new” edi-tion pumps reliably throughout the day and night.

The Putzmeister India After Sales & Parts Service is regarded highly by the people at Essar, but the message from Deepak Kumar Singh, Managing Director of Essar HED, is clear: “For me, the machines by Putzmeister are simply the best for concreting.”

At the Ruby Mill construction site in Mum-bai, two MX 32-4T self-climbing stationa-ry booms and two pumps of the type BSA 1408 HD are being used. In total, 50,000 cubic metres of concrete has to be placed.

1,100 m3 of concrete is used for each lev-el, including the ceilings, columns and in-ner walls. Two levels are completed each month.

The pumps are cleaned using sponge balls and wash-out pigs by simply pumping them with water. There is no need for any separate cleaning station.

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PM 4307 GB

Order now: Phone +49 (0) 173 3 09 26 63 · spareparts@putzmeister.deHotline for technical questions: +49 (0) 7127 599-297

Safe. Clean. Simple.

The new Pin Pour

Work safely and cleanly!Stop dangerous goosenecks! The boom is steadier – constant fl ow of concrete, even at low output No risk of injury from concrete splatters

Reduce your operating costs!Quick and easy assembly Less wear of delivery line pipe and end elbowEconomicAffordable

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for all end hoses with Ø 125 mm

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