The 4h pumping of Neufahrn: Large boom team places ... - Putzmeister

With a tunnel concreting
train in the city tunnel of
Malmö
Post
The magazine by Putzmeister Concrete Pumps GmbH 80
How long do truckmounted
concrete
pumps last?
Telebelt at the thirdlargest
embankment
dam in the world
The 4h pumping of
Neufahrn: Large boom
team places concrete at
motorway interchange
PM 4356 GB
1

Content Content / worth knowing
Title story
Munich: Motorway interchange at Neufahrn
24-hour concreting with two large booms 4
On site
Five of the largest stationary booms in the world used for the job
Large construction site in central Russia relies on
Putzmeister equipment 10
China: Telebelt conveys concrete for dam project
The third largest hydro-electric power plant in the world arises 14
50 questions
How long do truck-mounted concrete pumps last?
No old iron here – veterans on the construction site 1
Underground
Sweden: on track with Putzmeister in the Malmö city tunnel
Tunnel concreting train enables precise concreting
of the slab track 18
In brief
Governor of Baghdad visits Putzmeister
“Perilous ride on the wild buffalo”
An unusual tourist at the North Cape
Worth knowing
Exhibition dates / Interesting facts
Photo credits
Imprint
4
1
Photo credits:
Less traffic jam:
A motorway interchange
is being reconstructed
You may well ask:
How long do
concrete pumps last?
Unless indicated otherwise, all illustrations are copyright
Putzmeister Concrete Pumps GmbH.
17: Kernkraftwerk_Nowoworonesch_II, Wikimedia Commons,
licensed under CreativeCommons license by-sa-
3.0, Rosenergoatom · 24: China_edcp_location_map,
Wikimedia Commons, licensed under CreativeCommons
license by-sa-3.0, Uwe Dedering · 25: Putzmeister Machinery
(Shanghai) Co., Ltd. · 34: Citytunneln_karta,
Wikimedia Commons, licensed under CreativeCommons
license by-sa-3.0, Rjaber · 40: Feste_Fahrbahn_FFBögl,
Wikimedia Commons, licensed under CreativeCommons
license by-sa-2.0, Jailbird · 45: www.demis.nl · 46: Nordkapp_2010,
Wikimedia Commons, Hapesoft
3 4
Imprint:
PM 4356 GB PM 4356 GB
14
More power: Telebelt
places concrete for
hydro-electric plant
Editor:
Putzmeister Concrete Pumps GmbH
Max-Eyth-Str. 10
72631 Aichtal · Germany
Editorial department:
Volker Wehner, Petra Montag
Putzmeister Concrete Pumps GmbH
Layout/DTP: Petra Montag
Putzmeister Concrete Pumps GmbH
Print:
Offizin Scheufele GmbH & Co. KG
Tränkestr. 17
70597 Stuttgart · Germany
All rights and technical amendments reserved.
Although content is checked carefully, we
accept no liability for sites to which links
are given. The operators of external websites
are solely liable for their content.
Some of the illustrations show special machine
variants and snapshots which do not
always comply with the regulations of the
Industrial Employers’ Liability Insurance
Association.
© by Putzmeister Concrete Pumps GmbH
2010 · Printed in Germany (3.51012)
2
Exhibition
dates
January – April 011
18. – 21.01.2011
WOC World Of Concrete,
Las Vegas/USA
08. – 11.02.2011
bC India, Mumbai/India
22. – 26.03.2011
ConExpo, Las Vegas/USA
06. – 08.04.2011
USETEC, Cologne/Germany
By the way…
In 2009, a total of 1,338 customers
took part in 74 Putzmeister Academy
seminars, with numbers growing
all the time.
Over a lengthy period, concrete
pump owners have observed the
effects of their machine operators
undertaking training sessions with
resulting qualifications on their accident
frequency and costs. The results
show clearly that investment
in training pays off.
worth
know
ing
5

Title story Title story
4-hour pumping at Neufahrn:
The large-boom team concretes
at the motorway junction
Position M 6 -6
City
Munich
Position M 58-5
✈
Munich
6
On the morning of 4th August, two largeboom
concrete pumps arrived at the Neufahrn
motorway junction north of Munich
– one M 58-5 from Berger Beton and one
M 6 -6 from BFM Betonförderdienst in
Munich.
A sunny, almost autumnal day announces
itself with hazy, mild air and single wisps
of low cloud. The weather will stay beautiful
– perfect for the planned 4-hour
concreting that is due to take place today.
One notices the men on the construction
site are in a good mood – the best prerequisite
for starting the work and for the
challenging task that lies ahead of them.
Narrow junction at Neufahrn
This structure, which, when viewed from
above, looks like a fl atly pressed four-leaf
clover, can no longer cope with today‘s traffi c
volumes. Two national motorways intersect
at the Neufahrn junction – the A 9 and the
A 92. Along with the Munich motorway
ringroad (A 99) and the A 8 Ulm-Munich-
Salzburg, the A 9 is the most important north-south
route, especially for domestic and
international commercial and holiday traffi c.
