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The world leading e-magazine for<br />
• construction • demolition • quarrying • mining<br />
Vol 6 No 2<br />
International<br />
COVER STORY<br />
FORMWORK<br />
& FALSEWORK<br />
SUPPLEMENT<br />
No 2<br />
Mega bridge<br />
project: 64 m<br />
above the Sea of<br />
Marmara<br />
Hydro-demolition<br />
Efficiency in<br />
Tunnel<br />
Super-Sized<br />
Bronze Casting<br />
Challenges<br />
Skanska<br />
If Its Big and<br />
Ambitious Then It<br />
Must Be Texas!<br />
WHAT’S NEW IN PLANT & EQUIPMENT<br />
• Komatsu D85EX/PX-18 Crawler Dozer<br />
• . . . . and coming up at Intermat 2015<br />
• Family of Cats Play in the Spanish Sun<br />
• Latest Innovations in Trenchless Technology<br />
• Case N Series Backhoes Go Tier 4 Final<br />
• Komatsu Out To Impress At Intermat 2015<br />
• JLG at the Rental Show<br />
• Ten World Premiers from Hyundai<br />
• Xsite excavator control systems<br />
• Sennebogen At Intermat 2015<br />
• Floor saws from Wacker Neuson<br />
• Excavators, Skidsteers and More from Doosan<br />
• Takeuchi TB280FR Tier IV Final Excavator<br />
• Montabert Shows Innovation
EXPERIENCE THE WIRTGEN GROUP<br />
AT INTERMAT 2015 IN PARIS.<br />
Nothing is more important to us than communication with our customers. Tell us about your experiences with<br />
our machines as you feast your eyes on our innovations in Road and Mineral Technologies. Our experts are<br />
looking forward to your visit.<br />
www.wirtgen-group.com/intermat<br />
Road and MineRal Technologies<br />
inTeRMaT 2015<br />
Trade fair grounds Paris-nord Villepinte · France<br />
hall 5a · Booth no. J 124<br />
20 – 25 april 2015 · daily from 9 am to 6 pm<br />
www.wirtgen-group.com/intermat
CONTENTS<br />
5 Editorial Comment<br />
6 Panorama<br />
Australia: Towed Rock Crusher Delivers<br />
The Netherlands: SCX1000A-3 reaches new heights<br />
Azerbaijan: Load Cells Integral to Safe Completion of Crane Boom Lift<br />
Panama: Second Artificial Residential Island<br />
Australia: NSW Contractor Boosts Efficiency<br />
Germany: Tower Cranes Overcome Logistical Restraints<br />
Ghana: Tandem Working Increases Productivity<br />
Italy: Milan Out Bypass to Ease Congestion<br />
12 Turkey: Mega project: 64 m above the Sea<br />
15 Belgium: Hydrodemolition Efficiency in Tunnel<br />
17 USA: Steele Knows Dirt<br />
18 USA: Parking Deck Repairs at Pier 40<br />
20 New Zealand: TBM Alice starts second drive.<br />
21 FORMWORK & FALSEWORK SUPPLEMENT<br />
USA: Super-Sized Bronze Casting Challenges Skanska<br />
UK: Turner Access Launches the New Turner Beam<br />
USA: If Its Big and Ambitious Then It Must Be Texas!<br />
Doka Concremote - measurement of concrete-strength<br />
South Africa: At 947 m long - the Country’s Longest Viaduct<br />
Germany: Upmarket Residential Complex Optimizes Formwork<br />
UK: Super Mega Brace for its first major project<br />
Turkey: Skyland Office Tower, Istanbul<br />
An adjustable metal formwork for curved application<br />
Peru: ULMA Working On Mining and Hydropower Expansion<br />
Tata Steel Asymmetric Slimflor Beams<br />
41 Intermat 2015 Preview No 2<br />
Latest Innovations in Trenchless Technology<br />
Komatsu Out To Impress At Intermat 2015<br />
Ten World Premiers from Hyundai<br />
Sennebogen At Intermat 2015<br />
Excavators - Track & Wheeled, Skidsteers and More from Doosan<br />
Montabert Shows Innovation<br />
52 What’s New In Plant & Equipment<br />
New Komatsu D85EX/PX-18 Crawler Dozer<br />
A Whole New Family of Cats Play in the Spanish Sun<br />
Case N Series Backhoes Go Tier 4 Final<br />
New from JLG at the Rental Show<br />
Xsite excavator control systems<br />
Svantek’s New Sound Monitoring Device<br />
Tier IV Portable Genset<br />
New floor saws from Wacker Neuson<br />
Takeuchi TB280FR Tier IV Final Excavator<br />
New TC120 Tank Cutter Attachment<br />
New Enerpac Hydraulic Torque Wrenches<br />
59 Companies Featured<br />
Contractors World International Vol 6 No 1<br />
Page 3
Building<br />
the future<br />
together<br />
expertise - innovation - networking<br />
2 0 - 2 5 Av r i l 2 0 1 5<br />
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yAn MARTIn<br />
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VISITOR<br />
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www.intermatconstruction.com<br />
Code<br />
PROMOUK<br />
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Editorial Comment<br />
Getting Ready<br />
for Show Time in<br />
Europe<br />
Early Spring in Europe is the traditional time<br />
for the major event for the construction industry.<br />
This year it is Intermat, in Paris, but<br />
there is already information coming through about the<br />
most important event in the construction industry calendar - Bauma<br />
2016 which takes place every three years in Germany.<br />
Intermat is facing increasing challenges for its position in the 3 yearly<br />
cycle with ConExpo and Bauma. Many in the industry would prefer<br />
just one major event in Europe, one in Asia and one in North America.<br />
The stumbling block, at the moment, is Bauma China which is still<br />
very much an inward looking trade show. However, with the boom<br />
slowing down in China, now may be the time for the show to develop<br />
a wider appeal. To succeed, I believe that it needs a name change to<br />
Bauma Asia and perhaps a more central location such as Hong Kong,<br />
which still has the China connection.<br />
Some major players are giving Intermat a miss this year - mainly because<br />
of cost. Intermat is the most expensive of the three shows for<br />
exhibitors and although it matches the attendance of ConExpo, it is far<br />
away from the 500,000+ who will probably visit the next Bauma.<br />
Many companies attending, who Contractors World has spoken to,<br />
say that the French market and its north African connections is a valuable<br />
market and reason enough to exhibit. It will be interesting to see<br />
visitor numbers and where they come from. It would be useful to get<br />
genuine visitor numbers from major event organisers.<br />
For instance, while student and family days are important they do<br />
inflate figures.<br />
Intermat 2015 will be a very interesting event because it is the last<br />
opportunity for manufacturers to unveil Tier IV Final engine powered<br />
machines before the latest emission standard come into effect.<br />
Meeting these standards is more than just exchanging engines. The<br />
new engines are larger and get much hotter so need a larger compartment<br />
and additional cooling. This has resulted in machines being given<br />
a completely new look and design. The bigger, heavier engines deliver<br />
greater torque forces so machines can be more productive while reducing<br />
fuel consumption and emissions.<br />
I will be at Intermat 2015 from the beginning to the end and I look<br />
forward to reviewing some of the more interesting announcements.<br />
The second Intermat Preview in this issue gives you a taster of what’s<br />
to come.<br />
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better still, complete the short registration form NOW.<br />
Contractors World International Vol 6 No 1<br />
Page 5
Panorama<br />
Australia<br />
Towed Rock<br />
Crusher Delivers<br />
Australian earthmoving contractor,<br />
Sexton Earthworx, has<br />
again met the needs of Port<br />
Pirie Regional Council with it’s<br />
recent purchase of a Kirpy BPB<br />
250 Rock Crusher from Broons<br />
Pty, speciliast manufacturers<br />
of crushing and compaction<br />
equipment. The Kirpy is being<br />
used to produce gravel for road<br />
construction from materials on<br />
site.<br />
Redhill Wind Farm in South Australia was the location<br />
and the rock a good mixture of both limestone and ironstone.<br />
Kirby rock cursher, with it’s tungsten-carbide hammers,<br />
towed by Case IHI tractor, made light work of the<br />
rock.<br />
It consistently produces 40 minus material – ideal for<br />
binding the pavement together, giving many years usage<br />
for ratepayers.<br />
Owner of Sexton Earthworx, Graham Sexton, says that<br />
the Council was very impressed with the performance of<br />
the 2.5 m wide Kirpy unit in such rugged terrain.<br />
“They couldn’t believe how fast and consistently<br />
we crushed the rock – there were a few blank<br />
faces actually! Word is already getting around.<br />
I’ve been asked about crushing a section of the<br />
Strzelecki Track in the outback, where it’s down to<br />
20kph in some sections due to oversize rock in the<br />
pavement.”<br />
The Strzelecki Track is a 466 km route that was originally<br />
used to drive cattle. Today, the isolated track is the<br />
state’s toughest road trip and one of its most vital as it is a<br />
link to the Moomba gas fields, a distance of 350 km, taking<br />
a truck 8 hours to cover.<br />
Truckers regularly complain about the damage the<br />
track causes to tyres.<br />
South Australian crushing and compaction specialists,<br />
Broons, is excited about the potential uptake of<br />
the Kirpy crusher by private earthmoving contractors.<br />
Director Stuart Bowes agrees,<br />
“We are very proud of the performance of the Kirpy<br />
rock crushers and it seems the private earthmoving<br />
sector is finally realising the opportunities it<br />
brings. Councils have been a good market for the<br />
Kirpy machines, but the tide is now turning, they<br />
are contracting out much of their work. Whether<br />
crushing in a quarry, borrow pit or on the road<br />
itself, there is always a demand for good road<br />
base.”<br />
With thousand of kilometre of unpaved roads and track<br />
across Australia, the potential for strong, durable equipment<br />
that requires minimal maintenance is a signficant<br />
market.<br />
Broon Pty was established in 1973, initially to meet the<br />
requirements of the unique characteristics of Austrlian<br />
needs in curshing and compaction equipment.<br />
The company’s range of products are all towed<br />
solutions, thereby simplifying maintenance and maximising<br />
usage of available on-site tractors<br />
• Broons Pty<br />
The remote Trzelecki Track<br />
(Photo:www.1yearoff.com.au)<br />
Page 6 Contractors World International Vol 6 No 1
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Panorama<br />
The Netherlands<br />
SCX1000A-3<br />
reaches new heights<br />
The first Hitachi Sumitomo SCX A-3<br />
series model in The Netherlands has<br />
been acquired by Gebr. De Koning to<br />
work on concrete structure, waterworks<br />
and foundation contracts.<br />
The new SCX1000A-3 crawler crane<br />
was delivered to the Papendrechtbased<br />
company earlier this year.<br />
The SCX1000A-3 can be used as a<br />
70-, 80- or 90-tonne machine, due to<br />
various configurations from six counterweight parts.<br />
The crane’s dimensions mean that it is easily transportable,<br />
and can be efficiently assembled and disassembled<br />
when moving between job sites.<br />
Azerbaijan<br />
Gebr. De Koning also specified the options of a third<br />
winch and a wider skywalk on the 30 m boom for enhanced<br />
safety and easier assembly.<br />
• Hitachi Construction Machinery<br />
(Europe)<br />
Load Cells Integral to Safe Completion of Crane Boom Lift<br />
Straightpoint load cells were used to facilitate the safe removal<br />
and reinstallation of a 300 t crane boom on a 600 t<br />
crane barge in Azerbaijan recently.<br />
Azerbaijan, lifting and marine products provider Rigmarine<br />
offered a solution in Straightpoint’s 300t wireless compression<br />
load cells.<br />
Rigmarine managing director, Mike Duncan,<br />
explained that the load cells were used to conduct<br />
an engineering and feasibility study prior to<br />
completion of a full scope of work.<br />
“We successfully completed the job without<br />
incident and provided Caspian Marine<br />
Services with a comprehensive turnkey<br />
package, reducing the amount of contractors<br />
required for the project.”<br />
The scope of work included removal of the<br />
boom heel pins with custom-built hydraulic systems;<br />
jacking up of the boom to establish gross<br />
weight and confirmation of the center of gravity;<br />
and reinstatement of the boom after a refit.<br />
Duncan added:<br />
Caspian Marine Services, which operates a fleet of offshore<br />
marine support vessels serving the offshore oil and<br />
gas industry, was presented with a series of challenges before<br />
executing the project. The gross weight of the crane<br />
boom and centre of gravity was unknown, while the boom<br />
heel pins had never been removed from new and no supporting<br />
documentation was available.<br />
Force measurement, load monitoring and suspended<br />
weighing load cell specialist Straightpoint manufactures<br />
equipment capable of providing dynamic information<br />
about loads wirelessly, straight to a PC.<br />
With footprints in the Middle East, Kazakhstan and<br />
“Straightpoint’s 300t wireless compression<br />
load cells were the perfect component for<br />
the removal and reinstallation project given the<br />
challenging nature of the work and their reputation<br />
for accuracy, safety and versatility on demanding<br />
projects like this.”<br />
Straightpoint’s wireless compression load cells are<br />
available in capacities from 50 t to 500 t and manufactured<br />
from stainless steel and a load centring domed top.<br />
The unique design utilising double o-ring seals on the<br />
load cell ensures they are built for use in the harshest industrial<br />
environments.<br />
• Rigmarine<br />
Page 8 Contractors World International Vol 6 No 1
Panorama<br />
Video:<br />
4.00 min<br />
Panama<br />
Second Artificial<br />
Residential Island<br />
Royal Boskalis Westminster N.V. (Boskalis) has been awarded<br />
a contract from Compañía Insular Americana, S.A. to<br />
construct a second artificial island off the coast near the<br />
residential area of Punta Pacifica in Panama City.<br />
This project follows the successful construction of the<br />
first island by Boskalis, which was handed over to the client<br />
in early 2013.<br />
With a contract value of more than EUR 55 million the<br />
project is scheduled to commence in the course of the second<br />
half of 2015 and is expected to last for two years.<br />
The project involves constructing the second artificial<br />
island in the Pacific Ocean off the densely populated shoreline<br />
of Panama City.<br />
Nine hectares of land will be created by using approximately<br />
600,000 cubic meters of rock to form a perimeter<br />
and filling it with 1.3 million cubic meters of sand.<br />
A bridge will be built to connect the second island to<br />
Australia<br />
the first island.<br />
The client Compañía Insular Americana, S.A. is an affiliated<br />
company of Ocean Reef Island Inc for which Boskalis<br />
constructed the first artificial island.<br />
Boskalis will use tugboats and barges to transport the<br />
rock and a clamshell and excavators to install the rock perimeter.<br />
Thereafter, the island will be filled with sand supplied<br />
by a large trailing suction hopper dredger.<br />
Boskalis’ strategy is aimed at benefitting from key macro-economic<br />
factors which drive worldwide demand in our<br />
markets: expansion of the global economy, increasing energy<br />
consumption, global population growth and the challenges<br />
presented by climate change.<br />
This land reclamation project is driven by the necessity<br />
to create land to accommodate population growth in a<br />
densely populated region.<br />
• Royal Boskalis<br />
NSW Contractor Boosts Efficiency<br />
Like many regional centres within a couple of hours drive<br />
from Sydney, towns in the Newcastle area are experiencing<br />
a boom in residential development. The region is the second<br />
most populous metropolitan area in New South Wales<br />
after Sydney.<br />
Contractor Dave Izzard is kept busy providing services in<br />
excavation of trenches for electricity and plumbing works<br />
on residential development sites, road works and commercial<br />
constructions.<br />
After logging over 10,000 hours on his previous<br />
Terex loader backhoe, he decided it was time to get a new<br />
machine that would boost productivity.<br />
On his purchasing decision, Dave said:<br />
“Deciding on the new Terex TLB 840 loader<br />
backhoe was definitely the right way to go, as it<br />
has lots of features that let me work faster. The<br />
most noticeable improvement over earlier models<br />
is the braking system which is significantly more<br />
efficient and more positive,”<br />
“I have also noticed the machine is easier<br />
to steer, with its weight more evenly distributed;<br />
no doubt helped by the solid cast nose<br />
counterweight.<br />
“When working on sloping sites, less effort<br />
is needed and the machine can be worked<br />
faster when I’m back filling or slewing on uphill<br />
grades.”<br />
• Semco Equipment<br />
• Terex Construction<br />
Page 9
Panorama<br />
Germany<br />
Tower Cranes<br />
Overcome Strict<br />
Logistical Restraints<br />
The construction of a new shopping center<br />
in Montabaur, Germany, came with a tough<br />
schedule – just 12 months to build the huge<br />
new 14,000 m² Westerwald Fashion Outlet<br />
Center. Four Potain tower cranes were specifically<br />
chosen to meet the project’s strict<br />
deadline.<br />
The main contractor on the job, Fritz<br />
Mayer, called in four Potain topless tower<br />
cranes to assist in the €17.5 m project: A<br />
10 t capacity Potain MDT 218A J10, two<br />
8 t capacity MDT 178 cranes and a 6 t capacity<br />
MDT 128.<br />
The topless cranes were selected for their size – as time<br />
was of the essence, fitting four topless cranes on the job<br />
site were more efficient than if the work was done with<br />
fewer cranes.<br />
Mario Engelen, site manager said the shopping center<br />
project was a logistical challenge:<br />
“We work with a wide variety of building materials<br />
and often with prefabricated components. During<br />
the entire construction cycle, crane capacities have<br />
to match these<br />
tasks and every individual lift process.”<br />
Nauheim-based Hack rented the tower cranes to Fritz<br />
Meyer. Each crane lifted an average load of 22 t per day,<br />
and at peak times up to 66 t.<br />
Reinforced foundations were created where needed to<br />
support the cranes. The rigging phase was achieved with<br />
support from Potain riggers, the proven K mast system,<br />
masts in mono block design and with strapping utilizing the<br />
TIRAX system.<br />
• Manitowoc France<br />
Ghana<br />
Tandem Working Increases Productivity<br />
A fleet of Volvos are hard at work in Ghana helping the vertically<br />
integrated Justmoh Group in its mining, construction<br />
and road building activities.<br />
The Volvo machines work in tandem, increasing productivity<br />
on the job site.<br />
The Justmoh Group is one of the leading construction<br />
companies with experience in road construction, general<br />
construction, mining, dam building and quarrying. It also<br />
manufactures concrete and carries out cement distribution.<br />
The company uses a fleet of 12 Volvo machines, including<br />
seven articulated haulers – two A40F-Series<br />
and five A35F-Series models – and four excavators,<br />
including EC460, EC700 and EC480 BLC models. It<br />
also has one L220G-Series wheel loader to work on<br />
its toughest projects.<br />
Joseph Titus Glover, CEO of the Justmoh Group<br />
said:<br />
“Our machines perform like new, thanks to the<br />
fact that we service them on schedule. They also<br />
