2004 - Putzmeister

The Magazine for our Customers and Friends 59
PM 3581 GB
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Contents
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4
Latest News
Title Story
Engineering
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20
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16
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S-transfer tubes last for simply ages
The 10th session of training courses
at the PM-Academy
From the fair booth straight to the
construction site
International
Rotor PUMI ® The spirit of the gold-digger era in the
Emirates
Business success with multi-purpose
concrete pumps
pumps crushed aggregates
Domestic
14
Work goes on in Kárahnjúkar
whatever the weather
Tunnel Construction
18
Flexible „Fiver“ with more than 46 m
vertical reach
Less is definitely more
Safeguarding with wet shotcrete on
175 m 2 tunnel cross-section
BERGER concrete pumps for new lock
chamber construction
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4
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3
4
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S-transfer tubes last for simply ages
How can a workshop manager best get rid
of a written-off S-transfer tube from a
truck-mounted concrete pump? Pius Rölli
from the BETONPUMPEN AG
ZENTRALSCHWEIZ (BPZ) had a simply
ingenious answer, which even found favour
with his wife. He simply filled the S-transfer
tube with concrete and, before it hardened,
placed a pin into the upright transfer tube.
Workshop manager Rölli then fixed the
extensive cantilevered arms of a rotary
airer to this holder.
The unconventional airer in original PM
red (RAL 3020) has just one disadvantage:
The construction is so high that a man –
no, if we are honest, it is usually Mrs. Rölli
– has to stand on a chair to hang out the
washing on the high lines!
By the way, the S-transfer tube which has
found another use other than the one
intended was taken out of BPZ service only
after handling a throughput of 60,000 m 3
abrasive Swiss concrete and in the meantime,
has weathered many an Autumn gale
– and that free-standing. The construction,
together with the approx. 65 x 65 x 12 cm
base plate weighs around 240 kg. So any
questions about adequate insurance against
theft are totally unnecessary…
The 10th session of training
courses at the PM-Academy
In the autumn, Putzmeister-Academy
opened the 10th session of events since its
foundation with a programme of training
courses for 2004/05. What is extremely
encouraging is the growing interest shown
in the courses and the continuously increasing
number of participants.
Putzmeister began training machinists,
workshop managers and mechanics in 1994
using didactically prepared training material
and teaching modules covering a wide
variety of subjects. This was supplemented
later by numerous PC animations for
teaching purposes. The subject matter is
constantly up-dated and, in the meantime,
is available in many languages – not only
German, English, French and Spanish but
also in Russian, Chinese and Arabic.
The PM-Academy makes some of the
teaching material available either for
downloading from the Internet free of
charge (www.pm-akademie.de) or as a CD
version. The Putzmeister-Academy home
page is accessed 80,000 times a year – a
fact illustrating the enormous interest in
this useful information.
Heinz-Winrich Schulz, head of Customer
Training at the PM-Academy confirms that
providing tailor-made seminars on the
customer’s premises, and offering specialpurpose
training for participants from
certain regions, is meeting with increased
interest. As the PM-Academy employs
professional seminar leaders and uses upto-date
teaching materials and state-of-theart
technical equipment, it is well prepared
to meet these requirements. You can see a
current overview of the training programme
for the 2004/05 sessions also on the PM-
Academy home page (see above) but we
would also be pleased to send you the
information in the form of a brochure. For
further information, please call us under
+49(0)7127-599586.
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Latest News
From the fair booth
straight to the
construction site
Hardly had the new BSA 1005 D GRF – a
track-mounted concrete pump – put in its
first appearance at the BAUMA than it had
successfully handled its first deployment
on a major construction site.
The track-mounted BSA was put through
its paces by the MAX BÖGL group from
Neumarkt a company which had been
awarded the contract to build underground
railway stations Rokin, Vijzelgracht and
Ceintuurbaan as part of the extension work
to the Amsterdam metro network.
The three stations are being built using a
downward construction method with diaphragm
walls. The excavation pit is
secured first by means of a 32 m deep
supporting diaphragm wall and sheet pile
wall construction upon which a concrete
slab is placed. Then work can commence
on excavating the pit.
In order to support the middle floors of the
Vijzelgracht metro station, the MAX BÖGL
team placed a total of 150 fulldisplacement
piles using a rotary drill. As the construction
site is extremely cramped the site management
was in favour of a self-driven and
manoeuvrable concrete pump which was
connected via a hose up to 27 m in length
(125 mm in diameter) to the powered
rotary head of the drill. Approximately 3.5
to 4.0 m 3 concrete is required for concreting
a displacement pile (500 mm Ø). Each day,
around 10 to 12 of these displacement piles
were constructed on the Amsterdam site
using the BSA 1005 D GRF. On completion
of the pile foundation work, Robert Geitner
from the mechanical engineering department
at MAX BÖGL had only words of praise
for the off-road BSA: “With the self-driven
concrete pump, we were able to take the
rotary drill from drill hole to drill hole –
regardless of the soil conditions. If we had
used a “normal” stationary concrete pump,
we would have required an additional
vehicle for each placement. That would
have cost time and we would probably
have become stuck in the soft ground!”