The A 92 connects the state capital of Munich
with its airport and is also important
for Eastern European traffi c.
View of the construction site from the southern ramp.
The column for the nd bridge section has already been formed.
p The M 6 -6 on the north-western
ramp at the motorway junction
4 5
7
8

Title story Title story
The average volume of traffi c from the airport
towards Munich is currently approximately
24,000 vehicles in 24 hours. An
average daily traffi c fl ow of approximately
38,000 vehicles in 24 hours is predicted for
the year 2020. On average, that would be approximately
1,600 vehicles travelling via the
Neufahrn junction per hour – not to mention
rush-hour traffi c.
Large-scale reconstruction is required
In view of this projection, the only option is
a speedy connection via the existing motorway
junction using a direct ramp. The current
single-lane exit via a quadrant of the
„clover“ will be completely replaced by a so-
called „fl yover“ that channels a two-lane carriageway
from the A 92 to the A 9 towards
the south.
The customer is Autobahndirektion Südbayern
and the contractor is Hentschke Bau
GmbH in Bautzen.
The construction work at the Neufahrn motorway
junction commenced in April 2009
with the reconstruction of a connecting
ramp and the spillage that is required to
build the new bridge, with 110,000 cubic
metres of delivered soil. In 2010, comprehensive
excavation and ceiling work took
place at the Neufahrn motorway junction,
as well as bridge construction work in the
whole area. The construction project should
be complete by the end of 2011.
q In a good mood and with everything under control:
Harry Kirchmaier drives the M 6 -6 from BFM and Stefan Vogel drives the M 58-5
from Berger
10
p Dipl.-Ing. (engineering masters) Felix
Raschke, site manager for Hentschke
Bau GmbH, the company commissioned
for the project
9
Flyover concreted in two sections
Back to the concreting at the „fl yover“: Dipl.-
Ing. (masters in engineering) Felix Raschke,
the site manager, explains: „Today, we are
concreting section 1 of the ‚Flyover‘“.That is
the longer stretch, at 120 m. We started work
on the carcass in February of this year and
the construction work will continue until October.
After that comes the 2nd section – the
road section that is 80 m long.“In answering
the question about the particularities of this
motorway construction site, he responded
saying that the scaffolding work could only
be carried out at night. It was extremely important
that the motorway was completely
closed for this work and the strict compliance
with closing times applied here.
Concreting commenced at 6 a.m. Each of
the two truck-mounted concrete pumps
stands fully-supported at the foot of one of
the construction columns within one of the
northern clover quadrants of the motorway
junction. From this location, they pump concrete
to the sites of concrete placement on
the approx. 12 m high bridge. Meanwhile,
the traffi c fl ows freely on the circular paths
of the exits and under the structure.
At the beginning, the end hoses of both booms
and the respective machine operator of each
concrete pump met in the middle of the bridge
construction site. From there, each of them
works outwards.The horizontal reach of the
q The pumping duo started the concreting in the centre of the 1 0 m bridge.
From there, the booms move away from each other as they work.
large boom is fully utilised. The high level of
fl exibility of the 6-arm or 5-arm boom was an
important criteria for the managing directors
of BFM and Berger when they were making
the decision for a new large boom. When used
together with the sensitive Ergonic ® control,
the strengths of two booms can be fully utilised
in a situation such as this.
The M 62-6 from BFM and the M 58-5 from
Berger Beton have the longest horizontal
reach of any pumps across Bavaria. With
each having fl eets of more than forty concrete
pumps, both of these companies are among
the largest service providers in the state of
Bavaria.
6 PM 4356 GB PM 4356 GB 7
11

Title story Title story
In 24 hours, a total of approx. 2,000 m 3 of
concrete C40/50 was placed with a compressive
strength of 42.5 N/mm 2 (exposition
classes XC4, XD1, XF2). This is the quantity
of concrete for the entire cross-section of the
structure of section 1 including footbridges
and carriageway slabs (see the box containing
data about the concreting). The complete
superstructure (sections 1 and 2) will
contain 3,400 m 3 of concrete.