meet our cost per ton targets, which is making a<br />
lot of difference. We chose the Volvo brand because<br />
we like to have the best in order to do a<br />
good job.”<br />
Justmoh purchased its Volvo equipment<br />
through SMT Ghana – the region’s authorized<br />
dealer.<br />
• Volvo Construction Equipment<br />
Page 10 Contractors World International Vol 6 No 1
Panorama<br />
Italy<br />
Milan Out Bypass to Ease Congestion<br />
One of the most important ongoing infrastructure projects in Italy today is the TEEM<br />
construction site, Milan Outer Bypass, whose layout passes east of the city and is destined<br />
to ease congestion on the current ring road.<br />
The construction site, where concrete casting is involved, is managed by Icea on behalf<br />
of the main contractor, Arco TEEM Consortium, which includes Impresa Pizzarotti.<br />
Icea has recently completed working on casting the base of a big rainwater storage<br />
tank. The casting involved 700 m³, a Cifa K41L XRZ truck mounted pump fed by a fleet<br />
of Cifa mixers that ensured a continuous flow of concrete from the company production<br />
plant to the casting site.<br />
The pump was chosen<br />
by Icea for its versatility and<br />
hourly productivity (140<br />
m³/hour), as well as the<br />
horizontal envelop (that<br />
reaches over 35 meters)<br />
of the five sections boom,<br />
which could rach across<br />
the wide foundation.<br />
Icea owner, Angelo Di Fede<br />
said:<br />
“We have been<br />
working with<br />
Cifa machines for<br />
many years and<br />
we have never<br />
had any problem<br />
with machines<br />
we have in the<br />
fleet; ordinary<br />
maintenance<br />
interventions and<br />
small problems<br />
on the jobsite<br />
have always<br />
been solved by<br />
an efficient and<br />
prompt assistance<br />
service by Effretti<br />
professionals.”<br />
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“We give<br />
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to guarantee a<br />
satisfying jobsite<br />
productivity.”<br />
• Cifa<br />
Concrete Pumps<br />
Contractors World International Vol 6 No 1<br />
Page 11
Turkey<br />
Mega bridge<br />
project: 64 m<br />
above the Sea of<br />
Marmara<br />
Page 12 Contractors World International Vol 6 No 1
Six lanes over the Sea of Marmara – starting in 2017, over 5,000 vehicles<br />
per day will be able to cross the new Izmit Bay Bridge in Turkey.<br />
With a main span of 1,550 m the Izmit Bay Suspension Bridge forms<br />
part of the Gebze-Izmir expressway project being procured under a privatized<br />
concession arrangement.<br />
The proposed structure will be located at the<br />
eastern end of the Sea of Marmara, close to<br />
Izmit and approximately 50 km from Istanbul,<br />
Turkey. Crossing the Bay of Izmit, the bridge (and connecting<br />
highway) will provide three lanes of traffic in each<br />
direction.<br />
CH2M HILL’s bridge professionals provided full, independent<br />
detailed checking services which included a comprehensive<br />
assessment of seismic actions requiring state of<br />
the art non-linear methods of analysis and a review of the<br />
very extensive wind tunnel testing commissioned by the<br />
designer.<br />
The bridge is located close to the North Anatolian Fault<br />
which is one of the most active earthquake zones in the<br />
world. This has resulted in the adoption of special measures<br />
to resist seismic effects including the adoption of steel<br />
inclusion piles to improve ground conditions below the<br />
tower foundations.<br />
These foundations are placed on a layer of gravel that<br />
acts as a seismic fuse to dissipate energy under extreme<br />
seismic loading. Extensive linear, non-linear, and dynamic<br />
modelling was carried out including detailed finite element<br />
models and complex modelling of the non-linear behaviour<br />
of the seismic fuses.<br />
Deck Construction<br />
Crane service provider Aydin Vinc A.S. is tasked with making<br />
sure the logistics run smoothly when constructing this<br />
large-scale project – with the help of a new Sennebogen<br />
5500 crawler crane with 180 t load capacity.<br />
The Izmit Bay Bridge is being built around 50 km southeast<br />
of Istanbul and will be the longest and most advanced<br />
suspension bridge in the world.<br />
(pix previous page)<br />
A modern, six-lane suspension<br />
bridge is under construction<br />
across the Sea of<br />
Marmara near the Turkish<br />
town of Izmit.<br />
Customer Aydin Vinc A.S. is<br />
using a 180 t Sennebogen<br />
5500 crawler crane for<br />
lifting and logistics tasks<br />
where the bridge is being<br />
built.<br />
Contractors World International Vol 6 No 1<br />
Page 13
The ambitious infrastructure<br />
project is scheduled for completion<br />
in 2017 and will not only<br />
complete the highway from<br />
Istanbul to Izmir, it will also be<br />
the fourth longest suspension<br />
bridge in the world at a total<br />
length of about 2,700 m.<br />
The extensive project is currently<br />
progressing at full speed.<br />
As one of the contracted companies,<br />
crane service provider<br />
Aydin Vinc A.S. of Turkey relies<br />
on a Sennebogen 5500 crawler<br />
crane for numerous lifting and<br />
logistics tasks at the enormous<br />
construction site.<br />
Moving massive<br />
elements with ease<br />
With more than 250 cranes and<br />
other heavy equipment, Aydin Vinc<br />
A.S. is one of the largest logistics<br />
service providers in Turkey. Founded<br />
in 1980, the company specializes in<br />
heavy transport and port logistics in<br />
addition to crane rental.<br />
To minimise risk from<br />
seismic activity, over<br />
4,000 dampeners are<br />
installed across the<br />
bridge viaduct.<br />
The Sennebogen 5500 crawler<br />
crane provided for this job by our<br />
Sales and Service Partner Forsen A.Ş. in Turkey at the end<br />
of 2014 is equipped with a 35.5 m long main boom and can<br />
lift the massive bridge members into position with ease.<br />
The 180 t crane is powered by a 261 kW diesel engine.<br />
The flexible crawler crane is particularly suited for the<br />
job thanks to its stable wide-gauge undercarriage and 160<br />
kN winch. Even when under load, the heavy steel and precast<br />
concrete members can be transported and placed with<br />
precision.<br />
The Maxcab comfort cab, which can be inclined up to<br />
20°, offers the operator an ideal overview of the work area.<br />
Seismic Dampening Bridge<br />
Bearings<br />
The suspension bridge is located in Izmit Bay - a very highly<br />
seismically hazardous area . Therefore, all approaching viaducts<br />
will be isolated against a possible earthquake using<br />
4,376 seismic rubber bearings that will be installed on top<br />
of the viaducts.<br />
All 4376 bearings have been supplied by the Turkish<br />
specialists contractors, EM-KE Construction Ltd. by using<br />
Dynamic Isolation Systems (USA) and Robinson Seismic<br />
Ltd. (New Zealand) products.<br />
• Sennebogen<br />
• Aydin Vinc A.S<br />
Page 14 Contractors World International Vol 6 No 1
Hydrodemolition Efficiency in<br />
Tunnel Repair Solution<br />
The Belgian railway operator, Infrabel, urgently<br />
needed to repair defective concrete<br />
in the Biéreau tunnel just south of Brussels.<br />
Hydrodemolition with a Conjet Robot 365<br />
was used to selectively remove the damaged<br />
and decaying concrete at record<br />
speed.<br />
The 875 m long, 10.5 m diameter Biéreau tunnel<br />
forms part of the 4.4 km long dual Line 161D<br />
railway track linking the cities of Ottignies and<br />
Louvain-la-Neuve, 34 km south of the Belgian<br />
capital Brussels.<br />
The tunnel was opened in 1975 and during its near<br />
40 years of service, the tunnel’s concrete skin had deteriorated<br />
and parts were falling off. There was also evidence<br />
of longitudinal cracking.<br />
It needed urgent repairs and Belgian railway operator,<br />
Infrabel, has invested more than €4M in the tunnel’s<br />
restoration.<br />
Closing the tunnel completely was not possible due<br />
to public transport demands in the urban area. So it was<br />
decided the only option was to restore the tunnel in two<br />
sections and working and repairing the concrete from one<br />
track while trains passed by slowly on the other line.<br />
The restricted space and necessary safety and environment<br />
precautions were critical considerations for the<br />
overall renovation project, which had to be completed in<br />
just 220 days.<br />
Extremely Restricted Working<br />
Envelope<br />
Due to these restrictions, the restoration contractor,<br />
Bageci, a regional branch of industrial Belgian Group CFE,<br />
opted for the hydrodemolition technique, which uses a<br />
very high-pressure water jet to selectively remove the<br />
defective concrete from the walls and roof.<br />
Bageci bought a Conjet Robot 365 with multipurpose<br />
arm and a specially adapted feedbeam, carrying the cradle<br />
and jetting lance, to fit the curvature of the tunnel<br />
wall.<br />
Conjet’s representative in Belgium, BPC International,<br />
sold the hydrodemolition equipment. The company was<br />
also responsible for service, support and spare parts supply<br />
to guarantee 24 h productivity and availability of the<br />
robot..<br />
A 500 kW Hammelmann S1200-48 high-pressure water<br />
pump and the Conjet Robot were installed on flatbed<br />
rail wagons fitted with foldable, protective walls. This allowed<br />
the hydrodemolition and restoration work to be<br />
completed on one side of the tunnel while trains could<br />
safely pass on the opposite track.<br />
Contractors World International Vol 6 No 1<br />
Page 15
emoved 1,610 m³ of defective concrete from the tunnel<br />
circumference at an average depth of 80 mm to 100<br />
mm. The total area treated was approximately 17,000<br />
m².<br />
Bageci also removed the concrete debris, damaged<br />
rebar and applied new high quality concrete on the<br />
tunnel lining.<br />
“This restoration has been completed in 220 days<br />
with the Conjet Robot demolishing and removing<br />
concrete at a rate of about 1.35 m³/h. In my<br />
opinion this is an excellent result,”<br />
said Luc Bosmans.<br />
Bageci tunnel project manager Luc Bosmans said:<br />
“Due to the special safety and environmental<br />
demands and lack of space, hydrodemolition was<br />
really our only option from the very start. We<br />
thought it was going to be the most productive<br />
method for this tunnel work, and it proved to be<br />
very efficient.”<br />
In total, the Conjet Robot 365, together with the<br />
Hammelmann pump operating up to a pressure of 1200 bar,<br />
worked 1,370 hours in the Biéreau tunnel and selectively<br />
Bageci site manager, Sandro Bonsiambiante, added:<br />
“Throughout the tunnel the concrete has been<br />
harder and more resistant in some places, but with<br />
the auto regulation the Conjet robot selectively<br />
demolished and removed only the damaged<br />
concrete to the right depth over the entire surface.<br />
“Another advantage was the high availability<br />
of the equipment. There is a lot of environmental<br />
dust and wear and tear on equipment in this kind<br />
of application and the spare parts supply has been<br />
excellent with no serious break downs.”<br />
Conjet Configuration<br />
The Conjet Robot 365 consists of a carrier that includes<br />
pulse monitored drive wheels, electric and hydraulic systems<br />
and a simple, easy to use control system. The carrier<br />
can be equipped with optional attachments, such as<br />
standard feed beam, tower or a rotor assembly and can<br />
also be operated by a wireless control.<br />
The cutting head features a 45º attack angle of the jetting<br />
lance as standard, variable oscillation width and encoders<br />
for lance turning and cradle position.<br />
Relining the Tunnel<br />
Bageci chose, after consulting Grouttech, a dry mortar<br />
projection technique to reline<br />
the exposed reinforcement.<br />
The client had previous<br />
positive experience using this<br />
system due to its unmatched<br />
quality and ease of application.<br />
By applying the grout, under<br />
high pressure, through a<br />
capillary nozzle, Grouttech ensured<br />
a high quality shotcrete<br />
(C45) injection was achieved.<br />
Two 30 t. capacity batch silos<br />
were installed on flatbed rail<br />
wagons to provide a close supply<br />
system. This enabled maximum<br />
use of time as the work<br />
continued 24 hours a day.<br />
• Conjet<br />
• Groutech<br />
Page 16 Contractors World International Vol 6 No 1
Steele Knows Dirt<br />
Natural Gas Boom Grows<br />
Contractor’s Earthmoving<br />
Business<br />
With a name like Steele in Pennsylvania, you’d<br />
expect Steele Construction, Inc. owner Bill<br />
Steele to specialize in structural steel construction,<br />
or to own a foundry. Instead, he is recognized as<br />
one of the premier builders of timber-framed homes in the<br />
state. As new housing-starts dipped during the latest economic<br />
recession, Steele further grew his business on the<br />
strength of the Marcellus Shale natural gas boom.<br />
Bill Steele said:<br />
“We were lucky enough to get into a gas contract,<br />
and now our company is pretty much evenly split<br />
between the building of heavy timber frame and<br />
moving dirt,”<br />
The company specializes in site reclamation at new gas<br />
extraction sites after a well pad is finished. Typically, the<br />
area involved is about 1 acre (4,000 m²), but the surrounding<br />
area, including access routes, that was affected by the<br />
construction must be put back to its natural state.<br />
“Time is money and the gas companies want the<br />
reclaiming done within a tight time-line. The only<br />
way we could do it is with bigger equipment.”<br />
As a result, the company has invested in four new dozers<br />
- two 850L dozers and two 2050M<br />
dozers from Case Construction<br />
Equipment. The biggest change<br />
came with the size of the two<br />
2050Ms (214 horsepower, 45,414<br />
pounds).<br />
did. We get on the jobs faster, we get off the jobs<br />
faster and we are actually making more money<br />
with the bigger dozers,”<br />
Right-Sizing the Fleet<br />
Outfitted with a 6.3 yd³ (4.82 m³) blade and featuring<br />
81,000 pounds (36,740 kg) of drawbar pull, the 2050M<br />
represents a major increase in the company’s earthmoving<br />
power – without making it too difficult for Steele to transport<br />
the machine from site to site.<br />
“The roads up there are very narrow, bridges are<br />
small, just happens this is the largest dozer we can<br />
get into some of these pads. We still need two<br />
permits on this dozer, but we at least can get them<br />
across the bridges.”<br />
The machine also works well on varied terrain. When<br />
reclaiming ponds and other portions of well sites, the dozers<br />
occasionally work on steep slopes. The 2050M has<br />
proven to be extremely stable and capable of retaining its<br />
power, even in sloped conditions.<br />
• Steele Construction, Inc.<br />
• Case Construction Equipment<br />
“We went from very small to<br />
very big. It was a big step for<br />
us and I am happy to tell you<br />
it was the best step we ever<br />
Video: 2:55 min<br />
Contractors World International Vol 6 No 1<br />
Page 17
Pier 40, New York photo: Joe Mabel<br />
USA<br />
Parking Deck Repairs at<br />
New York’s Pier 40<br />
Located in New York, USA, Pier 40, is the largest<br />
pier structure on the Hudson River. Today, this<br />
historic structure is owned by the Hudson River<br />
Park Trust and Pier 40 is home to athletic fields and administrative<br />
offices. The perimeter of the property is surrounded<br />
by over 1 million square feet (92,900 m²) of commercial<br />
parking and is one of Manhattan’s largest parking facilities.<br />
When the Hudson River Park Trust inherited the pier,<br />
it came with a number of structural issues. Sections of the<br />
roof had deteriorated significantly as a result of delayed<br />
routine repairs, leakage, and spalling concrete. In addition,<br />
portions of the parking garage were closed to ensure public<br />
safety , thereby reducing the park’s operating revenue.<br />
Because of the size of the facility and the need to keep<br />
it operational, the Hudson River Park Trust addressed repairs<br />
in a phased approach. The company STRUCTURAL<br />
was awarded the contract for Phase 2 of the parking deck<br />
restoration project.<br />
Working together with the consulting engineers,<br />
Experion Design Group, the Long Island office of STRUCTURAL<br />
had crews remove the existing top slab of the parking deck<br />
along with the existing waterproofing, pitching slab, and all<br />
electrical and plumbing systems associated with the area.<br />
This exposed an unforeseen challenge. The surface of<br />
the existing precast planks underneath had a thin layer of<br />
cementitious material. This thin layer would not provide a<br />
solid surface for the new waterproofing system to hold on<br />
to.<br />
The team came up with the solution to hydroblast the<br />
deck in order to prepare the area. The contractor then installed<br />
hot applied waterproofing on precast planks and a<br />
pitched concrete topping.<br />
Crews were then able to repair the existing precast concrete<br />
channels, ribs, and floor spalls using repair mortar.<br />
They also installed a LED light system on the middle level of<br />
the parking deck, providing the area with the most energy<br />
efficient light fixtures with the required illumination levels<br />
based on local standards.<br />
Overcoming<br />
Challenges<br />
Throughout the project, debris<br />
had to be contained and kept<br />
away from the water – posing logistical<br />
challenges. The contractor<br />
had to transport waste and<br />
Crews had to remove the<br />
existing top slab of the parking<br />
deck along with the<br />
existing waterproofing system<br />
to prepare a surface for<br />
restoration.<br />
Page 18 Contractors World International Vol 6 No 1
STRUCTURAL installed<br />
hot applied<br />
waterproofing on<br />
precast planks and<br />
a pitched concrete<br />
topping.<br />
materials from the far side of the parking deck to the connecting<br />
street.<br />
Special caution also had to be given to transporting<br />
equipment in order not to further damage areas of the<br />
parking deck.<br />
Extreme cold temperatures and wind also posed challenges,<br />
but the successful pre-planning done by the team<br />
allowed for productive work to continue on throughout<br />
the winter. To combat the elements, crews worked on underside<br />
rib and floor repairs in smaller isolated phases that<br />
were enclosed and heated.<br />
Project Moving Forward<br />
Phase 2 at Pier 40 included over 95,000 sq.feet (8,800 m²)<br />
of restoration throughout the parking deck area and a total<br />
of 1,800 yd³ (1,376 m³) of concrete to pour the topping<br />
slab. The project was completed on schedule while still allowing<br />
for a diverse range of events and additional work to<br />
take place safely throughout the process.<br />
• STRUCTURAL<br />
High Profile Events Result in<br />
Additional Scope<br />
An additional complication but a significant revenue<br />
earner then occurred. As the project progressed,<br />
Pier 40 was also used for many high profile<br />
events, such as for a scene in a Hollywood<br />
action film.<br />
The scene needed to be shot within a two<br />
week time-frame. This meant that STRUCTURAL<br />
had to move its work trailer off the set, create<br />