So that traffi c can ultimately travel on the
road comfortably and safely, the fi nished
concrete surface receives another 8 cm thick
layer to the overall construction. The concrete
is fi rst primed and completely sealed
using epoxy resin. An asphalt sheeting (0.5
cm) comes next and then a protective layer
of mastic asphalt (3.5 cm thick). Finally, the
surface of the road is formed by a 4.0 cm
surface layer of stone mastic asphalt. n
Technical data of the concrete pumps on site
M 58-5 M 6 -6
Folding type 5-Arm roll-Z-fold 6-Arm roll-Z-fold
Vertical reach 57.6 m 61.1 m
Horizontal reach 53.6 m gross 57.1 m gross
49.4 m net 52.4 m net
Reach depth 42.4 m 44.3 m
Unfolding height 12.3 m 23 m
Delivery line DN 125, max. 85 bar Arm 1, 2 DN 125, max. 85 bar
Arm 3, 4, 5, 6 DN 117, max. 85 bar
Support width front / rear front / rear
normal approx. 11.1 m / approx. 11.5 m approx. 12.1 m / approx. 12.3 m
OSS approx. 8.7 m / approx. 8.0 m approx. 8.8 m / approx. 8.3 m
Properties of fresh concrete
Strength class C40/50
q In the middle of the motorway but nevertheless secure: The concreting is carried
out quietly while the traffi c can fl ow freely under the bridge construction.
This photo shows the M 58-5 on the north-eastern ramp.
12 13
Exposition classes XC4 Changing wet and dry (e.g. exterior components with direct
exposure to rainfall, components in water tidal zones)
XD1 Moderate moisture (e.g. components in areas where water
may spray from traffi c areas)
XF2 Moderate water saturation with de-icing agents (e.g. concrete
components in areas where water may spray from traffi c
areas that have been treated with de-icing agents)
t To determine the water content, the
concrete is heated up until it no longer
contains any liquid.The difference in
weight can be used to determine the
water content.
8 PM 4356 GB PM 4356 GB 9
Steel used
Untensioned reinforced steel 280 t Prestressing steel 107 t
Thickness of the layer of placed concrete
in the area of the webs 2.40 m in the centre of the carriageway 0.35 cm
q After a quick clean, the truck mixers
rejoin the queue of motorway traffi c in
order to fetch more concrete
14
‚ Exposition classes
and what they mean
To ensure that the durability is suffi cient,
concrete components must be strong
enough to withstand chemical and physical
impact on their environment and
their use. The impacts from the various
environmental conditions are classifi ed
into exposition classes that may have an
impact on the concrete, the reinforcing
steel and metallic components and that
are not accounted for as loads during
the constructive assessment. From this,
the requirements are derived for the
composition of the concrete to be used,
as well as the concrete cover and the
permitted crack width.
The designations for the individual exposition
classes are made up of the letter
X (for exposition), the identifi cation
for the type of damaging effect and a
number that denotes the intensity of the
damaging effects. The following abbreviations
are used from English for the
various types of effects:
0 for zero risk (no risk of attack)
C for carbonation
D for de-icing salt (chlorides that are
capable of changing, e.g. from deicing
salt)
S for seawater
F for frost (frost and de-icing salt)
A for chemical attack
M for mechanical abrasion, wear, or
similar
The strength of the relevant ambient
condition is assigned a classifi cation
from 1 to 4.
In Germany, the exposition classes are
regulated by DIN 1045-1 (08-2008).
In contrast to the previous version from
2001, the effect W „concrete corrosion
due to alkali silicic acid“ has been added
to the exposition classes. No minimum
concrete strength class is assigned to
this exposition.
[Source: wikipedia.de, licensed under
http://creativecommons.org/licenses/by-sa/3.0/deed.de.]

On site On site
Five MXKD 50 at a major nuclear power
plant construction site in central Russia
Five of the largest stationary booms in the
world – Putzmeister MXKD 50 – are taking
part in the construction of the Novovoronezh
NPP-2 nuclear power plant on the banks of
the Don river. At the end of 2009, Putzmeister
was awarded a contract to provide the equipment
for concrete distribution at the reactor
block: Five placing booms with a horizontal
reach of 50 m (fi tted on Manitowoc/Potain lattice
towers up 50 m tall), two BSA 2110 HP-D
stationary concrete pumps and a 300 m
ZX 125 delivery line.
At the start of 2010 and on a total of 10
tautliners (trucks that have a sliding curtain
for crane loading), the disassembled booms
travelled from the factory in Gründau to
Putzmeister‘s Russian headquarters in Moscow.
From there, the booms travelled on to
the site of use, approx. 500 km further south
in Novovoronezh. n
Technical data MXKD 50
Number of arms 4
Folding type Roll fold
Horizontal reach 49.9 m gross
Reach depth 39.2 m
Vertical reach 46.5 m
Weight 37,550 kg
p Disassembled and loaded: A total of ten trucks rolled on to Russia
15
p Autumn 010: Technicians from Putzmeister RUS travelled from Moscow and
are currently installing the concreting equipment at the huge construction site.
Novovoronezh-II-1
q With a horizontal reach of almost 50 m, the MXKD 50 is the largest stationary boom in the world on site
16 17
Reactor type WWER-1200 (AES 2006)
Power 1,085 MW (net)
1,170 MW (gross)
Start of construction 20.06.2007
Commissioning planned for 31.12.2012
Operator Rosenergoatom
10 11
18

50 questions 50 questions
6
Technology · Question 6
How long do truck-mounted
concrete pumps last?
19
21
Even Putzmeister engineers continue to
be surprised by how long truck-mounted
concrete pumps can be in service: some
machines have almost 40 years of service
under their belt.
Luckily, Putzmeister‘s Services department
employs true experts when it comes to spare
parts for old truck-mounted concrete pumps:
“Our computerised spare parts management
only began in 1983. Before then, everything
was done in our heads or was found in old
documents.”
Several times a month, we receive requests
that can only be solved by human intelligence.
One such example is the water-hydraulic
driven concrete pump B232, manufactured
in 1971. To put this machine out of
service has never crossed the mind of the
Polish entrepreneur Grzegorz Kujawski. He
regularly orders new spare parts.
What makes truck-mounted concrete
pumps grow old
Three factors determine the service life of a
truck-mounted concrete pump:
• how the machine is serviced and
maintained,
• the number of hours that it is in
operation,
• and the quantity of concrete that is
pumped.
p B / 9 years old/Poland
This water-hydraulic driven concrete pump B has been in use since 1971. Even in
008, it was still pumping a daily volume of 150 cubic metres of concrete.
According to the requirements that
Putzmeister‘s engineers are given, the
truck-mounted concrete pumps should be
able to keep working for at least 10 years.
The critical factor here is the design of the
placing boom. During pumping operations,
the boom is particularly stressed by the
load shifting. The number of load changes
is determined by the pump output and the
operating hours.
Anti-aging – past and present
In the past, designers could rely upon their
knowledge and experience and consult with
others regarding standards and regulations.
If there was any doubt, they increased the
strength of the material at heavily-used
points on the placing boom. As early as the
end of the 1970s, Putzmeister owned a test
q M 45-5/ years old/Austria
This M 45-5 worked almost 1 ,000 operating hours over 0 years before getting a
new owner.
20
p M 1- / 7 years old/Cyprus
This M 1- “Triplet” that was manufactured in 198 is still in top form. For its 6th birthday in 00 , it underwent a major overhaul
and was affectionately given the name “Our favourite grandmother”, which was prominently displayed on the boom.
rig to simulate long periods of use. If the
boom passed the test, the design could go
into series production. In practice, something
became clear: The machines keep working
for considerably longer than 10 years – provided
that they are well maintained. As is
the case with the machine from Poland.
Since the beginning of the 1990s, the designers
have used finite element analysis
(FEM) to precisely calculate the stress on
the components. A screen in the software
programme shows the tension that will later
appear in the material and shows the critical
points. The design, material and material
thickness can then be optimised. Using a
new boom test rig, the engineers can simulate
years of the life-cycle of the boom at
high speed.
q M 46-5/7 years old/China
Since 00 , this M 46-5 has pumped an annual volume of 90,000 m in Shanghai!
That is three times more than the same machines in Europe.
Practical test in China
How well do the computer-optimised designs
actually work in practice? There are no machines
that are 40 years old yet. However,
there are truck-mounted concrete pumps
that have worked considerably more than
you would assume from their year of manufacture.
In China, young machines are already old.
The M 46 shown (year of manufacture:
2003) has worked non-stop since its delivery:
pumping volumes of 90,000 cubic metres
of concrete each year are the norm – at peak
times, the pumping volume increases to
up to 12,000 cubic metres of concrete each
month. By comparison: In Europe, large
boom truck-mounted concrete pumps deliver
approx. 30,000 cubic metres of concrete
each year. In terms of European machines,
this machine has already survived the required
10 years well – and it continues to
run and run and run. n
1 PM 4356 GB PM 4356 GB 1
22

On site
Telebelt conveys enormous masses
of concrete at the third-largest
embankment dam in the world
At the Jinsha River – a tributary of the
Yangtze – the Xiluodu hydro-electric
plant is currently being built. Its main
purpose is to generate electricity but it
also fulfi ls other tasks: fl ood protection,
deposition of sediment, improvement of
shipping conditions, etc. It is expected
to produce from 57 to 64 billion kilowatt
hours of electrical energy each year,
making this plant the third largest hydroelectric
plant in the world.
A double-curved arch dam should dam up a
storage lake of 12.67 billion m 3 . The absolute
elevation of the dam crest is 610 m, the maximum
height of the dam is 278 m and the
overall length is 700 m. The total excavated
material for this project amounts to 39.81
million m 3 of which 25.61 million m 3 is above-ground
excavation and 14.20 million m 3 is
from the construction of tunnels.
In total, 16.72 million m 3 of concrete is required
for this project and 6.60 million m 3 of
this is required just for the body of the wall.