a debris pile to be used in the scene, and shore<br />
the roof area where a catapult mechanism was<br />
to be installed.<br />
When Super Bowl XLVIII was held at nearby<br />
MetLife Stadium at the Meadowlands Sports<br />
Complex in New Jersey, Pier 40 was the site of<br />
a Super Bowl event held by a national broadcast<br />
service provider. This also resulted in extra<br />
repair scope for the contractor that included<br />
installing proper shoring underneath the parking<br />
deck where heavy equipment was being<br />
stored for the event.<br />
Before and after pictures of renovation<br />
work at Pier 40, located in New York –<br />
one of the largest parking facilities in<br />
Manhattan.<br />
Contractors World International Vol 6 No 1<br />
Page 19
New Zealand<br />
TBM Alice starts second drive<br />
One of the world’s largest tunnel boring machines recently<br />
started its second drive for the large-scale “Waterview<br />
Connection” project in Auckland, New Zealand.<br />
The first 2.4 km long tunnel was completed in September<br />
after only eleven months. In the heart of the metropolis,<br />
the Herrenknecht EPB Shield S-764 is creating the shell for<br />
a road tunnel that will link two of the main State Highways<br />
together.<br />
The tunnel boring machine Alice has begun its second<br />
drive in New Zealand. Earlier, Alice – named after the main<br />
character of “Alice in Wonderland” – excavated the first<br />
2.4 km long tunnel in just eleven months, with best performances<br />
of 126 meters per week and 452 meters per month.<br />
On September 29 at 1:45 p.m. local time the gigantic<br />
boring shield finally broke through the wall to the first target<br />
shaft in Waterview.<br />
The “Waterview Connection” tunnel project is one of<br />
the largest infrastructure projects in New Zealand. The tunnel<br />
alignment runs below a densely populated residential<br />
area and several parks.<br />
The 2.4 km long link will become the longest road tunnel<br />
in New Zealand. For this project, Herrenknecht designed a<br />
machine concept perfectly adapted to the geological and<br />
structural conditions.<br />
With a boring diameter of 14.46 meters, the EPB Shield<br />
S-764 is one of the world’s largest tunnel boring machines<br />
of its kind. Its gigantic cutting wheel is driven by 24 electric<br />
motors with a total output of 8,400 kilowatts.<br />
It has relatively large openings for optimum removal of<br />
the excavated material and has been specifically designed<br />
for the expected geology.<br />
In the first section the TBM went through soils composed<br />
mainly of sandstone and siltstone. The cutting wheels’ central<br />
cutting tools could be changed from the rear area. The<br />
ripper tools for softer grounds were thus replaced with disc<br />
cutters for harder rock when needed.<br />
In addition to the actual TBM with three back-ups,<br />
which creates the tunnel shell, Herrenknecht designed and<br />
delivered an autonomous, fourth back-up.<br />
This followed TBM Alice at a distance on the first section<br />
already. Its task is to lay a “tunnel within the tunnel”.<br />
It creates a part of the tunnel invert that supply lines will<br />
later pass through.<br />
This method of operation fully independent of the TBM<br />
advance offers an important advantage: advance performances<br />
of the TBM and the lining of the invert do not limit<br />
each other and can be done in parallel to save time.<br />
After the first breakthrough the TBM and the first backup<br />
were turned by 180 degrees in a very tight space and<br />
moved to the starting position for the second drive.<br />
Because of the limited space, a temporary second backup,<br />
also supplied by Herrenknecht, was docked onto the<br />
machine. In the initial phase it is responsible for the extension<br />
of the supply and disposal lines.<br />
With it, Alice is now boring an approximately 300 meter<br />
long “launch tunnel”. After this first part of the second tube<br />
has been driven, the original configuration with the longer<br />
back-ups 2 and 3 will be re-docked to the TBM. Then Alice<br />
will get going at full speed.<br />
The shell of the second tube is due to be completed in<br />
2015. The opening to traffic is scheduled for the beginning<br />
of 2017.<br />
• Herrenknecht<br />
Page 20 Contractors World International Vol 6 No 1
A Contractors World International Supplement - the world<br />
leading e-magazine for<br />
• construction • demolition • quarrying • mining<br />
2015 - No 1<br />
International<br />
COVER STORY<br />
Super-Sized Bronze Casting<br />
Challenges Skanska<br />
Pegasus Slaying Dragon Sculpture,<br />
Gulfstream Park, Hallandale Beach,<br />
USA<br />
• The Country’s Longest Viaduct<br />
• Upmarket Residential Complex<br />
• If Its Big, Then It Must Be Texas!<br />
• Brace for its first major project<br />
• Skyland Office Tower, Istanbul<br />
• Mining and Hydropower Expansion<br />
Contractors World International Vol 6 No 1<br />
Page 21
Super-Sized<br />
Bronze Casting<br />
Challenges<br />
Skanska<br />
Pegasus Slaying Dragon<br />
Sculpture, Gulfstream Park,<br />
Hallandale Beach, USA<br />
For the erection of the extraordinary Pegasus<br />
bronze sculpture in Florida, it posed some serious<br />
challenges to the contractors, Skanska Construction<br />
Group, in providing safe access and support to the<br />
exceptionally large and complicated sculpture during<br />
erection.<br />
And statues do not come much bigger. It is the height<br />
of an 11 storey building - 110 feet (33.5 m) in height; 200<br />
feet (61 m) in length and weighs 472 tons.<br />
The Gulfstream Park located between Miami and Fort<br />
Lauderdale, is home to one of the most famous racetracks<br />
in the world.<br />
Austrian-Canadian businessman and horse expert,<br />
Frank Stronach, is currently expanding the Stronach Groupowned<br />
facility through the addition of a theme park. At its<br />
centre, since the end of 2014, stands a spectacular piece<br />
of bronze artwork: Pegasus, the fabled winged horse from<br />
Greek mythology, forms an ensemble with a dragon as a<br />
symbol of positive strength and the victory of good over<br />
evil.<br />
In order to be able to safely realise the bronze sculpture<br />
on site as well as within the planned time frame,<br />
Skanska worked with the Miami-based scaffolding contractor,<br />
Scafform, who decided to use the Peri UP Rosett Flex<br />
modular scaffold system. The modular scaffold system<br />
could deliver the flexibility and versatility necessary. The<br />
system can be adapted to the complex geometry in 25 cm<br />
The elements in the scaffolding allowed for adjustments<br />
in 25 cm steps and so could be shaped<br />
around the statute which has no straight lines.<br />
The scaffolding had to be close enough to provide<br />
access to all the surfaces for the finishing work.<br />
Page 22 Contractors World International Vol 6 No 1
increments.<br />
At peak there was more than two hundred<br />
works involved including four transla tors and<br />
thirty nine Chinese artisans who were brought<br />
in to weld the outer skin on the massive statue<br />
which is the second largest in the USA - the largest<br />
being the Statue of Liberty.<br />
The adaptable scaffold grid provided the required<br />
high level of flexibility for creating suitable<br />
working and access levels for<br />
the craftsmen and metal designers<br />
– adapted on the outside<br />
and inside to match the<br />
complex, organic form as well<br />
as continuously following the<br />
erection progress.<br />
While the main erection<br />
works were progressing,<br />
nearby, the smaller sections<br />
were simultaneously under<br />
construction. These were<br />
then joined to the sculpture<br />
which presented another<br />
challenge for the contractors.<br />
The scaffolding and access<br />
system had to allow space for<br />
the new sections to be be put<br />
into position.<br />
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For this, the Peri UP was<br />
combined with system components<br />
taken from the<br />
VARIOKIT engineering construction<br />
kit – a big advantage,<br />
especially for large-span<br />
bridging. Both systems are<br />
based on the metric grid arrangement,<br />
can be quickly<br />
assembled by means of compatible<br />
connecting elements,<br />
and are also available at short<br />
notice from the Peri rental<br />
programme.<br />
Heavy Duty Crane<br />
Demand<br />
A Liebherr LTM 1400-7.1<br />
mobile crane operated by<br />
American company Allegiance<br />
Crane worked on the project.<br />
The 400-tonner produced an<br />
astonishing performance and<br />
showed off its wide-ranging<br />
functionality.<br />
The LTM 1400-7.1<br />
Contractors World International Vol 6 No 1
operated by Allegiance Crane proved to be a good choice,<br />
as Michael Stark, owner of Stark Ingenieure and Günter<br />
Czasny deputy CEO, reports:<br />
“Adam Cote, the Manager of Engineering at<br />
Allegiance Crane,<br />
and his team were extremely professional on the<br />
site. We worked extremely well and closely with<br />
each other. And the crane produced an absolutely<br />
amazing performance. It has a compact design and<br />
has excellent setup processes coupled<br />
with enormous load capacities which<br />
meant we didn’t even have to move it<br />
between the various hoists. This saved<br />
us around half the time which was very<br />
important to us.”<br />
The LTM 1400-7.1 was equipped with<br />
Y-guying and full ballast for this job. The<br />
crane set-up was completed entirely by<br />
self-assembly. The left wing of the Pegasus<br />
was the heaviest single component, weighing<br />
in at a massive 58 tonnes. The Liebherr<br />
crane had to move this component to a radius<br />
of 22.3 metres.<br />
3D-puzzle with 1,250<br />
bronze pieces<br />
The oversized sculpture is an impressive<br />
33 m high and – Pegasus together with the<br />
dragon – over 60 m long. In order to realize<br />
such magnitude in connection with<br />
the organic shape in bronze, seemed an<br />
unbelievable, virtually impossible challenge<br />
at the beginning for all members of<br />
the project management team.<br />
Located in the southwest of Germany,<br />
A Liebherr LTM 1400-7.1 was<br />
equipped with Y-guying and full<br />
ballast for this job was pushed<br />
to its limits in lifting the massive<br />
loads which had to be positioned<br />
very preciesly.<br />
Page 24 Contractors World International Vol 6 No 1
Turner Access<br />
Launches the New<br />
Turner Beam<br />
Working with leading industry suppliers, Turner<br />
Access has developed the Turner X500 series of aluminium<br />
beams.<br />
The access scaffolding not only had to support the<br />
various shape characteristics of the statute but also<br />
had to provide access for the skilled Chinese artisans<br />
to work from.<br />
Göppingen based Strassacker art casting foundry, together<br />
with the Stark engineering consultancy, from Ludwigsburg,<br />
who were commissioned to undertake the costing, calculation<br />
and design of the steel structure, developed an implementation<br />
concept.<br />
As a result, this allowed 250 t and 400 t of bronze and<br />
steel respectively to be formed in a period of only 2 years<br />
thus realising the customer’s conceptual presentation in a<br />
larger than life format.<br />
A total of 1,250 bronze parts were ultimately needed<br />
to assemble the sculpture as a 3D puzzle around the supporting<br />
steel structure. The dimensions were truly enormous:<br />
each of the castings was approximately 3 m² large<br />
and weighed 200 kg, having being elaborately produced by<br />
a partner company in China according to Strassacker specifications<br />
and then shipped to Florida.<br />
The bronze sections, with a combined weight of 268<br />
ton, required 26 shipping containers whilst the associated<br />
440 tons of steel required a further 23 containers. All taking<br />
6 weeks to travel from China to Florida. To hold the<br />
structure together there are are in excess of 18,000 bolts.<br />
The $30 million project is on schedule for completion<br />
by Summer 2015 with finishing touches being finished to<br />
associated features These include a waterfall, fountain,<br />
landscaping and a theatre on Greek mythology. The future<br />
may see a large ferris wheel added to the complex as it<br />
broadens its visitor appeal beyond that of horse racing and<br />
gambling.<br />
• Peri Formwork<br />
• Liebherr<br />
• Skanska USA<br />
• Strassacker Foundry<br />
The Turner Beam (X500) is 500 mm deep and<br />
designed to be stronger and provide greater load<br />
carrying capacities than deeper beams. The new beam<br />
delivers lower weights, better handling and higher installation<br />
productivity.<br />
By comparison with similarly sized beams, design engineers<br />
will need fewer of the new beams to achieve the<br />
same loading, resulting in savings in storage, transport<br />
and handling costs.<br />
The X500 is available in modular lengths from 1 m<br />
to 7 m that can be quickly and simply connected using<br />
aluminium spigots and locking pins, manufactured from<br />
high strength corrosion resistant steel suitable for marine<br />
corrosion environments, to make-up custom lengths<br />
whilst maintaining regular node and vertical spacing.<br />
The beam’s top and bottom horizontals and main<br />
verticals are made from high strength 48.3 mm OD aluminium<br />
tube capable of accepting standard scaffold<br />
couplers.<br />
The beam design also allows for fixing connections<br />
to be made near structural node points. Fixing connections<br />
must only be made and loads must only be applied<br />
directly to the main top and bottom horizontal 48.3 mm<br />
OD tubes and to the main 48.3 mm OD tube verticals<br />
and not to any other part of the beam.<br />
The beam is manufactured in Scotland under a BS<br />
ISO 9001 approved Quality System and has been independently<br />
analysed, assessed and tested to the requirements<br />
of BS EN 12811 and BS EN 1999.<br />
• Turner Access<br />
Contractors World International Vol 6 No 1<br />
Page 25
If Its Big and Ambitious<br />
Then It Must Be Texas!<br />
The new and improved LBJ Express<br />
is a major infrastructure development<br />
that is an innovative solution<br />
to the age-old problem of road<br />
congestion.<br />
The LBJ Express close to Dallas, Texas, is<br />
a public private partnership, with limited<br />
funding from taxpayer sources.<br />
The project will incorporate dramatic improvements<br />
to Interstate 635 (IH-635) and Interstate<br />
35E (IH-35E) in Dallas County featuring rebuilt<br />
main lanes, a continuous frontage road system,<br />
and 13 new miles (21 km) of managed toll<br />
lanes.<br />
The LBJ Express is an ambitious project that will<br />
transform approximately 17 miles (27 km) of<br />
roadway in a five-year time period by working<br />
on several construction areas simultaneously.<br />
During project construction, traffic must<br />
be moving at all times, with at least four lanes<br />
open in each direction and an exit always available<br />
during peak traffic times.<br />
The current capacity of today’s LBJ Freeway<br />
When completed the expressway<br />
will feature complex multi-lane<br />
interchanges.<br />
Page 26 Contractors World International Vol 6 No 1
will be nearly doubled with the creation of up to six new<br />
express managed lanes on IH-635 and four new managed<br />
lanes on portions of IH-35.<br />
LBJ Express Continues to Take<br />
Shape<br />
Some consider the LBJ Express project in Dallas, Texas to<br />
be the largest bridge and road project in the United States,<br />
and when you consider some of the project statistics, it<br />
would be difficult to disagree.<br />
• $2.7 billion in cost<br />
• 200 companies involved in construction<br />
• 2,000 construction workers on the project<br />
• 500,000 lf (150,000 lm) of utility relocations<br />
• 9,000,000 yd³ (6.9 million m³) of excavation<br />
• 400 trucks being utilized<br />
• 500 alternative pieces of equipment being used<br />
• 5,715 bridge beams to place<br />
Challenging Formwork Demands<br />
For a large part of the contract, the USA company, EFCO,<br />
has been part of several components of the LBJ Express<br />
project since the beginning and is currently providing formwork,<br />
engineering and field service support on Segments<br />
1 and 2 being constructed by Trinity Infrastructure LLC. of<br />
Heavy steel forms from bridge beams required precision handling<br />
by the crane operator.<br />
Dallas, Texas.<br />
Trinity Infrastructure LLC is a partnership between<br />
Ferrovial–Agroman and W.W. Webber LLC.<br />
It’s Got to Look Good<br />
Aesthetics have been a major area of concern on this project.<br />
Establishing and maintaining a consistent concrete appearance<br />
was just one of the criteria that drove the decision<br />
to select EFCO as the formwork provider.<br />
All EFCO systems capitalize on the long-lasting, dentresistant<br />
qualities of steel formwork face sheets. Grade<br />
strips, feature strips and assorted other architectural design<br />
features can be easily fastened directly to any EFCO<br />
all-steel face sheet with self-tapping screws.<br />
Trinity Infrastructure’s complete forming package included<br />
the EFCO Round Column and PLATE GIRDER forming<br />
systems. Column requirements for Segment 1 and 2 of the<br />
LBJ Express varied in dimension from 48” to 72” (1 m to 2<br />
m) diameter and up to 80’-0” (24 m) in height.<br />
Architectural reveal strips made of special UHMW plastic<br />
provided the architectural design.<br />
Cap sizes varied from 4’-0” to 6’-8” (1 m to 2 m) wide<br />
and up to 10’-0” tall x 104’-0” long (3 m x 31 m). EFCO<br />
PLATE GIRDER forms are a logical choice with cap dimensions<br />
of this size. Designed to be self-spanning,<br />
the shear enormity and weight of these cap forms<br />
required EFCO’s 100K shoring towers to support<br />
the 1,725,000 lb (782,500 kg) load for some of<br />
these caps<br />
Another Section. Another<br />
Contractor<br />
Archer Western Contractors, Ltd and EFCO have<br />
teamed up to complete another important<br />
Contractors World International Vol 6 No 1<br />
Various cranes, from mobile to crawler are<br />
called in as required to lift the formwork<br />
modules.<br />
The choice of cranes was dictated by access<br />
and the ground conditions.<br />
Page 27
When completed<br />
the expressway will<br />
relieve the severe<br />
traffic congestion<br />
that is a regular<br />
occurrence.<br />
portion of this overall project. Archer Western is working<br />
on a $12M segment of this project on the East side of IH-<br />
35E from Loop 12 to IH-635.<br />
They are constructing the elevated managed lane direct<br />
connectors between NB IH-35E and IH-635 adjacent to<br />
the existing general-purpose lanes of IH-35E. They are also<br />
constructing ramps and frontage roads along this corridor.<br />
All of this work will serve as the entrance to the IH-635 corridor<br />
from the South.<br />
For this project, Archer Western selected EFCO to provide<br />
forming systems to construct the multi-column, hammerheads<br />
and straddle bridge caps requiring over 5,000<br />
yd³ (3800 m³) of structural concrete.<br />
EFCO supplied round column formwork for 48” (1200<br />
mm), 60” (1500 mm) and 72” (1800 mm) columns up to 48’<br />
(14.4 m) in height. EFCO PLATE GIRDER panels were also<br />
used to form 8’ x 5’ (2.4 m x 1.5 m), 9’ x 6’ (2.7 m x 1.8 m)<br />