The concreting work commenced in 2008. It
is expected that the fi rst generator sets can be
installed in June 2012. From June 2013, the
fi rst electrical energy should be generated
and the entire project should be completed
by 2015. US$ 7.36 billion has been invested
in the Xiluodu hydro-electric plant.
The devices in the Xiluodu dam that are
planned for fl ood water fl ow include seven
overfl ow drainage openings at a size of 12.5 m
x 13.5 m, below them eight outlets at a size
of 6 m x 6.7 m and four exceptionally large
overfl ow tunnels (with a diameter of up to
15 m) – two tunnels on the right embankment
and two more on the left. The overfl ow
capacity of the project amounts to up to
49,923 m 3 /s. The power that is generated by
the overfl ows is almost 100 million kilowatts
and is therefore the highest in the world. The
four overfl ow tunnels are the largest of their
kind in the world and have a discharge rate
of 16,000 m 3 /s, which is about a third of the
entire outlet capacity of the plant.
The water quantity and fl ow rate place
high demands on the concrete
These numbers are not just attributed to the
size of the tunnel but also to the fl ow rate
of the river, which is amongst the fastest in
the world (up to 50 m/s). Since these four
overfl ow tunnels were designed to cope with
exceptionally large quantities of water at an
extremely high fl ow rate, the concrete that is
used here must be of outstanding quality. The
difference between this concrete and a pumpable
concrete mix lies mainly in the proportions
of the individual concrete raw materials
23
‚ The longest river in Asia
with the changing name
The 6,300 km long Chang Jiang (also
known as the Yangtze - the “Long River”) is
the longest river in Asia and, after the Nile
and the Amazon, is the third-longest river
in the world. It originates as the Dri Chu
(Tibetan “river of the female yak”) from the
Ganjajubu glacier at an altitude of 5,405 m
and continues under the name of Jinsha
Jiang – “Gold Sands River” – from north
to south along the entire border between
Sichuan and Tibet. In the Hengduan Mountains,
it crosses the border between Sichuan
and Yunnan. From the city of Shuifu, it
fl ows under the name of Yangtze until it
reaches the East China Sea to the north of
Shanghai.
‚ The dam should reduce
sludge load
In the Red Basin, the Yangtze is fed by numerous
tributaries that drain, for example,
the eastern slopes of the Tibetan highlands.
T I B E T A N P L A T E A U
14 PM 4356 GB PM 4356 GB 15
TIBET
that are used. Pumpable concrete requires a
relatively high fl owability so that it can fl ow
through the delivery line. This means that
concrete raw materials such as cement and
fl y ash are required in large quantities. However,
cement creates a lot of hydration heat
when setting the concrete, meaning that the
temperature and crack formation are diffi cult
to control. The dissipation of the hydration
heat may pose a problem, particularly with
structures such as a dam.
25
Mekong
The tributaries feed the Yangtze with large
quantities of sand, silt and clay – an annual
quantity of approximately 680 million tons,
which is as much as the Nile, the Mississippi
and the Amazon together! This makes the
“Long River” one of the most sediment-rich
rivers in the world. Where it is damed – like
at the huge Three Gorges Dam – the fl ow
velocity of the water slowes down, sediment
is stored in the reservoir and gradually silts
up. The Xiluodu dam should counteract this.
It is expected that the dam should reduce
the quantity of sludge in the Yangtze by a
third.
‚ Mammoth producers
of energy
Once completed, the Xiluodu hydro-electric
plant will produce 12,600 MW of power.
This means that, with regard to power
plant capacity, it would be the secondlargest
hydro-electric plant in China after
the Three Gorges project and the third-largest
in the world. The China Yangtze Three
Gorges Project Development Corp. is plan-
Jinsha Jiang
YUNNAN
SICHUAN
Xiluodu
Dam
Telebelt comes out ahead
Telebelt is a mobile belt conveyor that can
continuously convey any kind of bulk materials
and concrete and is unrestricted by the
pumpability of the concrete. Telebelt is therefore
the perfect solution for pouring highquality
mass concrete as it not only means
that fewer cracks are formed but it also reduces
the costs for the concrete.
Yangtze
On site
ning three more giant hydro-electric plants
at the overfl ow of the Yangtze, namely Wudongde,
Baihetan and Xiangjiaba. At 38.5
million kWh each year, their combined
power generation should be double that of
the Three Gorges Project.
‚ Special confi guration:
Arch dam
In valleys that are very high and narrow,
the preferred dam to build is the arch dam.
The wall forms a vertically and horizontally
tensioned arch towards the side of the
water. Due to the arch-shaped design that
is directed against the fl ow of the river, the
mass of water is distributed over a larger
surface area and therefore puts less stress
on each unit of area. Signifi cantly fewer
materials are required to construct these
dams than are required for other types of
dams. However, the water pressure is diverted
over the arch to the foundations in
the mountain at the side. The attachment
to the rock is therefore particularly important
with this wall design.
Three Gorges
Dam
C h i n a
The fi rst Telebelt TB 105 delivered by
Putzmeister has been used in the Three
Gorges Dam project since the year 2000. To
date, the number of operating hours amounts
to more than 20,000 hours and the device
continues to work properly – clear proof of
the robustness and reliability of the Telebelt.
Due to this experience, the company responsible
for the Three Gorges project ordered
two more Telebelts of the new type TB 110G
for the team from SinoHydro Bureau 7. Since
24

On site
p Telebelt being used to concrete the cable crane platform
q Telebelt is placing concrete at the gate of a tunnel
16
26
the machines are very convenient to operate
and the boom can be gently and smoothly
telescoped, swung, lifted and lowered, the
two TB 110G devices are very popular on the
construction site. The machine has evoked
a positive response among the workers from
SinoHydro Bureau 7: Concrete pouring has
become child‘s play. However, if we look at
the quantity of concrete that the Telebelt
must continuously pour for each concreting –
more than 1,000 m 3 of concrete – it becomes
clear just how hard the work is for the workers
on the construction site.
Telebelt is in great demand across the
entire power plant construction site
The Xiluodu hydro-electric plant is a huge
construction site. Several projects are ongoing
at the same time and these are co-ordinated
centrally. The individual construction
teams work closely together.
It is often the case that immediately after one
concreting task has fi nished, the belt conveyor
travels to the next site of use on the
construction site. Thanks to its high levels of
fl exibility and mobility, the Telebelt is often
27
used “on the front line”. The TB 110G from
Putzmeister was therefore not only used on
the construction sites of SinoHydro Bureau 7
(in other words, to construct the overfl ow
tunnels, the foundations of the cable crane
structure and for above-ground concreting,
etc.), but it also considerably helped the
construction sites of Hydro Bureau 6 and Hydro
Bureau14 (among others) when constructing
the surge tank, the underwater outlet,
the main transformer building etc. As a result,
on one occasion, the Telebelt was used
on fi ve different construction sites within
six days, during which time it continuously
placed 4,800 m 3 of concrete for the overfl ow
tunnel, the cable crane platform and the underwater
outlet. The high level of effi ciency
demonstrated by the belt conveyor is another
performance feature that is recognised on
the construction site. For example, the TB
110G generally requires only 2.5 minutes
to drain a mixer of 6 m 3 for the work on the
cable crane platform and, at a slightly higher
speed, it requires only 1.8 minutes to drain
the mixer. This extremely high machine output
signifi cantly contributes to completing
the work within the scheduled time. ■
Greater versatility with Telebelt in
semi-trailer confi guration
• Chassis versatility meets local weight
restrictions
p Telebelt pumps concrete for the
overfl ow tunnel
u The aggregate in the concrete that is
used is up to 60 mm. A pump doesn‘t
stand a chance, but it‘s a “feast” for the
Telebelt.
• Greater mobility on-site
• Material placement does not rely on the
chassis engine
• Promotes lower operation costs and
reduced fuel consumption
On site
• Tandem Dolly available to move
Telebelt semi-trailer on-site with a
dozer, wheel loader or other available
equipment
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Underground
With the “Special train” to Sweden:
A slab track system is being
created in the Malmö city tunnel
A slab track is being laid in the tunnel
section with two individual 6 km tunnels.
The sleepers are embedded in concrete
and can absorb the vibration caused by
high-speed trains in a better way due to
having an extremely fl exible insert.
Maximum precision is required when the
tracks are installed. The sleeper shoes
that have been freshly embedded in the
concrete must not be subjected to vibration.
Even the slightest variations in the
alignment of the tracks can result in the
railway no longer complying with the original
designs for high-speed travel.
The order for constructing the slab track
in the Malmö city tunnel was placed with
Rhomberg Bahntechnik GmbH.
The objective was to fi nd a solution for installing
the concrete track bed over a distance
of two times six kilometres without a major
amount of vibration. The plan was to do the
concreting at a speed of 15 – 20 m/h.
Railway engineering specialist Rhomberg
(based in Bregenz in the Austrian Vorarlberg
area) made contact with the representative
of Austrian company Putzmeister, Hans Eibinger
GmbH. Together with the Concrete
Project Division department at the main
Putzmeister plant in Aichtal, all of the par-
ties involved collaborated to produce a solution
for supplying a tunnel concreting train
based on the patented installation solutions
of Rhomberg Bahntechnik.
Comprehensive planning
During the planning of the tunnel concreting
train it had to be taken into considera tion
that the freshly embedded sleeper shoes
could only bear a certain amount of load.
Beginning with the setting speed of the concrete
and the travel speed of the concreting
train, it was calculated that a distance of between
250 and 400 m had to be maintained
Fast connection: Malmö city tunnel
The city tunnel is a section of railway that is under construction
in Malmö/Sweden with an overall length of approx.