and 12’ x 7’ (3.6 m x 2.1 m) rectangular columns also topping<br />
out at 48’ (14.4 m) height. Approximately 4,600 yd³<br />
(3,500 m³) of concrete were placed.<br />
In addition to the column formwork, Archer Western<br />
also utilized the EFCO PLATE GIRDER for all of its bridge cap<br />
formwork. The bridge caps ranged from 4’-6” x 5’-6” (1.35<br />
m x 1.65 m) multi-stem caps to 40’ (12 m) long hammerhead<br />
caps that were 7’-6” (2.25 m) wide and up to 12’ (3.6<br />
m) deep, to post tensioned straddle caps that were up to<br />
10’ (3 m) deep, 6’-6” (1.98 m) wide and form lengths up to<br />
96’ (28.8 m) long.<br />
EFCO 6’-0” (1800 mm), 9’-0” (2700 mm) and 12’-0”<br />
(3600 mm) PLATE GIRDER panels were utilized throughout<br />
the job and handled the majority of the work.<br />
With the extra heavy loading of some of the caps and<br />
the offset hammerhead caps the standard EFCO 50K and<br />
100K per leg shore tower systems were used in conjunction<br />
with 70K support brackets for the<br />
cap support.<br />
Radius back brackets and standard<br />
flat back brackets were both utilized<br />
on this project to provide support solutions<br />
that best fit the requirements of<br />
the cap.<br />
• EFCO<br />
• Archer Western<br />
• Trinity Infrastructure<br />
Page 28 Contractors World International Vol 6 No 1
Doka Concremote<br />
- online measurement<br />
of concrete-strength<br />
in real time<br />
The Austrian formwork company, Doka, has introduced<br />
more technology to the job site with its innovative<br />
Concremote system.<br />
Concremote determines fresh concrete-strength development<br />
on the structural element to help speed up the<br />
construction processes and increased safety.<br />
A key parameter affecting the construction workflow is<br />
the development of compressive strength and hydration<br />
heat of concrete during construction. Stripping and curing<br />
times and the time for prestressing are all calculated based<br />
on concrete-strength development, for instance.<br />
Heat development measurements are important for<br />
monitoring stresses in the component that develop as a<br />
result of temperature variances. It helps avoid cracks and<br />
future structural damage.<br />
Based on measured concrete-strength values, Doka<br />
Concremote concrete monitoring enables users to determine<br />
the steps to be taken and thus ensure and optimise<br />
the construction process.<br />
The trend towards industrialisation of building processes<br />
has been evident for some years as more an more<br />
processes benefit from close monitoring that modern technology<br />
makes possible. However, some measurements are<br />
still determined obtained by testing laboratories, manually<br />
and at great labour costs. These are becoming fewer as<br />
automated processes take over.<br />
Concremote makes an active<br />
contribution in this regard.<br />
Usually construction companies determine concrete<br />
strength by means of general target values and/or complicated<br />
testing methods. The Doka Concremote makes it easier<br />
as it combines the established weighted maturity method<br />
with modern measuring and information technology.<br />
By incorporating sensor placement into the casting process,<br />
the system measures concrete strength by way of heat<br />
development. There is no need for a person to be present<br />
on the site for reading and securing the measured data.<br />
Sensors measure temperature development of the<br />
fresh concrete at regular intervals and transmit these data<br />
to a computing centre. Here, the weighted maturity method<br />
is used as the basis for calculating and providing reliable<br />
information on the strength development of the concrete<br />
in real time.<br />
Concremote uses two types of sensors: slab sensors,<br />
which are inserted in the fresh concrete after it has been<br />
screeded and cable sensors that are incorporated directly<br />
into the form-ply of the wall formwork and repositioned<br />
together with the formwork.<br />
Contractors World International Vol 6 No 1<br />
Wireless transmission of the measured values starts automatically.<br />
The system’s life-long batteries, sturdy sensors<br />
and wireless data transmission make it highly user-friendly<br />
reliable and able to withstand the harsh environment.<br />
Measuring results can be accessed at any time on a<br />
secure web portal. Also, users can be alerted by e-mail or<br />
text-message as soon as the specified early strength has<br />
been reached.<br />
The systems offers wide-ranging possibilities for optimizing<br />
the construction process: if a customer has entered<br />
a specific target value for a site, the strength values enable<br />
him to make precise recommendations regarding e.g. the<br />
earliest times for stripping the formwork, climbing and prestressing,<br />
and for the end of curing. The real-time measured<br />
data can also be taken into consideration for optimizing<br />
the concrete formulation.<br />
• Doka<br />
Page 29
In Durban, in the province<br />
of KwaZulu-Natal, works<br />
continue on highway<br />
expansion with construction<br />
of a $14 million motorway<br />
junction, the N2-M41 Mount<br />
Edgecombe Interchange.<br />
A challenging part of the<br />
project is construction of<br />
two viaducts, one of which<br />
will be the longest in South<br />
Africa. One viaduct will be<br />
26 m high and 947 m long.<br />
The second, also 18 m high<br />
by only 443 m in length.<br />
South Africa<br />
At 947 m<br />
long - the<br />
Country’s<br />
Longest<br />
Viaduct<br />
In 2010, on the N2 motorway, another viaduct had to<br />
be constructed (see article in Contractors World) of<br />
the Megni valley in which the Italian formwork company,<br />
Pilosio supplied the formwork for all the concrete<br />
work, including the bridge deck and Enerpac provided the<br />
jacking system for the incremental bridge launching system.<br />
With this past experience it is not surprising , therefore,<br />
that the contractors chose the same two companies<br />
for this technically very challenging project.<br />
Once again, Pilosio, nailed down the major contract for<br />
the supply of temporary structures directly from the yard<br />
to the South African branch of CMC,<br />
The challenging nature of the project meant that 70%<br />
of the formwork solutions are custom-made, including the<br />
launching bridge system. Another challenge was not interfering<br />
with the traffic below.<br />
Pilosio supplied:<br />
• 200 m² of standard P300 formwork for foundations and<br />
piers.<br />
• 500 m² of special steel formwork, divided into five sets<br />
Page 30 Contractors World International Vol 6 No 1
The 20 m long bridge deck<br />
sections are produced on<br />
land and then pushed out<br />
incrementally using the<br />
bridge launching system<br />
towards the completed pier<br />
heads.<br />
for the construction of the viaduct piers<br />
• 350 m² of additional special steel formwork made up of<br />
three sets for the construction of pier cups.<br />
• Two sets of formwork model, MAXIMIX, and custommade<br />
products for a total of 940 m² for the casting of<br />
the bridge decks.<br />
• The OMNIMODE system integrated with customized<br />
solutions for the construction of suspended working<br />
platforms during the launching phase of the decks,<br />
• Climbing system.<br />
Through experience and working with the contractors,<br />
Pilosio was able to offer the best solution in terms of speed<br />
of work, site safety, optimization of equipment and also of<br />
aesthetics.<br />
The Pilosio technical department responded quickly<br />
and expertly to the various criteria of the project, such as<br />
rapid supply times, coordination with the various<br />
organizations involved in the project, the need to<br />
design a formwork system for the piers adaptable<br />
to two different sizes and a scaffolding system optimized<br />
for the launching bridge system.<br />
Construction methods<br />
The construction is jointly funded by Sanral and the<br />
KZN Department of Transport and the upgrade will<br />
take about three years to complete. The civil construction<br />
is being undertaken by Italian construction<br />
company CMC di Ravenna, with construction being<br />
supervised by engineering and development consultant<br />
Smec South Africa.<br />
Sanral’s contract with CMC di Ravenna stipulates<br />
minimum targets for employment from within the<br />
eThekwini municipality region, as well as for small<br />
contractors and businesses from KZN.<br />
The scope of work for the southern approach<br />
that includes the widening of the northbound carriageway<br />
from four lanes to five lanes; widening the<br />
The large area Pilosio steel forms used for the<br />
23 m high piers allow plenty of room for the<br />
workers to access the rebar, etc.<br />
Contractors World International Vol 6 No 1<br />
Page 31
Aerial view, taken<br />
mid-January 2015,<br />
shows the progress<br />
the multimillion<br />
dollar motorway<br />
junction in Durban,<br />
South Africa taking<br />
shape.<br />
southbound carriageway from three lanes to five lanes; an<br />
additional northbound three lane auxiliary off‐ramp; and<br />
median barriers and retaining walls.<br />
As foundations showed no significant issues, it was decided<br />
to use the standard formwork model P300.<br />
For the casting of piers and pier cups, the P300 modular<br />
system could have been used for the casting of octagonal<br />
The octagonal shaped piers rise to 23 m. A high<br />
quality finished was required to the exposed concrete.<br />
Reason for Pilosio making custom-sized 5 m<br />
high steel forms<br />
piers. However, given the particular characteristics of the<br />
project, the time schedule would be longer and the exposed<br />
finish less aesthetic than with a system of customized<br />
formwork. Pilosio, therefore, created special customsized<br />
steel formwork to guarantee faster working, a better<br />
aesthetic finish and, above all, allow the realization of casting<br />
to 5 m height at a time on piers of up to 23 m in height,<br />
as required by the company. The climbing system also provided<br />
greater safety for operators.<br />
These custom formworks leave neat, aligned visible<br />
holes in the concrete, as the tie are removed Finally, having<br />
26 stacks of identical sections, the additional cost in<br />
opting for custom-made solution, was balanced by the<br />
faster working speed achievable.<br />
In fact, with the equipment once delivered, the<br />
company could cast three piers simultaneously. For<br />
casting the pier cups, the CMC company asked for<br />
custom made formwork to cast 3 + 3 m in height. The<br />
piers are supported by towers in MP, with safety access<br />
stairs.<br />
The Most Complex Section<br />
The most complex part of the viaduct concerns the<br />
casting of the bridge decks, which are produced on one<br />
of the abutments and then pushed out using the incremental<br />
bridge launching system.<br />
For the onsite casting of the 20 m long decks, a mixed<br />
formwork system is used consisting of the OMNIMODE<br />
system for the base and exterior of the ashlar, with major<br />
beams in steel and secondary beams in wood to<br />
form the outer shape of the MAXIMIX beam.<br />
The second phase of the casting of the upper horizontal<br />
decking is made with SIMPLEX support towers,<br />
which are modular and extremely fast to assemble and<br />
handle.<br />
• Pilosio<br />
Enerpac<br />
Page 32 Contractors World International Vol 6 No 1
Germany<br />
Upmarket Residential Complex<br />
Optimizes Formwork<br />
The massive shell construction of an upmarket residential<br />
complex in Berlin consists almost entirely of concrete and<br />
encompasses two basement levels, a ground floor and two<br />
upper storeys.<br />
To secure the building excavation for the basement levels,<br />
the 12 metre deep excavation was secured and constructed<br />
on all four sides by a Berlin type pit lining - a system<br />
using back anchoring<br />
On completion of the earth and civil engineering works,<br />
the construction company set about the shell construction<br />
works, making use of Pashal systems for the great variety<br />
of formwork tasks.<br />
As construction progressed speeded up, the project<br />
manager also came more and more to appreciate the advantages<br />
of these formwork and shoring systems. Especially<br />
as, for this special project, all of the formwork and shoring<br />
tasks could be handled within the system, eliminating the<br />
need for time-consuming special solutions.<br />
Paschal supported both the contractors and the subcontractors<br />
with the full planning, logistics for the hire of<br />
equipment and the training of the formwork crew on site.<br />
Concrete, right from the start<br />
The basis of the project, the 28 x 25 m x 12 m deep foundation<br />
pit was first secured all round by a Berlin type pit<br />
lining. Once the entire foundation pit had been dug out,<br />
the foundation for the building was laid in the form of a<br />
65 cm to 125 cm thick reinforced concrete<br />
base plate.<br />
The reinforced walls of the basement<br />
levels were formed as single-sided walls<br />
with the LOGO.3 formwork system and concreted<br />
with water-impermeable concrete.<br />
For this, the formwork team combined<br />
two formwork units of 6.50 m wide x 4.30<br />
m high and created each of the external<br />
concrete walls in 12 concrete sections. This<br />
made it possible to create a uniform pattern<br />
Contractors World International Vol 6 No 1<br />
Throughout the structure, all concrete<br />
could be formed using the<br />
modular components from the<br />
advanced systems available from<br />
Paschal<br />
Page 33
To transfer the horizontal<br />
forces of the weightbearing<br />
construction,<br />
legs from the GASS<br />
Aluminium Shoring<br />
System were used horizontally,<br />
providing safe<br />
and reliable support for<br />
the LOGO.3 formwork<br />
during the concreting<br />
work.<br />
of crossed horizontal and vertical joints.<br />
An open staircase – with angular corners on the outside<br />
and oval on the inside – with a concrete parapet was<br />
formed using a combination of the TTR formwork system<br />
for the internal core and LOGO.3 for the exterior.<br />
To take up the vertical loads, an support unit was constructed,<br />
formed and concreted in the second basement<br />
level.<br />
Car-lift shaft in two height<br />
operations<br />
A feature of this expensive residential structure is a car lift<br />
system to deliver cars from ground level to the basement.<br />
On completion of the slab over the first basement level,<br />
the first task was to create the internal walls of the lift<br />
shaft in reinforced concrete with a formwork height of 4.75<br />
m, to allow these walls – as stipulated by the planner of<br />
the weight-bearing structure – to be used as an abutment<br />
supporting the single-sided formwork of the two external<br />
walls.<br />
To take up the horizontal forces, legs from the aluminium<br />
GASS shoring system were placed horizontally. The<br />
walls of the car lift shaft were created in operations undertaken<br />
at two heights.<br />
1st height operation: To create the external walls in<br />
the second basement level to a formwork height of 5.65 m,<br />
LOGO.3 was secured as single-sided formwork with 6.00 m<br />
high supporting jacks.<br />
2nd height operation: To make it possible to bring the<br />
shaft walls up to the level of the wall above the first basement<br />
level, there was an intermediate level created in the<br />
car lift shaft with system parts from the shoring system.<br />
The wall formwork was assembled and laid on<br />
this working platform and then lifted into vertical<br />
position by a crane.<br />
Indoor Swimming Pool<br />
The bottom of the swimming pool projects into the<br />
lower basement level, it was, therefore, formed using<br />
water-impermeable concrete after the external<br />
wall and the beam running through between these<br />
two boundaries had been completed.<br />
The bottom of the pool covers an area of 95 m²<br />
and was created using H20 beams from the Paschal<br />
deck system along with plywood panels from the<br />
contractors stock.<br />
Once the required degree of concrete strength<br />
had been achieved, the bottom of the pool was used<br />
as the supporting surface for the supporting jacks for<br />
the single-sided wall formwork.<br />
As forces of 160 kN were in play on each leg of<br />
the supporting jacks, additional props were placed<br />
under the floor of the pool.<br />
• Paschal<br />
Page 34 Contractors World International Vol 6 No 1
Super Mega Brace for its first major<br />
project<br />
Groundforce Shorco has used its<br />
new Super Mega Brace support<br />
system with integral hydraulic<br />
rams for the first time on a major<br />
project for the renewable energy<br />
sector.<br />
The equipment was supplied<br />
to main contractor, Clugston<br />
Construction, for use in the construction<br />
of a concrete energyfrom-waste<br />
fuel bunker situated<br />
on the Wilton International wasteto-energy<br />
site in Redcar, Teesside<br />
UK.<br />
Clugston, together with process<br />
partner, CNIM, is building the<br />
new plant which, when completed, will burn domestic<br />
waste supplied by Merseyside Waste as fuel to generate<br />
energy.<br />
The imported waste will be transported by train and<br />
stored in a huge concrete bunker prior to being burned to<br />
generate heat and power.<br />
Construction of this concrete bunker has required the<br />
excavation of a 13 m deep box structure below ground level.<br />
The completed bunker is 50 m long and 20 m wide.<br />
The walls of this bunker are lined with a series of contiguous<br />
concrete bored piles installed by specialist contractor,<br />
P J Edwards, with foundation design by engineer Byrne<br />
Looby.<br />
Supporting these piled walls at such a depth has required<br />
a very strong and rigid temporary propping solution<br />
supplied by Groundforce’s major projects division.<br />
Clugston’s chief engineer Ray Postolowsky said:<br />
“Until you’ve cast the reinforced concrete base slab,<br />
there’s a risk of the bottom of the piles ‘kicking in’ under<br />
the pressure of the ground behind them.”<br />
So to prevent this happening, Groundforce provided<br />
temporary propping at the base of the excavation and another<br />
level of support higher up to satisfy the high deflection<br />
and stiffness requirements calculated by Clugston’s consulting<br />
engineer, Tata Steel Projects.<br />
The upper level of the excavation is supported by two<br />
MP500 hydraulic props which are attached directly to the<br />
face of the concrete capping beam – a massive structure<br />
which is up to 5 m thick in places.<br />
The lower level was supported by three more MP500s<br />
which span across the width of the box, and four MP250<br />
knee-braces, one spanning each corner of the rectangular<br />
excavation.<br />
All of the props in the lower level bear against<br />
Groundforce’s Super Mega Brace beams which transfer the<br />
loads from the contiguous concrete piled retaining wall.<br />
So the lower level props can be removed when the base<br />
slab has been cast and the high level props can be removed<br />
when a bunker dividing wall has been constructed.<br />
Strongest Brace in the Industry<br />
The Super Mega Brace is the strongest proprietary hydraulic<br />
brace in the industry. The modular hydraulic components<br />
are quick to assemble and lift into place.<br />
This project was designed by Tata Steel Projects and is<br />
one of the first fully Eurocode-compliant schemes that<br />
Groundforce’s Major Projects department has worked on.<br />
Stiffness was a key factor in the design and so,<br />
rather than keep the props under hydraulic pressure,<br />
Groundforce was required to lock them off mechanically<br />
to ensure rigidity in the frame.<br />
Specially-designed welded isolation plates were<br />
used to isolate the hydraulic element of the MP250<br />
props, though not the larger MP500s.<br />
• Groundforce<br />
• Clugston Construction<br />
• P J Edwards<br />
Contractors World International Vol 6 No 1<br />
Page 35
Turkey<br />
Skyland Office Tower,<br />
Istanbul<br />
At 284 m height each, the<br />
Skyland Office Tower and<br />
Residence Tower will be<br />
Turkey’s tallest buildings<br />
upon completion.<br />
Construction of the Skyland<br />
Office Tower in progress in<br />
the heart of Istanbul building<br />
will be Turkey’s tallest structure.<br />
Doka’s Platform SCP is a feature of the<br />
construction.<br />
This high-rise-core forming machine<br />
ensures rapid construction progress.<br />
Doka is also providing Xclimb 60<br />
protection screen for both the Skyland<br />
Office and Residence Towers.<br />
Developer, Eroğlu, selected the<br />
name “Skyland” for his three skyscrapers:<br />
at 284 m height each, the Skyland<br />
Office and Residence Towers and the<br />
Skyland Hotel. The main building contractor<br />
is Alcen.<br />
Challenging Formwork Demand<br />
The challenge presented by the office tower in terms of<br />
formwork technology is twofold:<br />
• The architects decided on a triangular ground plan and,<br />
therefore, the building core.<br />
• The risk of earthquakes in Istanbul presents special<br />
challenges related to static engineering.<br />
Thus, lower level walls are 1.5 m thick, at 100 m they<br />
measure 1.1 m, with the wall thickness reduced to 60 cm<br />
in the final storeys. Additional stability is created thanks to<br />
monolithic construction, where walls and floors are reinforced<br />
in one go.<br />
Given these demands, Doka’s self-climbing Platform<br />
SCP was proposed. Alcen Owner, Alparslan Sabanci, said:<br />
“We got introduced to this system during the<br />
Ağaoğlu Maslak 1453 project; now we are using it<br />
to erect the entire primary core of this skyscraper.<br />
Doka submitted a better engineering solution”,<br />
“The construction progress<br />
shows that we made the<br />
right decision when selecting<br />
the Platform SCP.”<br />
Optimised platform<br />
for high-rise cores.<br />
Any ground plan can be formed<br />
quickly and flexibly with the new<br />
version of this modular high-rise<br />
core forming system. A few highperforming<br />
hydraulic cylinders raise<br />
the wall formwork – in this case<br />
Doka’s large-area formwork Top 50<br />
Page 36 Contractors World International Vol 6 No 1
– along with the working platform in one lift to the next<br />
casting section.<br />
With its newly developed lifting unit, the Platform SCP<br />
now adapts even more flexibly to complex layouts.<br />
As well as anchoring the lifting units to the structure<br />
on both sides, there is also an extended solution which<br />
makes it possible to transfer the forces on one side only.<br />
This makes it easy to use the system where there would<br />
not otherwise be enough walls, or where there are openings<br />
in the opposite walls.<br />
An adjustable<br />
metal formwork for<br />
curved applications<br />
In order to optimize and accelerate the construction<br />
progress, Doka experts pulled out all the stops during planning<br />
and divided the forming jobs between two platforms.<br />
They can, therefore, be climbed independent of each other<br />
to the next casting section and add more flexibility to the<br />
processes. Thus, the planned weekly cycle is within close<br />
reach.<br />
Safety is the deciding factor.<br />
The self-climbing Platform SCP offers a high level of safety.<br />
The all-round enclosure of working surfaces allows work<br />
to take place safely and unaffected by weather conditions.<br />
Very large platform surfaces make it easy to access for reinforcement<br />
and site equipment.<br />
The building contractors put their trust in the protection<br />
screen Xclimb 60 with trapezoidal sheet enclosure at<br />
both, the Skyland Office Tower and the Residence Tower.<br />
Construction company, EGDC, is currently building a<br />
13.50 m high tank for water storage at Aytré (17) near<br />
La Rochelle, France, using the CTR 3010 formwork by<br />
SATECO.<br />
The curved formwork is made up of 3 parts consisting<br />
of a 1.5 0m lower extension and 4 standard 3<br />
m panels, overall height 13.50 m.<br />
The 5 mm thick metal formwork of the CTR 3010<br />
panel is designed to provide a better concrete finish in<br />
addition to fast and highly accurate vertical assembly.<br />
This flexible enclosure for all high-rise projects consists of<br />
a hydraulically climbed system that can also be quickly repositioned<br />
by crane if sufficient crane capacity is available.<br />
Protection screens can be easily sized, permitting lastcentimetre<br />
adjustment to any layout. This Doka system ensures<br />
safe working conditions at any height on 15 tower<br />
constructions in Istanbul.<br />
• Doka Formwork<br />
The complete form is assembled on the ground<br />
and then lifted in a single operation. The formwork<br />
system allows the use of self-compacting concrete<br />
casting of any height.<br />
The circumference of the tank is fully reinforced<br />
with an internal brace made up of scaffolding which<br />
also provides a working board.<br />
The specific layout of this tank requires 4 primary<br />
castings spaced to ensure the stability and safety of<br />
the iron assembly.<br />
Finally, when casting resumed, the EGDC Company<br />
used hydro expansive joint ribbon to seal the successive<br />
castings of the construction.<br />
• SATECO<br />
Contractors World International Vol 6 No 1<br />
Page 37
Peru<br />
ULMA Climbing systems: SBF and BMK<br />
Bracket in Cerro Verde iron ore mineral<br />
processing plant<br />
ULMA Working On Mining and<br />
Hydropower Expansion<br />
ULMA has many years of experience, a wide scope of expertise<br />
in this area and has carried out a considerable number<br />
of projects in Peru.<br />
The growing demand for energy that comes with the<br />
fast development in the country has led to a multiplication<br />
of the construction of energy infrastructure. This has<br />
brought an increasing demand for ULMA solutions, given<br />
the proven expertise in the country.<br />
Expanding Mining Operations<br />
With prior experience from 2007, ULMA gets involved for<br />
the second time in this project, this time, in the expansion<br />
of the Cerro Verde mine managed by GyM S.A.<br />
This expansion is going to triple the ore processing capacity<br />
of the mine that produces more than 20% of the<br />
copper of the country to 360,000 tonnes.<br />
ULMA has provided specific solutions for this project.<br />
The 2.5 m thick slab required extra horizontal reinforcement<br />
against heavy wind that significantly increased the<br />
weight of the structure. The bracing of the T-60 shoring<br />
towers helped increasing their load capacity by more than<br />
1 tonne to support the slab.<br />
Hydroelectric Power Plant, Cerro<br />
del Aguila<br />
One of the largest projects currently in progress and one<br />
that will become the second largest hydroelectric power<br />
plant in Peru is Cerro del Aguila with a production of 510<br />
MW.<br />
The project means a real challenge due to the technical<br />
complexity, but also because of the location and the difficult<br />
access to the area.<br />
A consortium of GyM and Astaldi appointed ULMA as<br />
formwork supplier for the construction of the dam, the<br />
powerhouse and the intake.<br />
The dam is 80 m high<br />
and 270 m wide at the<br />
crest.<br />
The expansion of the<br />
iron ore mine operated<br />
by Cerro Verde<br />
Mining Company,<br />
Arequipa, Peru, will<br />
triple the processing<br />
capability.<br />
Page 38 Contractors World International Vol 6 No 1
In the first construction stage of the intake, modular<br />
formwork was used to provide utmost versatility: ORMA<br />
for straight walls, CLR and FLECTOR circular formwork for<br />
2.6 m high tiers of curved walls.<br />
BRIO modular scaffolding was used to enable workers<br />
to carry out parallel works while the construction went on.<br />
In the second and third stage, the walls were built with<br />
SBF single-sided climbing bracket. Because the product was<br />
new to the Peruvian market, the workers were trained on<br />
how to use it in order to increase the assembly efficiency.<br />
Tata Steel<br />
Asymmetric<br />
Slimflor Beams<br />
Tata Steel relaunches its Asymmetric Slimflor Beams<br />
(ASBs) making them more accessible than ever before,<br />
with a shorter production time and improved<br />
availability. Responding to customer feedback, the<br />
ASBs are to be produced to order, enabling accurate<br />
programming for construction projects.<br />
Manufactured in the UK to the exacting standards<br />
required for CE-marked products, and recently certified<br />
to BES 6001, ASBs beams are now available on a<br />
project basis from rolling campaigns for smaller minimum<br />
order quantities per serial size (>120 tonnes).<br />
The shorter lead-time, typically 6-8 weeks, along with<br />
rollings for smaller quantities provides customers<br />
with greater flexibility.<br />
Work is advancing on the construction of the<br />
2nd largest hydropower scheme in Peru, at<br />
Cerro del Aguila<br />
In this type of project, machinery is constantly moved<br />
from one place to another, which had to be taken into<br />
account when building the slab. The solution to this was<br />
achieved by using MK Shoring and Gantry Bracket MT<br />
as support for the MK Truss, BRIO and ENKOFLEX beam<br />
formwork.<br />
• ULMA<br />
An integral part of the Advance sections range,<br />
ASBs have been specifically designed for use with<br />
ComFlor 225 deep decking to create the Slimdek system,<br />
an engineered solution that offers a service-integrated,<br />
minimal depth, cost-effective shallow floor<br />
construction ideal for car parks, residential developments,<br />
hospitals and commercial buildings where<br />
minimising floor depth, and achieving onerous acoustic<br />
and vibration criteria are key consideration.<br />
Mike Hoare, Product Marketer, Construction<br />
Structures said:<br />
“ASBs are an essential part of a cost-effective<br />
shallow floor solution. The composite action,<br />
which is assisted by the embossed surface<br />
on the upper flange of the ASB, significantly<br />
increases the structural strength of the floor.”<br />
“We are keen to demonstrate the flexibility<br />
that ASBs can offer to construction programmes.<br />
In addition to our extensive products<br />
and service offering, we have a team of<br />
structural engineers on-hand to offer our customers<br />
free design assistance for optimal use<br />
of ASBs in any building project.<br />
• Tata Steel<br />
Contractors World International Vol 6 No 1<br />
Page 39
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Contractors World - Intermat Preview 2<br />
Latest Innovations in<br />
Trenchless Technology<br />
Contractors around the world<br />
have recognised the many benefits<br />
that trenchless technology deliver<br />
and as technology advances so<br />
companies such as Tracto-Technik<br />
apply it to new models.<br />
This will be evident on the<br />
TractoTechniik stand at Intermat<br />
2015 with the launch of the<br />
Grundodrill 18ACS, which works<br />
highly effcient in mixed soils as well<br />
as in hardest rock at signficantly reduced<br />
operation costs and construction<br />
times.<br />
The Grundodrill 18ACS works<br />
with a twin tube drill rod consisting<br />
of an inner tube with plug-in connector<br />
and outer tube with Elicon thread.<br />
For bores in rock the “Rockbreaker” steering head with<br />
roller chisel is applied. When drilling, the outer tube steers<br />
the Rockbreaker and the inner tube, which is connected<br />
to the roller chisel, transfers a torque of 2.500 Nm up to<br />
350 rpm directly onto the chisel. This way, it reduces the<br />
amount of Bentonite required to a very small quantity,<br />
keeping the costs for purchase, treatment and disposal<br />
down to a minimum without impairing the performance.<br />
With a Cummins Tier IV compliant 126 kW diesel engine,<br />
consuming less than 10 l/h, and a thrust and pullback<br />
force of 180 kN, it is possible to do standard fluid-assisted<br />
bores up to 400 m length and rock bores up to 300 m<br />
length with an upsizing diameter of 20” maximum. A rod<br />
magazine holds up to 225 m.<br />
Having a working width of 2,3 m and an axis-centre<br />
distance between drilling axis and obstacle of only 1 m<br />
the 15,200 kg unit is also ideal for applications in limited<br />
spaces as for example mountainous regions or inner cities.<br />
Inclination angle is variable between 12° and 30° to give a<br />
wide drilling envelope.<br />
At just 66 dB(A) sound level, the drill is also suitable<br />
for use in sensative areas such as in residential housing estates<br />
or near hospitals. The rubbersised steel track helps<br />
minimse damage to ground surface and also provides easy<br />
traction over difficult ground conditions.<br />
New Pipe Rehabiliation Solution<br />
Intermat will also see the official introudction of the TT<br />
PipeREDUCER. This further extends the application range<br />
of the Grundoburst static pipe bursting system by the ‘Pipe<br />
reduction’ relining technique for the trenchless renovation<br />
of pipes.<br />
The pipe reduction method allows for a PE pipe string<br />
with reduced diameter which adapts to ‘close-fit’ to the<br />
inside of an old pipe wall whilst being pulled through the<br />
host pipe.<br />
A benefit of this method is the fact that the diameter of<br />
the old pipe is only slightly reduced. At the same time the<br />
hydraulic capability of the pipeline is improved.<br />
Due to the close-fit installation no annular space remains<br />
avoiding costly grouting. This method results<br />
in a mechanically robust and new pipe with<br />
an extended service life.<br />
Further advantages of the reduction method<br />
using the TT PipeREDUCER are short construction<br />
times and minimal civil engineering works which<br />
result in considerably lower cost compared to<br />
open construction. Thus the reduction method<br />
provides a reliable and versatile technique for<br />
the economic, close-fit renovation of gas, water<br />
or drainage pipes in need of rehabilitation.<br />
• Tracto-Technik<br />
Contractors World International Vol 6 No 1<br />
Page 41
Contractors World - Intermat Preview 2<br />
Komatsu Out To Impress At<br />
Intermat 2015<br />
As reported in the last issue of Contractor World<br />
International, “Komatsu Goes Crazy with New Equipment<br />
Launches” there seems to be nothing holding the company<br />
back as it begins the roll out of their new integrated technologically<br />
advanced machines.<br />
Development in technology and the company’s partnership<br />
with Topcon has enabled Komatsu to build in advanced<br />
features instead of them being optional exterior<br />
‘add-ons’ .<br />
At this time, it is the range of excavators and dozers that<br />
are benefitting the most with available intelligence with automatic<br />
bucket placement and blade control for optimum<br />
efficiency with little operator involvement.<br />
Today, in dozing operations, instead of manually setting<br />
the blade, the operator simply inputs the required parameters<br />
on the monitor. All he then needs to do is position<br />
and steer the machine. Accurate dozing pass after pass.<br />
In excavation, similar positioning technology delivers<br />
the precise depth and width of excavations. Invaluable<br />
when trenching as their is no excess material taken out.<br />
The technology in excavators was introduced with the<br />
PC210LC-10 model. Intermat will see the PC240LCi-11 -<br />
the first in a new series introduced alongside a D61li-23<br />
dozer and D37EXipXi dozer.<br />
Appropriate technology will also feature on the company’s<br />
latest in articulated dump trucks and wheel loaders.<br />
Taking Technology to A New Level<br />
Intermat will also see Komatsu’s latest model with hybrid<br />
technology. Owners of existing Komatsu hybrid excavators<br />
quickly discovered that the higher initial investment is soon<br />
recouped in fuel savings.<br />
New PC240LCi-11<br />
This new excavator further illustrates<br />
Komatsu technology and ability to innovate.<br />
The more environmentally<br />
friendly EU Stage IV<br />
Komatsu engine gives up<br />
to 6% improved fuel<br />
efficiency.<br />
The PC240LC-11 maintains the lifting performance and<br />
stability of previous Komatsu models, but with an engine<br />
delivering a net 141 kW (189 HP) @ 2.000 rpm and operating<br />
weights between 24.700 kg and 26.200 kg.<br />
The PC240LC-11 is equipped with the latest KOMTRAX<br />
remote monitoring technology with data access via the web<br />
or via KOMTRAX Mobile on your smart phone. In addition<br />
to providing data such as fuel levels, operating hours, location,<br />
cautions and maintenance alerts, KOMTRAX is further<br />
enhanced to monitor AdBlue levels and KDPF regeneration<br />
and now also provides fuel theft alerts.<br />
A new Operator Identification System reports key operating<br />
information for multiple operators and the new Auto<br />
Idle Shutdown function helps to lower operating costs.<br />
All major components on the new PC240LC-11 including<br />
the engine, hydraulic pumps, motors, and valves are<br />
designed and produced by Komatsu.<br />
Variable Speed Matching allows the engine speed to<br />
adjust based on the hydraulic pump output for both light<br />
and heavy-duty applications. Additional enhancements<br />
have been made within the hydraulic system to reduce hydraulic<br />
loss, resulting in better efficiency.<br />
Operator environment<br />
The cab provides a comfortable and quiet work environment<br />
that helps operators maximize productivity. Proportional<br />
control joysticks are fitted as standard for the precise operation<br />
of attachments. The ROPS certified cab, specifically<br />
designed for hydraulic excavators, gains strength from a reinforced<br />
box structure framework.<br />
A Neutral Detection System further improves safety:<br />
if the work equipment levers are not in a neutral position<br />
when the lock lever is released, the machine is prevented<br />
from any movement.<br />
The operator can easily select up to six working modes<br />
to match machine performance to the application. The<br />
standard rear-view camera gives a wide landscape view of<br />
the area directly behind the machine, and the new monitor<br />
panel’s default screen shows the camera image as well as<br />
gauges. An optional second camera is available.<br />
Big dozer has rough-cut-to-finishgrade<br />
automated efficiency<br />
A star attraction at Intermat will be the new 40,505 kg<br />
(89,300 lb) D155AXi-8, Komatsu’s first intelligent machine<br />
control crawler dozer in this size class, and the newest addition<br />
to the next generation of machine control and dozer<br />
technology.<br />