2 x 6 km.
The tunnel is intended to connect the rail traffi c
from Söderslätt with the Öresund rail traffi c,
turn the Malmö C main station into a transit
station, relieve the strain on the “Kontinentalbanan”
and increase the catchment area of
the Öresund rail traffi c.
The tunnel is being opened on
04.12.2010.
‚ www.citytunneln.com/en/
The project’s website (english)
Route:
Red = Tunnel section under construction
Yellow = Surface railway section under
construction
Grey = Completed sections
t The concreting train with electrically
operated concrete pump, which is fed
via a conveyor belt
Underground
p A locomotive with the rail wagon
shuttles between the concrete handover
point and the concreting train
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34

Underground Underground
p The patented concrete paving machine when embedding the sleeper shoes
between the concrete paving machine and
the pump unit. The entire pipeline would
therefore have to be made mobile. The pump
unit consists of an electrically powered concrete
pump and two mixing drums, whereby
the fi rst one would be used to supply the
system with fresh concrete, and the second
one would provide the concrete for ensuring
that a continuous concreting cycle could be
maintained.
Concreting train
The concreting train consists of various railway
wagons on which all of the necessary
components for carrying out a continuous
and smooth procedure are mounted (including
the necessary cleaning and maintenance
work). All systems are protected by an emergency
power unit.
Pump and delivery line
The Putzmeister stationary concrete pump
is on the third wagon, plus a small conveyor
belt for feeding the concrete pump. In order
to prevent the pump from drifting during
the pumping procedure, the frame of the rail
car is fi lled with concrete and the support
legs of the pump are directly screwed to it.
The pump can be operated using a cable-connected
remote control during the pumping
process. The concrete is transported from
the pump to the concrete paver up to 400 m
away via a steel delivery line that is installed
on special wagons. The maximum permitted
concrete pressure of the delivery line is
130 bar. The delivery line has a diameter
of 125 mm and a wall thickness of 7.1 mm.
Since the slab track in the Malmö city tunnel
also has a long curve with a radius of 760 m,
the line has been adapted accordingly in
order to be able to run on the patented alignment
system made by Rhomberg Bahntechnik.
Non-critical load transmission was
a challenge during dimensioning.
Paving machine
The patented paving machine is located at
the end of the delivery line and consists of
an upstream working and transport platform
and a hopper. The concrete is transported to
the track bed via three special chutes. The
concrete is pre-smoothed using skimming
boxes and then compressed using vibrators.
Cleaning
Particular attention was also paid to having
an environmentally friendly disposal and
cleaning concept that meets the strict regulations
in Sweden. In order to clean the
35 36
p The main power supply is provided
by a diesel unit with output of approx.
400 kW that is equipped with a soot
particle fi lter for operating in the tunnel.
p The concrete pump is screwed to the
superstructure of the railcar
delivery line with water, a media separating
device must fi rst be installed. This ensures
that residual concrete and washing water do
not mix. The residual concrete in the line can
therefore still be laid in the track bed. The
media separation system consists of the combination
of sponge ball – soaked cement bags
– sponge ball – wash-out pig – sponge ball.
Team success
It was possible to successfully deal with this
complex project by means of close collaboration
between participating project partners
Rhomberg, Eibinger and Putzmeister. Not
least the competent service engineers from
Eibinger and their involvement, along with
the effi cient service contributed to the success
of this new solution for supplying concrete.
n
Pre-deployment test run
An initial test run of the tunnel concreting
train for constructing the slab track
in the Malmö city tunnel took place on
06.08.2009 at the Rhomberg Bahntechnik
test site.
During the test run, 10 m 3 of concrete
was laid in the prepared track bed using
the concreting train. A stroke time of 4.2
seconds was determined during the pumping
process, which represents a delivery
rate of approx. 38 m 3 /h. The hydraulic
pressure reached a maximum of approx.
215 bar when this took place. Starting
Slab track system
A slab track (previously also referred
to as a ballast-less track or ballast-less
superstructure) is a railway line that is
used in railway, road and underground
train construction in which the ballast
and the sleepers are replaced with a solid
track structure made from concrete or
asphalt.
with a conveying distance of about 250 m,
this results in a calculated friction coeffi -
cient of 2.6. No more than 25 – 30 m 3 /h
is required in the actual pumping process
in Malmö, meaning that the required delivery
capacity is therefore provided.
In order to simulate the situation on site
as realistically as possible, part of the
slab track in Malmö was modelled in
Dornbirn/Austria. The sleeper shoes of
the rails were embedded in concrete (see
fi g. below).
The mixer drum was fed with fresh concrete
with a truck-mixer pump during the
test.