Jason Anetsberger, product manager-Intelligent<br />
Machine Controls, Komatsu America Corp said:<br />
“The D155AXi-8 is ideal for highway construction<br />
Page 42 Contractors World International Vol 6 No 1
and large residential or commercial site-prep<br />
projects.”<br />
“If you’re looking for something that accurately<br />
and efficiently moves massive amounts of<br />
material, look no further.”<br />
Innovative Integrated Intelligent<br />
The D155AXi-8 machine control system features enhanced<br />
‘intelligence’ that allows automated operation from heavy<br />
dozing to fine grading.<br />
It has the ability to sense and control blade load, optimize<br />
the start of the cut and minimize track slip, achieving<br />
up to 8% greater efficiency in moving material in a startto-finish<br />
grading test, compared to typical aftermarket machine<br />
control systems.<br />
The lack of blade mounted sensors means there’s no<br />
need for operators to climb on the blade to install/remove<br />
GNSS antennas, no coiled cables to snag and no electrical<br />
connections to worry about.<br />
Powered by a 264 kW (354 HP) Komatsu SAA6D140E-7,<br />
Tier 4 Final emissions certified engine, the new dozer<br />
emits 80% less nitrogen oxides (NOx) than its Tier 4 interim<br />
predecessor.<br />
This variable<br />
geometry turbocharged<br />
and<br />
after cooled,<br />
The Komatsu<br />
HB215LC-<br />
Hybrid<br />
tracked<br />
excavator<br />
15.24 litre diesel engine features Komatsu Diesel Particulate<br />
Filter (KDPF) and Selective Catalytic Reduction (SCR) systems<br />
and achieves fluid-neutral fuel economy.<br />
Time-Saving Productivity<br />
An automatic gearshift transmission and lock up torque<br />
converter team up to select the optimal gear range depending<br />
on jobsite conditions and load, and are designed<br />
to provide maximum operation efficiency.<br />
The patented SIGMADOZER blade, designed to dig and<br />
roll up more soil at the blade’s center, holds more material,<br />
reduces digging resistance and dozes up to 15% more soil<br />
while using less power, compared to a typical semi-u blade.<br />
Blade capacity ranges from 9.4 - 12.70 m³ (12.3 - 15.6 yd³)<br />
Operator Comfort<br />
The D155AXi-8 ROPS pressurized cab has large, tall windows<br />
and superb sealing for outstanding visibility and less<br />
noise and dust inside the cab.<br />
The D155AXi-8 cab damper mounts isolate the cab<br />
from the machine frame, softening shocks and vibrations<br />
and providing unmatched operator comfort.<br />
The D155AXi-8 is covered by the Komatsu CARE program<br />
for the first three years or 2000 hours, whichever<br />
comes first.<br />
And There Is More<br />
Also starring at Intermat 2015, and still unmatched on<br />
the worldwide construction market today, is the Komatsu<br />
HB215LC-2 third-generation Hybrid excavator - a product<br />
of patented Komatsu technology.<br />
Komatsu components harness free kinetic energy, converts<br />
it to electricity for a powerful and quiet performance,<br />
a fuel consumption reduced by up to 40%, and a considerably<br />
lower carbon footprint.<br />
A total of 29 Komatsu machines will be showcased,<br />
among which several other models presented in Europe<br />
for the very first time such as the PC360LC-11 hydraulic<br />
excavator, the PW148-10 Wheeled Excavator and a High<br />
Reach Demolition PC490LC-10 excavator.<br />
• Komatsu Europe<br />
Contractors World International Vol 6 No 1<br />
Page 43
Ten World Premiers from<br />
Hyundai<br />
Hyundai Heavy Industries Europe (HHIE) will present an<br />
extensive range of equipment for the construction, utility,<br />
forestry & logging, recycling & waste handling and mining<br />
& quarrying industries at Intermat 2015. Amongst these<br />
will be 10 models having their world premier.<br />
Intermat is the launch platform for the first six models<br />
of the new excavator range.<br />
The engineers at Hyundai have taken the opportunity<br />
of the Tier4/ StageIV momentum to completely redevelop<br />
the machines.<br />
Hyundai says that many improvements from operator<br />
feedback have been implemented to create ultimately<br />
better, stronger and more robust machines for customers<br />
worldwide.<br />
Having their world premier will be HX220 L , HX260 L<br />
, HX300 L , HX330 L , HX380 L and HX520 L heavy excavators.<br />
The new models will also introduce new<br />
nomeclature.<br />
To easily identify the new series of machines<br />
the model names have changed. The model<br />
numbers begin with two letters - ‘HX’ stands for<br />
Hyundai crawler excavators and ‘HW’ - stands for<br />
Hyundai wheeled excavators.<br />
The following three numbers indicate the operating<br />
weight in tons, multiplied by 10. So the ‘220’ has a total<br />
operating weight of 22 tons. The last three letters reflect<br />
the specific option on this machine – ‘CR’ stands for compact<br />
radius, ‘LR’ stands for long reach and ‘MH’ stands for<br />
material handling, etc.<br />
New engine for better performance<br />
The new engines are compliant with the latest regulations<br />
(Tier4 final and EU Stage IV final) for exhaust Nox reduction<br />
and particle matters. Hyundai has opted for a combined<br />
solution of EGR and SCR technologies.<br />
As is the norm for these advanced engines, a saving<br />
in fuel consumption of 3 to 6 percent has been achieved<br />
compared to previous models. Hyundai has selected several<br />
engine suppliers for the new machines. The HX220 ~<br />
HX380 are equipped with new Cummins engines and the<br />
HX520 with a new Scania engine.<br />
New exterior design<br />
The new engines and assoicated modules are larger and<br />
run at a higher temperature. To provide more efficient<br />
cooling, side vent holes have increased in size. The new<br />
sized vents have also resulted in a slightly changed graphical<br />
design resulting in better brand recognition.<br />
Also the rear working lamp has been re-positioned for<br />
an improved view, a new guard rail has been installed for<br />
enhanced safety when climbing up the machine and maintenance<br />
air filters are now more accessible. The cabin has<br />
an improved front glass window for a wider, undistorted<br />
view.<br />
Re-designed cabin for more<br />
comfort<br />
These<br />
finishing<br />
touches on<br />
the inside of<br />
the cab mean<br />
greater comfort<br />
for the<br />
operator. The<br />
interior of the<br />
cabin has been rearranged<br />
to provide 10<br />
percent more space for the operator<br />
and better air circulation with the newly developed airconditioning<br />
system. The operator has more available storage<br />
space and, more importantly, a new instrument panel<br />
and controls.<br />
A new, larger eight inch monitor screen is easier to<br />
read and integrates more functions including centralized<br />
switches for a number of applications.<br />
The main view on the screen is adjustable to the operator’s<br />
preference and can be controlled by touch and/or by<br />
the new haptic control button (a common feature in many<br />
cars today). Connection with a mobile phone is now easier<br />
than ever as well as connections with outside cameras for<br />
an all-round view.<br />
Page 44 Contractors World International Vol 6 No 1
EXPERIENCE THE WIRTGEN GROUP<br />
AT INTERMAT 2015 IN PARIS.<br />
Nothing is more important to us than communication with our customers. Tell us about your experiences with<br />
our machines as you feast your eyes on our innovations in Road and Mineral Technologies. Our experts are<br />
looking forward to your visit.<br />
www.wirtgen-group.com/intermat<br />
Road and MineRal Technologies<br />
inTeRMaT 2015<br />
Trade fair grounds Paris-nord Villepinte · France<br />
hall 5a · Booth no. J 124<br />
20 – 25 april 2015 · daily from 9 am to 6 pm<br />
www.wirtgen-group.com/intermat<br />
Page Contractors 45 World International Vol 6 No 1<br />
Contractors World International Vol Page 6 No 451
Contractors World - Intermat Preview 2<br />
Milan Wamsteker, marketing<br />
manager of HHIE, said,<br />
“Hyundai has<br />
succeeded in raising<br />
the quality of the<br />
machines in so many<br />
aspects that it is almost<br />
too much to explain!<br />
We invite everybody to visit<br />
us at Intermat in hall B and take the<br />
time to experience this new generation<br />
of machines. We guarantee that a visit to<br />
Hyundai will be time well spent. Hyundai<br />
quality has never been better!”<br />
The company has begun a radical<br />
update programme to the wheel<br />
loader range which resulted in the<br />
new Tier4/StageIV compliant series.<br />
Under HL series, new machines at<br />
Intermat include the HL 955 and HL960<br />
Brand New Wheel Loader Range<br />
Intermat is also to be the world premier for Hyundai’s new<br />
wheel loaders - HL955 and HL960 - the first in a new series.<br />
The engineers at Hyundai have once again utilized the<br />
Tier4/StageIV momentum to re-design the wheel loaders.<br />
With the new engines the machines are compliant with<br />
the latest regulations (Tier4 final and EU Stage IV final) for<br />
exhaust Nox reduction and particle matters. Hyundai has<br />
selected several engine suppliers for the new machines but<br />
the HL955 and the HL 960 are equipped with new Cummins<br />
engines.<br />
Again, the side vent holes have increased in size for a<br />
better airflow towards the engine. Also the head lamps<br />
have been re-designed for less vibration and longer durability,<br />
the standard bucket has been optimized for 5%<br />
more efficiency and less spill during driving and the engine<br />
is now easier to accessi with the electrical powered, fully<br />
opening engine hood. The cabins are<br />
fully ROPS/FOPS certified.<br />
More comfort for the Operator<br />
The wheel loader cabin has been completely redesigned<br />
for noise reduction, less vibration and more space for the<br />
operator.<br />
The ergonomically improved operator seat with seat<br />
mounted adjustable control levers are designed<br />
with the operators comfort in mind. All<br />
switches and buttons are now neatly<br />
centralized and easy to access, including<br />
the auxiliary spool control<br />
button that is integrated in the<br />
joystick.<br />
Easier to read, full colour<br />
monitor has more<br />
functions including engine<br />
mode, fuel/energy<br />
consumption, weigh measurement,<br />
hydraulic control<br />
and Intelligent Clutch Cut-Off.<br />
The monitor can be controlled by touch but has also<br />
additional short cut buttons for a variety of functions.<br />
Connection with a mobile phone or tablet is now easier<br />
with the mobile phone screen mirroring feature and connectable<br />
cabin speaker.<br />
Focus on Mini Excavator Range<br />
with a New Addition.<br />
The new 1.7 t canopy equipped R17Z-9A mini-excavator<br />
that is to have its world premier at Intermat, has a Kubota<br />
D902 engine rated at 11.7kW (15.7 hp). It fills a gap in the<br />
existing line-up between the R16-9 and the R27Z-9.<br />
When fitted with a 960 mm long dipper arm, the R17Z-<br />
9A provides a maximum dig depth of 2,190 mm. This mini<br />
excavator achieves true zero swing capability and it has<br />
two speed travel, travelling at 2.2 km/h at the lower end<br />
and 4.1 km/h at the higher end of its range.<br />
Operators can fully customise their work environment<br />
and operating preferences to fit their individual<br />
needs. In addition the boom cylinder is placed in the<br />
traditional position under the boom.<br />
As with all the Hyundai mini-excavators in the 1t –<br />
8t class, the latest model has a 2 year/3000 hour full<br />
factory warranty,<br />
Ready for New Challenges<br />
Mr O.G. Kwon, new CEO Hyundai Heavy Industries<br />
has set some objectives for HHI to work towards.<br />
“To survive and thrive amid fierce competition<br />
it is essential to remain price competitive in our<br />
sector. HHI has initiated competence-enhancing<br />
efforts for each of its business divisions by<br />
launching a special ‘Task Force’. “<br />
• Hyundai Heavy Industries<br />
Europe<br />
Page 46 Contractors World International Vol 6 No 1
Contractors World - Intermat Preview 2<br />
Sennebogen<br />
At Intermat<br />
2015<br />
A 300 m² stand at Intermat will feature several<br />
new products from leading crane manufacturer,<br />
Sennebogen. .<br />
Two machines, the 6113 telescopic crawler<br />
crane and the new 640 HD duty cycle<br />
crawler crane, will be making their debut at<br />
the exhibition.<br />
There will also be representative models<br />
from the company’s Green Line material<br />
handling machines.<br />
The new Sennebogen 6113 is the largest<br />
model in the telescopic crawler crane range<br />
and was reviewed in Contractors World<br />
International Vol 5 No 5.<br />
New Duty Cycle Crawler Crane<br />
The new Sennebogen 640 HD to the current E-Series introduces<br />
a new size to fit between the smallest model, the 30<br />
t 630 HD and the 55 t. 655 HD.<br />
The 640 HD is particularly suitable in the areas of well<br />
digging, underground engineering, and mining as well as<br />
for use as a crane.<br />
Due to a robust construction, a powerful multi-circuit<br />
hydraulic system, and the strong slewing drive, the 40 ton<br />
duty cycle crawler crane is particularly well-suited for special<br />
civil engineering work.<br />
Applications requiring leaders or rope grapples can be<br />
realized with the same high level of reliability as that offered<br />
for operation of hydraulic casing oscillators in the areas<br />
of well digging or underground engineering.<br />
It can be used with a 2.3 m³ drag bucket or for casing<br />
machines up to DN 2000. For lifting work, maximum boom<br />
length is 46.7 m (46 m maximum hook height) and maximum<br />
load is 40 t.<br />
Power is from a Cat C-7 ACERT Tier IIIa diesel rated at<br />
188 kW. Another option is the Cat C-7 ACERT Tier III rated<br />
at 205 kW.<br />
The base machine features 2 x 12 t free-fall winches,<br />
12.5 t counterweight and crawler track fitted with 800 mm<br />
triple bar shoes.<br />
The ‘maXcab’ is resiliently mounted with sliding door.<br />
The ergonomically designed cab with air-suspension seat<br />
provides excellent 360° visibility.<br />
Material Handling Machines<br />
The Green Line material handling machines are<br />
designed to cope with the tough demands in recycling,<br />
scrap handling, port handling, and many<br />
other special applications around the world.<br />
The modular system enables the most appropriate<br />
machine to be designed, eliminating the<br />
need for compromise.<br />
A number of undercarriage variants, from<br />
mobile to crawler gantry, and various equipment<br />
lengths and attachments ensure Green Line machine<br />
flexibility. The E-Series machines offer convincing<br />
performance thanks to modern fuel-saving<br />
Stage IV engines with optimal fuel efficiency<br />
and the highest level of operating comfort.<br />
• Sennebogen<br />
Contractors World International Vol 6 No 1<br />
Page 47
Contractors World - Intermat Preview 2<br />
Excavators - Track & Wheeled,<br />
Skidsteers and More from<br />
Doosan<br />
If you are planning a visit to Intermat<br />
2015 and you are interested in excavators,<br />
wheel loaders and similar,<br />
then you should allow extra time<br />
when calling at the Doosan stand.<br />
The Doosan stand is three in<br />
one. Apart from Doosan models,<br />
the stand is also host to Bobcat<br />
and Doosan Portable Power.<br />
What’s new? At this point in<br />
time, eleven tracked excavators,<br />
2 wheeled excavators, 3 telescopic<br />
handlers, 2 new genset and<br />
2 compressors.<br />
New DX210W-5 Stage IV Wheeled<br />
Excavator<br />
Typical of the new machines on show is the DX210W-5 - a<br />
new 21 tonne Stage IV compliant wheeled excavator which<br />
will be shown alongside the DW170W-5 model (pictured).<br />
As well as meeting the latest Stage IV emission regulations,<br />
it goes much further. The new series also embrace a new<br />
livery - a distinctive new machine styling scheme that is<br />
common to all new Stage IV machines from Doosan.<br />
Fleet Management System<br />
In common with all Doosan Stage IV excavators above 14<br />
tonnes, the DX210W-5 is factory-installed with the new<br />
CoreTMS wireless fleet monitoring system as standard.<br />
Designed specifically for the Doosan range, the system is a<br />
new tool providing comprehensive information about machine<br />
performance in a dual mode (satellite, GSM).<br />
Increased Power and Fuel<br />
Efficiency<br />
The new excavator is powered by the 6-cylinder, turbocharged<br />
Doosan DL06P water-cooled diesel engine providing<br />
an output of 141.2 kW (189 HP) at 1900 rpm, a 17%<br />
increase in engine power over the previous generation machine.<br />
The engine offers lower costs by meeting Stage IV<br />
Buckets: 0.66 – 0.90 m³<br />
Operating weight:<br />
16.8 t<br />
Digging depth (std front):<br />
5745 mm<br />
Digging reach (std front):<br />
9090 mm<br />
Digging height (std front):<br />
10045 mm<br />
Overall width:<br />
2500 mm<br />
Height (std front):<br />
3136 mm<br />
Overall length in travel position (std 8320 mm<br />
front):<br />
Tail swing radius:<br />
2795 mm<br />
Travel speed:<br />
37 km/h<br />
emission regulations without the need for a diesel particulate<br />
filter (DPF), through the use of cooled exhaust gas<br />
recirculation (EGR) and selective catalyst reduction (SCR)<br />
after-treatment technologies.<br />
As well as the engine, new innovative and exclusive features<br />
have been introduced that reduce fuel consumption<br />
by an average of 10%.<br />
Among these features is the new ‘Trip Meter Setting’<br />
screen which allows operators to check fuel consumption<br />
daily (or over a desired period) directly from the control<br />
panel. To save even more fuel, there is a special Doosandeveloped<br />
system, Smart Power Control (SPC), which monitors<br />
both engine and pump power and limits unnecessary<br />
outputs depending on whether the work is light or heavy.<br />
The SPC can be used with all 4 work modes (E, S, P, P+).<br />
As well as the 17% increase in engine power, the<br />
DX210W-5 has 14% more engine torque. The new Posicon<br />
hydraulic system offers a 3% increase in hydraulic capacity,<br />
which translates into an 8% improvement in the bucket<br />
force and 6% more arm force.<br />
Outstanding Comfort and<br />
Controllability<br />
The DX210W-5 utilises a cab suspension system which reduces<br />
vibration by 20% and complements this with a 2<br />
dB(A) reduction in external noise level and a 4 dB(A) reduction<br />
in cab noise.<br />
The operator also has the benefit of improved side visibility,<br />
a new user-friendly 7 inch FT LCD colour monitor<br />
Page 48 Contractors World International Vol 6 No 1
Contractors World - Intermat Preview 2<br />
control panel, fully automatic<br />
climate control system, more<br />
storage compartments as well<br />
as an improved layout with<br />
the most important switches<br />
grouped together within easy<br />
reach on the right console.<br />
New Bobcat Telescopic Handlers<br />
for the Rental Industry<br />
At Intermat 2015, the Bobcat area will provide the stage for<br />
the global launch of several new telescopic<br />
handler models from the company.<br />
The first of the new telehandlers<br />
is the new TL358 6 m lift<br />
height compact telehandler,<br />
which is available<br />
with two rated capacities<br />
of 2.6 or 3 tonne.<br />
Bobcat is also showing the new 13 m and 14 m lift height<br />
T35130S and T35140S telehandlers aimed particularly at<br />
the rental industry and offering a 3.5 tonne maximum lift<br />
capacity.<br />
New Compact Telescopic<br />
Handler<br />
The new TL358 6 m telehandler has a very compact<br />
format, with restricted 2.10 m width and<br />
height dimensions.<br />
This new model has been designed to meet<br />
many applications and customer needs (primarily in<br />
construction, industry and rental) where its overall compact<br />
dimensions, powerful 74.5 kW engine and hydraulics,<br />
manoeuvrability and true loading capacity offer a very productive<br />
alternative to smaller machines limited in performance<br />
and use.<br />
TL358 T35130S T35140S<br />
Maximum lifting capacity: 2600 or 3000 kg 3500 kg 3500 kg<br />
Maximum lifting height: 5800 mm 12550 mm 13600 mm<br />
Maximum horizontal reach: 3100 mm 8600 mm 9800 mm<br />
Maximum travel speed: 40 km/h 30 km/h 30 km/h<br />
Stabilisers Stabilisers<br />
New 13-14 m Telescopic Handlers<br />
aimed at the Rental Industry<br />
The new T35130S and T35140S telehandlers have a simpler<br />
design intended to meet the needs of the rental business.<br />
The easy-to-use compact stabilisers ensure that the<br />
full capabilities of all the new telescopic handlers can be<br />
utilised in the most confined working areas and close to<br />
walls (minimal loss of reach).<br />
in-<br />
As in other new generation machines, the two<br />
models also feature the new Panoramic Cab<br />
which has a large parabolic windscreen. In the<br />
cab, there is a new dashboard with digital<br />
display and intuitive controls<br />
including a joystick with<br />
tegrated forward/reverse<br />
(FNR) control for improved<br />
productivity<br />
and safety.<br />
The working<br />
envelope for<br />
the T35130S<br />
telehandler<br />
has a maximum<br />
lift height of 12.55<br />
m and a maximum forward reach of 8.6 m. The Bobcat<br />
T35140S telehandler has a maximum lift height of 13.6 m<br />
and a maximum forward reach of 9.8 m.<br />
• Doosan<br />
• Bobcat<br />
Montabert Shows Innovation<br />
Montabert will use Intermat to reinforces its position in the hydraulic drifting market with the<br />
introduction of the new Montabert HC95 drifter.<br />
Contractors World International Vol 6 No 1<br />
This new multipurpose drifter is<br />
available in 3 versions - one to replace<br />
a drifter already installed on a drilling<br />
machine; one for underground<br />
drilling in mining and one for surface<br />
drilling in quarries, etc.<br />
Montabert claim that the new<br />
drifters require less maintenance<br />
than any other drifter and yet deliver<br />
increased performance and<br />
efficiency.<br />
Anti-seismic BRV<br />
Other products being launched by<br />
the French company includes a patented system and entirely<br />
designed by Montabert teams to detect and prevent<br />
damage caused by vibrations.<br />
The anti-seismic BRV is an electronic system intended<br />
to regulate the rock breaker’s power based on the vibrations<br />
it generates.<br />
Using sensors placed in sensitive areas (railway tracks,<br />
bridges, buildings, etc), the system will lower the rock<br />
breaker’s power based on guidelines provided by the contractor.<br />
This eliminates the need to use a laboratory to<br />
measure seismic velocities and the associated costs.<br />
• Montabert<br />
Page 49
New Komatsu D85EX/PX-<br />
18 Crawler Dozer<br />
The D85EX/PX-18 crawler dozer has an operating weight<br />
ranging between 26.800 kg and 30.190 kg (depending<br />
on machine configuration), it is powered by a Komatsu<br />
SAA6D125E-7 engine that is EU Stage IV emissions certified<br />
and with a net 197 kW (264 HP).<br />
William Groven, Product Manager for dozers says:<br />
“Thanks to its automatic transmission, the<br />
D85EX/PX-18 always operates in its most efficient<br />
working range. This function drastically enhances<br />
the machine’s productivity and lowers its fuel<br />
consumption, making it the most fuel efficient in<br />
its class”.<br />
The Komatsu engine integrates a Komatsu Diesel<br />
Particulate Filter with high passive regeneration rate and<br />
Selective Catalyst Reduction (SCR), to further reduce NOx<br />
capacity of 7,2 m³ and improves dozing performance and<br />
increases productivity by up to 15% over a conventional<br />
Semi-U blade.<br />
The blade features a frontal design concept adopted<br />
for digging and rolling material at the center of the blade.<br />
Soil-holding capacity is increased and digging resistance is<br />
reduced for a smoother flow of material. Larger amounts<br />
of soil can be dozed with less power.<br />
Cab design offers optimal operator<br />
environment<br />
A comfortable and quiet work environment helps operators<br />
maximize productivity. The newly enhanced ROPS<br />
(Roll-Over Protection) cab is large, with excellent side visibility.<br />
Standard features include a high capacity air suspension<br />
heated seat, viscous cab mounts to reduce shocks and<br />
vibrations even in adverse conditions,<br />
an upgraded high-resolution<br />
large colour 7” LCD monitor<br />
on which all machine information<br />
is displayed, and a rear view monitoring<br />
system that can be synchronised<br />
with reverse operation.<br />
Komatsu’s ergonomically designed<br />
Palm Command Control<br />
System (PCCS) gives operators full<br />
control and offer a relaxed posture<br />
with precision control to eliminate<br />
operator fatigue. Thumb push buttons<br />
simplify transmission gear<br />
shifting.<br />
Electronic control<br />
powertrain for<br />
smooth operation<br />
The new dozer uses an electronic control powertrain system<br />
that significantly improves operation and productivity.<br />
Powerful turns under various work conditions are achieved<br />
with the Hydrostatic Steering System (HSS).<br />
emissions using the AdBlue additive.<br />
An advanced electronic control system manages the<br />
airflow rate, fuel injection, combustion parameters and<br />
after treatment functions, ensuring that the engine optimizes<br />
performance and reduces emissions.<br />
Komatsu patented SIGMADOZER<br />
blade<br />
The SIGMADOZER blade gives the machine a high blade<br />
The D85EX/PX-18 is equipped with the latest KOMTRAX<br />
remote monitoring technology. In addition to providing<br />
data such as fuel levels, operating hours, location, cautions<br />
and maintenance alerts, the system has been further enhanced<br />
to monitor AdBlue levels, KDPF regeneration and<br />
fuel theft.<br />
A new Operator Identification System reports key operating<br />
information for multiple operators. The new Auto<br />
Idle Shutdown function helps to improve operating costs<br />
by reducing unnecessary idle time.<br />
• Komatsu Europe<br />
Page 50 Contractors World International Vol 6 No 1
A Whole New Family of<br />
Cats Play in the Spanish<br />
Sun<br />
Caterpillar may have decided not to attend Intermat 2015<br />
- the platform for the launch of new equipment for many<br />
companies. However, the recent event at the Caterpillar<br />
Demonstrations and Learning Centre at Malaga, Spain<br />
demonstrated that the company continues its R&D program<br />
with the introduction of a raft of new models. The<br />
new announcements were not restricted to a specific product<br />
type but across a wide range.<br />
The company presented the latest additions to their<br />
range of tracked excavators, tracked dozers, articulated<br />
dump trucks, wheel loaders, tracked loaders, material handlers<br />
and backhoe loaders. The presentations also showed<br />
the company’s commitment to using technology to further<br />
lower fuel consumption while increasing productivity and<br />
overall operating efficiency.<br />
The Spanish weather also contributed with two warm,<br />
sunny days providing the perfect backdrop to the new additions<br />
to the Cat family.<br />
Technology Supersedes<br />
Engineering<br />
Ten years ago when a company introduced a new model,<br />
the emphasis was mainly on stronger undercarriage, a bigger,<br />
more spacious cab, stronger booms and arms to increase<br />
payload and other engineering enhancements.<br />
Today, manufacturers have realised that weight to load<br />
ratios are as good as they can be in engineering terms. The<br />
emphasis, today, is on the rapid growth in digital technology,<br />
which, when integrated into the mechanical systems<br />
can provide an almost autonomous solution to routine<br />
tasks, maintenance and investment management.<br />
However, there continues to be further engineering<br />
improvements to strengthen critical areas for improved<br />
Contractors World International Vol 6 No 1<br />
stability and load handling capabilities.<br />
Latest in Excavators<br />
The new Cat 336F L/LN excavator, replacing the 336E L/LN,<br />
is powered by a C9.3 ACERT engine, rated at 321 metric<br />
horsepower (236 kW) that meets EU Stage IV emissions<br />
standards. This and other new features enhance overall<br />
fuel efficiency and deliver fuel savings of up to 8 percent,<br />
compared with its predecessor.<br />
A heavy-duty, 6.5 m reach boom and three stick options<br />
—3.9 m (available only with the long undercarriage),<br />
3.2 m and 2.8 m — provide excellent all-around versatility<br />
for general excavation work, such as multipurpose digging<br />
and loading. The 6.18 m mass-excavation (ME) boom<br />
and matching 2.55 m stick are designed for enhanced performance<br />
and production when moving high volumes of<br />
heavy material.<br />
Many customers will welcome the news that the latest<br />
models are to have advanced technology fitted as standard.<br />
Cat Grade Control Depth and Slope, a factory-integrated<br />
system standard for the new 336F models, uses protected<br />
sensors in the front linkage to provide real-time positioning<br />
and cut/fill data through the cab monitor.<br />
Operators save time by attaining specifications on the<br />
first pass, while conserving fuel, reducing machine wear,<br />
conserving fill materials, and minimizing grade-checker<br />
involvement.<br />
The system can also be upgraded to meet customer<br />
needs. Cat dealers can easily upgrade the system to 3D capability<br />
with Cat AccuGrade GPS or Universal Total Station<br />
(UTS) packages.<br />
LINK technologies, such as the Product Link system,<br />
Page 51
What’s New In Plant & Equipment<br />
Cat 313F L GC excavator designed for costconscious<br />
customers who do not need a machine<br />
that’s working continuously.<br />
wirelessly connect owners to their machines, providing<br />
access to data—such as location, hours, fuel consumption<br />
and idle time.<br />
Such technology put fleet owners and plant hire<br />
companies in control, in real time. The ability to see<br />
if a machine is where it should be and doing what it is<br />
supposed to be doing has to be a welcomed service.<br />
All this contributes to increased productivity which<br />
means more time in the cab of the operator. Hence<br />
the roll-over-protective-structure (ROPS) cab is spacious<br />
and quiet with large glass areas for all-around<br />
visibility. Positive air filtration pressurizes the cabin<br />
to keep out dust, and height-adjustable joystick consoles,<br />
large colour monitor, and available air-suspension/heated/<br />
cooled seat ensure operator comfort.<br />
Operators will also appreciate the interior sound level of<br />
73 d(B)A.<br />
For enhanced safety, standard equipment includes<br />
time-delay working lights and a rearview camera.<br />
Take Your Pick<br />
With the introduction of the Cat 313 F L GC excavator,<br />
Caterpillar is trying to satisfy different customer needs.<br />
This model is configured for what the company refer to as<br />
‘Life Cycle Value Customers’ - that is customers who have<br />
a relatively low machine utilization; work at a low cost<br />
per hour and where productivity is balanced to the job<br />
requirements.<br />
Matthew Newman, Global Product Application<br />
Specialist explained that not all customers have the same<br />
demands and, for many, they had to make a compromise in<br />
selecting the most suitable sized machine for their typical<br />
jobs. It will also be a popular choice for rental companies.<br />
T h e<br />
Cat 313 LC is configured to reduce<br />
the need for a compromise by providing durability and<br />
lower cost of ownership. In performance terms, it has almost<br />
the identical working envelope as the 312E.<br />
The machine’s new and simple hydraulic system delivers<br />
ample and reliable power for digging, lifting, and attachment<br />
use. The load-sense pump and main control<br />
valve calculate exact work demands—all to deliver the stick<br />
and bucket force needed to get work done with low owning<br />
and operating costs. For added machine versatility, the<br />
model can be equipped with high- and medium-pressure<br />
hydraulic circuits along with a quick coupler to handle a<br />
range of Cat buckets and work tools.<br />
Latest Mini-Excavators<br />
The Caterpillar event was also an opportunity to get close<br />
up to the company’s latest mini-excavators that were introduced<br />
late last year. (See Contractors World UK & Ireland<br />
Vol 4 No 4).<br />
The 305E2, 305.5E2 and 308E2 are direct replacements<br />
for existing E series models.<br />
Further Enhancements to Loaders<br />
Malaga was the launch platform for several new models<br />
from the Caterpillar wheel loader range. These included<br />
the M318F, M320F, 938M, 950M, 960M and 963K tracked<br />
loaders together with the MH3022, MH3024 and MH3037<br />
material handlers.<br />
The latest in compact M-Series wheel loaders use a 56<br />
kW (75-gross horsepower) Cat C3.3B engine with an electronically<br />
controlled hydrostatic drive system that meets<br />
US EPA Tier 4 Final / EU Stage IIIB emission standards.<br />
The Cat Hystat system can achieve up to a 36 km/h<br />
(22 mph) top speed for these models with the optional<br />
stop-to-shift transmission that allows the operator to<br />
Cat Compact Wheel Loaders now Tier IV Final<br />
engine compliant.<br />
Page 52 Contractors World International Vol 6 No 1
What’s New In Plant & Equipment<br />
choose between maximum rimpull and maximum travel<br />
speed via a convenient switch on the RH console. It also<br />
automatically regulates speed during downhill travel.<br />
The Deluxe cab features two side-entry doors, low-effort<br />
electro-hydraulic joystick, suspended pedals, tilt steering<br />
wheel, air-suspended and heated seat and optional security<br />
keypad.<br />
Options include the Road Feature and Load Feature<br />
Packages, which include a new electronic, soft-touch keypad<br />
for convenient control of most functions. The Road<br />
Feature Package includes a Ride-Control system that cushions<br />
boom cylinders when the machine is traveling with<br />
a load in rough terrain, smoothing the ride and retaining<br />
material.<br />
Medium Sized Loaders<br />
In the larger wheel loader range, the new Cat 950M (19,769<br />
kg )and 962M (20,296 kg) wheel loaders feature a Cat C7.1<br />
ACERT engines that also meet Stage IV emission standards.<br />
The new engines deliver more power than their K-Series<br />
predecessors and contribute to a potential<br />
10% gain in fuel efficiency (25% better than<br />
the H series). This was achieved from the<br />
enhanced performance of the redesigned<br />
hydraulic system and the new engine,<br />
which works at a lower average speed and<br />
creates less heat.<br />
An improved interface between the<br />
operator and machine controls further<br />
boosts production potential, and the new<br />
Cat Payload Measurement system enables<br />
operators to confidently deliver exact<br />
loads, while allowing managers to monitor<br />
machine productivity.<br />
The new models also feature major drive-train refinement,<br />
new cab amenities, optimized Z-bar linkage and a<br />
range of Cat Performance Series buckets and work tools<br />
that expand overall machine versatility.<br />
In the cab, the new electro-hydraulic joystick steering<br />
is also available on the 950M and 962M featuring speed<br />
sensing force feedback for unparalleled comfort and control.<br />
A new multipurpose color touch screen display dramatically<br />
simplifies the operator interface with machine<br />
controls, rear vision camera and the new fully integrated<br />
Cat Production Measurement system.<br />
The mobile scale device accuately loads truck, stores<br />
the data and can, via the optional printer, produce a receipt<br />
of the amont of material loaded. This system is not<br />
yet certifiable for accuracy, as required by local authoriaties<br />
and regulators, but it is only a matter of time before the<br />
technology proves itself. At that time, it will be possible to<br />
dispense with manned weightbridges.<br />
Stair-like steps and repositioned grab handles facilitate<br />
safely entering and exiting the M-Series cab, as does the<br />
wider door opening. An available switch in the electronic<br />
service center allows ground-level unlatching of the door,<br />
which then swings open via a gas strut.<br />
A heavier counterweight and a larger bucket capablity<br />
means 20 t. trucks can be loaded in 3 passes.<br />
Improving Markets<br />
Paolo Fellin, Vice President - Global Construction &<br />
Infrastructure said that they expect to see a continued<br />
growth out of the depressed markets within Europe but it<br />
will become a more competitive market.<br />
One reason for this could be Chinese manufacturers<br />
looking to export as local demand<br />
decreases. There is a general concensus<br />
that the markets will find a new level some<br />
58% below the peak of 2008 but signficantly<br />
higher the the low experienced in 2009.<br />
Mr Fellin explained how fully integrated<br />
technology is enabling Cat customers to<br />
benefit. In truck loading, by loading to optimum<br />
level, maximum efficiency is achieved<br />
with less spillage from overloading. For<br />
highway trucks, overloading can result in a<br />
costly fine, being able to measure loading<br />
eliminates this.<br />
Enhanced bucket loading features, return to dig, etc<br />
also contribute to fewer passes which translates to less<br />
fuel.<br />
Fleet owners and plant hire companies have also welcomed<br />
the opportunity to manage their equipment in real<br />
time. To see where delays are occuring and to track machine<br />
usage and location.<br />
• Caterpillar<br />
Contractors World International Vol 6 No 1<br />
Page 53
What’s New In Plant & Equipment<br />
Case N Series Backhoes<br />
Go Tier 4 Final<br />
Case Construction Equipment introduces its line of Tier<br />
4 Final backhoe loaders, including the new 580N EP –<br />
a lower-horsepower version of the company’s 580N<br />
backhoe that maintains the same backhoe lift capacity<br />
and breakout force with greater fuel efficiency and a<br />
maintenance-free Tier 4 Final solution.<br />
All Case N Series backhoes come standard with<br />
SiteWatch telematics, and can be outfitted with a variety<br />
of industry-exclusive standards/options such as<br />
Power Lift, Ride Control, Comfort Steer, ProControl,<br />
Easy Flex side lights and a mechanical universal backhoe<br />
bucket coupler that allows contractors to use attachments<br />
from competitive machines on their Case backhoe.<br />
Each machine is also available in the proven CASE<br />
Extendahoe configuration for extended digging and reach<br />
capabilities.<br />
All CASE N Series backhoes feature the company’s overcenter<br />