37 38 39
At speeds of more than 200 km/h, it is
particularly important to note that, as
well as having better track stability, the
maintenance costs of the slab track are
signifi cantly less. It is more resistant to
deformation and the effects of the weather,
and track position problems (and
therefore speed restriction sections) hardly
ever occur. The slab track is expected
to have a service life of at least 60 years.
This increases the availability, reliability
and profi tability of the railway line.
40
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In brief
The Governor of Baghdad, his Excellency
Salah Salem Abdelrazaq Al-Hameed, paid
a visit to Putzmeister on 22nd September.
As the representative voted by the people,
he enjoys the status of a minister, and governs
the Governorate of Baghdad. The
delegation was accompanied by representatives
of Liebherr, our partner fi rm
in Iraq.
Governor of Baghdad
visits Putzmeister
“Perilous
ride on the
wild buffalo”
It goes without saying that the “solution” shown here
in no way meets the applicable safety regulations: A truck
mixer feeds a truck-mounted concrete pump. As usual. The
pump in its turn feeds the hopper on a shotcrete
machine. Fine too. The shotcrete
machine is suspended over 10 m
in the air from a truck-mounted
crane, and is manned by two
daring machine operators.
One of them sits on the
hopper by the end hose,
the other controls the
spray arm. Strange and
dangerous! Not exactly a
prime example of slope
reinforcement! Well, at
least the men had their
hard hats on.
The visit was taking place because of concrete
plans by the local government for the
production and pouring of concrete by staterun
construction fi rms in infrastructure projects
carried out by them. A visit to the plant
and demonstration of a BSF 58-5.16 H truckmounted
concrete pump were therefore on
the programme. Having a go at operating it
clearly pleased the Governor.
As well as Putzmeister, the delegation
also visited the companies Liebherr and
Bomag. The trip was fi lmed and will be
shown on Iraqi television.
Putzmeister has been successfully active
in Iraq for over 25 years. There are currently
more than 100 Putzmeister truckmounted
and stationary pumps working
in Iraq to help with rebuilding the country.
q The easy operation of the M 58-5
via remote control clearly pleased the
Governor
41 42
43
An unusual
tourist
at the
Nordkapp
The Pumi 31.89 S owned by the Norwegian
company Arnesen Beton AS had a long
trip to its destination: a round trip of 470
km in total, from the works in Alta to the
Nordkapp, and back again. Once there, it
Norway’s North Cape – the northernmost
point in Europe‘s road network
The Nordkapp is a shale plateau on the
Norwegian island of Magerøya, rising
sheer from the Arctic Ocean. It lies at
71° 10‘ 21“ north, some 520 km north
of the Arctic Circle. Since being linked to
the road network in 1956, the Nordkapp
has been the northernmost point in Europe
that can be reached by car from the
European continent.
Since 1999, the island of Magerøya has
been connected to the mainland via the
Nordkapp Tunnel. The tunnel is 6,875
metres long, burrowing under the Magerøy
Sound at a maximum depth of 212
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was used to renew the foundations of the famous
sculpture. “Not a huge job, but a nice
one!” according to Pål Vidar Arnesen, Production
Manager.
metres. It counts among the deepest and
steepest of tunnels – in parts, it encounters
inclines of 9 %.
45
For over 30 years, Arnesen Beton has been
supplying and pumping ready-mixed concrete
in Norway‘s northernmost regions.
Tourism with tradition
In 1845, with the fi rst arrival of the
“Prinds Gustav” steamer from Hammerfest,
the Nordkapp had its fi rst taste of
tourism. The fi rst organised group tours
from London were arranged by the
“Thomas Cook” travel agency in 1875.
It was not until 1893 that the Nordkapp
made its real breakthrough as a tourist
destination, when the “Hurtigrute”, the
fi rst permanent sea route along the coast
to the North, was established. Today, the
Nordkapp is a tourist destination with
around 200,000 visitors per year.
‚ www.nordkapp.no
In brief
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Putzmeister Services information
Change to single piston
and save money
Costs in €
9,000
8,000
7,000
6,000
5,000
4,000
,000
,000
1,000
Calculation based on empirical service life of 40,000 m 3 for 230 diam. single pistons, and 15,000 m 3 for 230 diam. compact pistons
Changing from compact pistons to
single pistons will reduce your costs
by more than 50 %
• Putzmeister single pistons are more
cost-effective under all conditions of
use, because they have been proven to
have a service life that is 2 to 3 times
longer than that of compact pistons.
• One-off conversion costs
• Particularly suitable for higher
pressures and abrasive concrete
Replacement
interval
compact
piston:
15,000 m 3
Replacement interval
single piston:
40,000 m 3
50,000 100,000 150,000 00,000
• Reduced consumable costs and
shorter downtimes on your machine
• Even some machines from
other manufacturers can be
equipped with Putzmeister
single pistons
Additional information is available from:
Phone +49 (0) 7127 1019 · spareparts@putzmeister.de
Compact
piston
Single
piston
m pumped
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