design, which transfers weight to the front of the<br />
machine for smooth roading and better traction, and allows<br />
the operator to dig closer to the machine.<br />
Controls on the N Series are simpler, with adjustable<br />
pilot control towers, a control pattern selector and adjustable<br />
wrist rests. Each machine also comes standard with<br />
Adjustable SmartClutch, which lets operators customize<br />
the feel of forward-to-reverse transitions (smooth, moderate<br />
or aggressive) to their preference.<br />
The full range of N Series backhoes feature the SmartFit<br />
bucket tooth system, which features heavy-duty self-sharpening<br />
teeth and a hammerless fastener system for easy<br />
installation.<br />
The New Case 580N EP<br />
The Case 580N EP is designed for contractors just getting<br />
started and the rental market, with lower owning and operating<br />
costs and a maintenance-free Tier 4 Final solution.<br />
The 580N EP features particulate matter catalyst – a<br />
combination of a diesel oxidation catalyst (DOC) and a<br />
high-efficiency flow-through filter that requires no fluids<br />
and no diesel particulate filter (DPF) maintenance/upkeep.<br />
At 74 horsepower – and with a backhoe bucket breakout<br />
force of 11,517 pounds, backhoe lift capacity of 2,858<br />
pounds, and peak torque of 233 foot-pounds – the latest<br />
model provides ample power and performance while<br />
still keeping fuel, maintenance, and owning and operating<br />
costs low.<br />
While the new model is designed to optimize efficiency<br />
and power for price-conscious buyers, it can be outfitted<br />
with a full selection of options for greater machine and attachment<br />
flexibility.<br />
All remaining Case N Series backhoes – the 580N, 580<br />
Super N, 580 Super N Wide Track and 590 Super N – feature<br />
new Fiat Powertrain (FPT) engines with selective catalytic<br />
reduction (SCR) technology to meet Tier 4 Final standards.<br />
The system does not include a DPF or any other components<br />
that require intensive/long-term maintenance or<br />
regeneration. Operators who remember to top up the diesel<br />
exhaust fluid (DEF) tank when they refuel will notice<br />
no additional regular maintenance activities with the new<br />
solution.<br />
• Case America<br />
New from JLG at the<br />
Rental Show<br />
JLG Industries, Inc launched its 53 ft (16.15 m) rough-terrain scissor lift<br />
at the 2015 Rental Show - a high-capacity scissor lift that lets operators<br />
place more personnel, tools and materials in the platform for more<br />
productive shifts.<br />
With an operating weight of 17,000 lb ( 7,711.07 kg) and platform<br />
load capacity of 1,500 lb (680 kg), the latest introduction has steel<br />
hoods for toughness and automatic levelling of the outriggers for rapid<br />
set up.<br />
It features a standard four-foot multi-position roll out platform<br />
Page 54 Contractors World International Vol 6 No 1
What’s New In Plant & Equipment<br />
extension that is both smooth and easy to use. For even<br />
more space, customers can add an optional four-foot<br />
platform extension, with load capacity of 500 lb (226.80<br />
kg)<br />
Paul Kreutzwiser, JLG Industries’ global product director<br />
for scissors and vertical lifts said:<br />
“The JLG 5394RT gives users the big-job reach they<br />
need and the serviceability they want. The engine<br />
compartment offers easy access to all service<br />
points and a swing out tray for more serious work.<br />
The tilt-down modular ladders are easily lowered<br />
or removed for even better component access.”<br />
This machine offers excellent 40% gradeability and is<br />
well suited to commercial construction, steel erection,<br />
panelling installation, and stadium and convention center<br />
construction. It should also find use for on-location<br />
shooting for TV and movie productions, as well as sporting<br />
events.<br />
Travel speed with platform elevated is 0.50 mph (0.80<br />
km/h). With the platform lowered, maximum speed is 4<br />
mph (5.63 km/h). Power is via a Kubota diesel engine rate<br />
at 18.5 kW<br />
New Telehandler<br />
JLG also used the Rental Show to launched the G15-44A<br />
telehandler – the largest telehandler in the JLG line.<br />
Designed for the North American market, the JLG G15-<br />
44A has a 15,000 pound capacity and what the company<br />
claim to be several class-leading distinctions among comparable<br />
heavy-duty telehandlers, including:<br />
Xsite excavator<br />
control systems<br />
The modular structure of MOBA’s Xsite range of excavation<br />
systems offers a high level of flexibility, providing you with<br />
a suitable solution for every project, whether it be small or<br />
large.<br />
The 2D system is an entry-level system that provides all<br />
the 2D functions for smaller projects. This unit includes a<br />
• 31 foot horizontal reach<br />
• 18 inch ground clearance<br />
• 20 mph maximum travel speed<br />
• 61 second boom cycle time<br />
The machine has, for this size, a very tight outside<br />
turning radius of 14 ft 6” (4.42 m) and a low gross vehicle<br />
weight of 32500 lb. It is powered by a 130 -horsepower<br />
Tier 4i Cummins 4.5L diesel engine that is powerful, reliable<br />
and delivers 130 hp / 96.98 kW<br />
• JLG Industries<br />
large touchscreen display with the option of upgrading to<br />
3D at any time.<br />
Only the GNSS extension must be added to be able to<br />
work in 3D. By doing so, you can create simple 3D profiles<br />
directly on site.<br />
Measuring and checking work is reduced because of<br />
the system’s GNSS positioning functionality.<br />
The high-end 3D system offers even more 3D functions:<br />
for example, 3D models can be read and used in all widelyavailable<br />
formats and without the need for any conversion<br />
processes. All data is saved for later documentation and<br />
its cable-free data exchange capacity allows fast transfer of<br />
information from office to construction site and vice versa.<br />
• MOBA<br />
Svantek’s New Sound<br />
Monitoring Device<br />
Svantek UK has introduced the a new, low cost yet practical<br />
miniature outdoor logging of environmental sound system<br />
(MOLES) capable of providing constant monitoring for<br />
up to four weeks on a single charge<br />
Contractors World International Vol 6 No 1<br />
Page 55
What’s New In Plant & Equipment<br />
Using Svantek’s Class<br />
1 SVAN 971 sound level<br />
meter and featuring a<br />
weatherproof, robust<br />
and compact design<br />
with IP65 protection<br />
level, the MOLES is<br />
a fully autonomous<br />
environmental noise<br />
monitoring solution<br />
that can be easily deployed<br />
in the field.<br />
Lightweight and long-lasting, the internal batteries can<br />
be swapped without interrupting measurement. External<br />
batteries can be added to extend life to eight weeks or<br />
more.<br />
The system is available with options for 1/1 and 1/3<br />
octave real-time analysis and triggered audio recording. It<br />
also offers two in 10 audio recording making it ideal for<br />
measuring levels of noise from wind turbines.<br />
The units are supplied with free SvanPC++ software<br />
with the option of environmental calculations / tonal assessment.<br />
They provide 4GB storage capacity and data can<br />
be stored on a micro SD card.<br />
John Shelton, Managing Director at Svantek comments:<br />
“The MOLES is based on our diminutive and well<br />
proven SVAN 971 instrument. It is an integrated<br />
kit with long-term rechargeable battery<br />
and outdoor protection for both meter and<br />
microphone. Extremely cost effective, it is perfect<br />
for independent environmental noise assessors or<br />
larger consultancies.”<br />
Tier IV Portable<br />
Genset<br />
• Svantek<br />
Atlas Copco Portable Energy heavy-duty QAS 45 portable<br />
generator features an Isuzu 4LE2X engine and a diesel<br />
oxidation catalyst (DOC) to achieve Tier 4 Final emission<br />
levels. The QAS 45 is rated for 45 kVA of prime power for<br />
applications such as construction, oil and gas, rental and<br />
large events.<br />
The generator is designed for predictable<br />
power and optimal operation, The unit<br />
is equipped with a Leroy Somer AREP alternator<br />
and features a 72.5-gallon fuel tank for<br />
run times as long as 30-hours under typical<br />
loads. DeepSea 4510 controls complete<br />
the package.<br />
capability and all functions are set with warning and showdown<br />
safety limits that can be easily customized by the<br />
user.<br />
The generator has been designed for versatility with<br />
its standard voltage selector switch that allows operators<br />
to adjust the machine’s output to 480/277, 208/120 and<br />
240/139 volt 3-phase settings, as well as 120/240 volt single<br />
phase for varying applications and equipment.<br />
This versatility gives users greater flexibility on jobsites<br />
and can increase utilization at rental centers. Operators<br />
can lock the front panel voltage adjust potentiometer to<br />
prevent unintentional adjustments to the voltage, which<br />
can cause overheating or equipment damage.<br />
In addition, the genset features two 120vac GFCI duplex<br />
receptacles that are always powered, so contractors<br />
can operate small hand tools while running larger loads.<br />
The low decibel levels means it can be used on noisesensitive<br />
jobsites and residential areas with its soundattenuated<br />
enclosure and a vertical radiator and exhaust<br />
discharge. The spillage free base-frame is sized for 110 percent<br />
containment of all the machines fluids and fuel, giving<br />
users confidence in the most environmentally sensitive<br />
areas.<br />
Maintenance was a key factor when the QAS 45 was<br />
designed. Large access doors and single side maintenance<br />
ensures that service downtime is kept to a minimum. The<br />
DOC after-treatment device requires no regeneration or<br />
maintenance.<br />
The engine meets Tier 4 Final emission standards without<br />
the need for diesel exhaust fluid or a diesel particulate<br />
filter system, thereby eliminating any maintenance for<br />
those systems.<br />
Further, engine fluids are plumbed to the edge of the<br />
skid to eliminate the hassle of maneuvering pans into the<br />
interior space. And, the extended life filters have 500-hour<br />
service intervals resulting in reduced maintenance costs.<br />
The unit comes equipped on a class-leading single axle<br />
trailer with robust tie-downs for safe transport on a flatbed.<br />
The unit also can be skid mounted for easy movement<br />
with a forklift. All units come with an integral standard single-point<br />
lifting eye in the enclosure for manoeuvring with<br />
a crane, and is rated for lifting the complete genset with<br />
trailer and fuel.<br />
• Atlas Copco<br />
Portable Power<br />
The backlit display shows all critical<br />
machine information, which can be viewed<br />
through a clear viewing panel in the door.<br />
The generator controller features remote start<br />
Page 56 Contractors World International Vol 6 No 1
What’s New In Plant & Equipment<br />
New floor saws<br />
from Wacker<br />
Neuson<br />
Wacker Neuson revises the gasoline-driven<br />
floor saws and reduces<br />
HAV.<br />
The gasoline-driven<br />
floor saws from<br />
Wacker Neuson have been revised and<br />
now offer additional benefits for end users and contractors.<br />
The redesign has resulted in reducing the hand-arm<br />
vibrations (HAV) even further and now below the exposure<br />
level of 5 m/s² specified by the EU. This enables longer operating<br />
times and fatigue-free working.<br />
The new floor saw series includes four models - BFS<br />
735, BFS 940, BFS 1345 and BFS 1350 - with blade diameters<br />
from 350 to 500 mm. The wheel base has been optimized<br />
to provide a wide track with a short wheel center<br />
distance for optimal stability and controllability. All models<br />
are equipped with Honda gasoline engines.<br />
The full-frame chassis is constructed from high tensile<br />
strength steel for rigidity of the frame without increasing<br />
the weight.<br />
As the center of gravity is located precisely over the cutting<br />
axle, the cutting force of the blade is maximized in<br />
combination with an optimal coordination of the torque.<br />
Wacker Neuson claim that the performance of the floor<br />
saws is 20 per cent higher than with comparable equipment.<br />
Through the infinitely adjustable cutting depth from<br />
120 to 195 millimetres, the gasoline-driven floor saws produce<br />
a high quality, clean cut in various materials. The double-face<br />
water sprinkling ensures a long service life of the<br />
blade and therefore saves costs.<br />
• Wacker Neuson<br />
Takeuchi TB280FR<br />
Tier IV Final<br />
Excavator<br />
A multi-function colour display<br />
monitor puts the operator in complete<br />
control by providing a clear and instant<br />
view of all vital systems such as particulate<br />
matter accumulation and the lift/load percentage<br />
on the craning safety system.<br />
The auxiliary output flow has been increased<br />
and is selectable between 148 l/m and 58 l/m,<br />
providing a better match for certain types of accessory<br />
tools.<br />
A factory fitted twin pump flow (Hyflow) is<br />
now standard – a feature that will appeal to drilling contractors<br />
who appreciate the excavator’s capability to drill<br />
very close to its track frames.<br />
The TB280FR has a standard operating mass of 8,653 kg,<br />
putting the excavator in the CCF 7.5 class (7.5 to 10 tonnes),<br />
however the machine’s operating mass when rigged with a<br />
hydraulic hitch and GP bucket will be closer to 9 tonnes. If<br />
fitted with optional steel tracks with rubber pads, this will<br />
add additional mass of 205 kg.<br />
What was previously the medium length stick is now<br />
standard equipment, giving a maximum digging depth of<br />
4,885 mm (including the hydraulic hitch).<br />
The new TB280FR retains its unique Full Zero Turn capability,<br />
thanks to its patented side shifting boom system.<br />
This enables the machine to work between two walls, excavating<br />
at the front and being able to load a truck placed<br />
behind the excavator.<br />
A major advance is a cabin that features integral ROPS<br />
& FOPS level II protection, with the addition of a retractable<br />
sun shade.<br />
The TB280FR also retains Takeuchi’s signature self-adjusting<br />
track tensioning system, triple flanged track rollers,<br />
two way control pattern selector, pilot system accumulator,<br />
auto downshift drive motors and numerous other Takeuchi<br />
innovations.<br />
• Takeuchi USA<br />
The Takeuchi TB280FR excavator has been released<br />
in to the North American and Australian markets<br />
. It has more power, greater dig depth and reach<br />
as well as higher tractive forces than the model it<br />
supersedes.<br />
The new Tier IV final specification of the Yanmar<br />
4TNV98CT diesel engine provides 51.6 kW Gross<br />
power for potentially a ten percent productivity<br />
improvement.<br />
Owners of the TB280FR are able to optimise fuel<br />
consumption with the excavator’s auto engine idle<br />
system.<br />
Contractors World International Vol 6 No 1<br />
Page 57
What’s New In Plant & Equipment<br />
New TC120<br />
Tank Cutter<br />
Attachment<br />
The new Brokk TC120 Tank Cutter attachment is<br />
manufactured by their associate company, Darda.<br />
The attachment delivers maximum cutting control<br />
and the versatility for continuous steel cutting<br />
abilities.<br />
The 1,194 mm x 432 mm (47” x 17”) tank cutter<br />
can be used with the Brokk 160, 260 and 400<br />
model. It adds more flexibility to the jobsite with<br />
its hydraulic rotation capabilities and 127 mm<br />
(5”) wide jaws. It exerts 75 tons of cutting force<br />
at 7,250 psi to easily cut through half-inch thick<br />
steel plate.<br />
Although this attachment can be used in a variety of<br />
applications, such as in salvage yards and balers, it’s commonly<br />
employed for cutting steel tanks, pipes and vessels.<br />
By using the electric Brokk machine with the TC120 instead,<br />
operators reduce the risk of exposure to toxic emissions<br />
as well as preventing fires as exists with oxy-cutting<br />
methods.<br />
The TC120 attachment also benefits contractors with<br />
its extended reach. Brokk machines’ remote capabilities,<br />
coupled with arms that extend as far as 8.2 m (27’), easily<br />
reach restriced places, improving efficiency while minimizing<br />
labour costs.<br />
• Brokk<br />
New Enerpac Hydraulic Torque<br />
Wrenches<br />
Enerpac is replacing the standard S & W-Series torque<br />
wrenches with the new, enhanced “X-Edition” tools.<br />
These “X-Edition” tools are very compatible with the<br />
current S & W tools, but have several new features to help<br />
increase safety, performance and durability for operators.<br />
Key innovations include:<br />
Safety: A robust new manifold design with a unique<br />
recessed sealing face provides excellent safety and endurance.<br />
Tough new positioning handles, plus an additional<br />
handle mounting option for narrow access applications, facilitate<br />
safe fastening by keeping operators’ hands clear of<br />
pinch points in even hard to reach areas.<br />
Performance: Each X-Edition S-Series wrench and<br />
W-Series cassette is factory tested and calibrated, providing<br />
users with performance verification right from the start.<br />
A CE-ATEX statement is provided with every X-Edition<br />
tool, enabling operators to use these tools with confidence,<br />
even in explosive environments.<br />
An optional angle of turn attachment provides measurement<br />
of rotation for X-Edition S-Series tools.<br />
Durability: A tough new tilt and swivel manifold provides<br />
horizontal and vertical manoeuvrability with greater<br />
durability, and fits all X-Edition S & W-Series torque<br />
wrenches.<br />
Enerpac will continue to provide service parts for existing<br />
tools. The standard S & W-Series tools will however be<br />
phased out, and be replaced by the new X-Edition tools.<br />
• Enerpac<br />
Page 58 Contractors World International Vol 6 No 1
COMPANIES FEATURED<br />
• Archer Western<br />
• Manitowoc France<br />
• Atlas Copco Portable Power<br />
• MOBA<br />
• Aydin Vinc A.S.<br />
• Montabert<br />
• Bobcat<br />
• P J Edwards<br />
• Brokk<br />
• Paschal Werk<br />
• Broons Pty<br />
• Peri<br />
• Case Europe<br />
• Pilosio<br />
• Case USA<br />
• Rigmarine<br />
• Caterpillar<br />
• Royal Boskalis<br />
• Cifa Concrete Pumps<br />
• SATECO<br />
• Clugston Construction<br />
• Semco<br />
• Conjet<br />
• Sennebogen<br />
• DHybrid<br />
• Skanska USA<br />
• Doka Formwork<br />
• Steele Construction<br />
• Doosan<br />
• Strassacker Foundry<br />
• EFCO<br />
• STRUCTURAL Contractors<br />
• Enerpac<br />
• Svantek UK<br />
• Fast-Form Systems<br />
• Takeuchi USA<br />
• Groundforce<br />
• Tata Steel<br />
• Groutech<br />
• Terex Construction<br />
• Herrenknecht<br />
• Tracto-Technik<br />
• Hitachi Construction Machinery<br />
• Trinity Infrastructure<br />
• Hyundai Heavy Industries<br />
• Turner Access<br />
• Intermat 2015<br />
• ULMA<br />
• JLG Industries<br />
• Volvo Construction Equipment<br />
• Komatsu Europe<br />
• Wacker Neuson<br />
• Liebherr Cranes<br />
• Wirtgen<br />
• Mammoet<br />
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Contractors World International Vol 6 No 1<br />
Page 59
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