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Title Story
Work goes on in
Kárahnjúkar what-
ever the weather
Black ice and snow flurries make the going rough for
site traffic. Here a truck mixer “abandoned” on the
roadside.
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At the beginning of 2002, following
extensive investigations and environmental
surveys, a referendum taken by the
people of Iceland voted in favour of the
construction of a gigantic hydroelectric
power plant. The project involved the use
of machines under the Sika ® /Putzmeister
alliance and Sika ® concrete additives in
both the construction of the 193 m high
Kárahnjúkar embankment dam and for
shotcrete work in the numerous galleries
and the two gigantic underground
chambers.
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Vatnajökull Glacier in the north east of
Iceland, an area which can only be accessed
under great difficulty. In the winter months
– and here that means from October to
May – the journey from the nearest town
Egilsstadir (around 50 to 100 km from the
individual contract sections) and from the
camps to the individual construction
sections is frequently interrupted by
blizzards. Then access routes are impassable
for hours, and sometimes even days.
And these are the months when the
temperature can drop to –15 °C.
Title Story
Colossal hydro-electric power plant
creates jobs in the aluminium industry
The gigantic hydro-electric power plant is
being built to cover the energy requirements
of the American ALCOA group for
its new aluminium smelter. The state-of-the
art plant is being constructed on the east
coast of Iceland in the bay at Reydarfjordur
which remains free of ice all year round.
The investment is forecast to require 1.1
billion US dollar (about 880 million A).
The six turbines in the Kárahnjúkar power
plant with an output of 690 MW will serve
the aluminium smelter and must be onstream
by October 2007. On completion of
the project, the immense – and reliable –
ice melt from the Vatnajökull Glacier in the
Spring will ensure a steady supply of
energy. The number of people employed in
the traditional fishing industry has dropped
tremendously in the past few years and the
new aluminium plant will be creating new
and long-term jobs for Iceland.
LANDSVIRKJUN, the national electricity
company will be later operating the
Kárahnjúkar power plant which is mainly
state-financed. Building costs alone amount
to more than 1 billion A on top of which
come investments for developing the
infrastructure.
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Title Story
An embankment dam, almost 200 m
high, and a 53 km long head race tunnel
Works on the gigantic Kárahnjúkar Project
involve among other things the construction
of the 730 m long and 193 m high
Kárahnjúkrstifla main dam (construction
section KAR 11) and the head race tunnel
with a diameter of 7.2 to 7.6 m (contract
section KAR 14). Pressurized water is fed
on the one hand along the so-called head
race tunnel from the dam to the vicinity of
the power plant (a distance of 39.6 km) and
on the other hand from the considerably
smaller Usfar reservoir through the Jökulsa
Tunnel (over a distance of 13.3 km). Both
of these contract sections are being carried
out by the Italian construction company
IMPREGILO whose team has been on the
site since February 2003. At peak times
more than 1,200 employees are working on
the two construction sites.
The main dam is a rock and gravel construction
requiring the installation of a
5-phase crusher plant and an extensive
conveyor system. IMPREGILO used a
Putzmeister Type BSF 36.14 H truck-
mounted concrete pump with a two-layer
delivery line for concreting the dam
abutment and for lining the dam surface.
The wearing surface of this PM pipe is
particularly robust, allowing considerably
longer stand-up times. An extremely
important factor, considering the concrete
aggregates are made of hard volcanic basalt
lava.
To reduce construction times, the head race
tunnel will be driven not only from the
dam side but also from three access adit
tunnels (total length approx. 6.9 km). In the
meantime, several new concrete mix units
have been set up in the region of the main
dam and on the sites of the three access
adit tunnels. In addition to the usual types
of site-mixed concretes, the units also
produce wet shotcrete which is reinforced
with steel fibre (40 kg/m 3 ). From the access
adit tunnels, IMPREGILO will drive the
total length of the 53 km long head race
tunnel using three large TBMs – ROBBINS
tunnel drills. The steel fibre reinforced
shotcrete is used to ensure safety during
driving operations, for the final permanent
lining of the head race tunnel and the three
access adit tunnels. IMPREGILO will be
placing a total of around 70,000 m 3 steel
fibre reinforced shotcrete in the various
galleries of the dam.
Besides the IMPREGILO company, the
FOSSKRAFT working group is also
playing a decisive role at the Kárahnjúkar
large-scale project site. The working group
comprises the following companies:
HOCHTIEF (who are in charge), PHIL &
SON, ISTAK and IPC and is working on
contract section KAR 15 which includes
the construction of the access galleries
(diameter 7.5 m) to the underground turbine
halls (dimensions 127 m x 14 m x 35 m)
and to the neighbouring transformer hall
(103 m x 13.5 m x 15 m), two 410 m high
vertical head race tunnels (4 m in diameter),
a 1.3 km long tailrace tunnel (9 m in diameter)
and a 1 km long cable tunnel (4 m
in diameter). The machine halls alone require
2,000 m 3 of in total 10,000 m 3 fibrereinforced
wet shotcrete and 17,000 m 3 of
approximately 40,000 m 3 structural
concrete.
Layout plan of the Kárahnjúkar Project showing the main and side dams, head race tunnels and pressure tunnels (Fig.: LANDSVIRKJUN)
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Complex temperature-controlled concrete aggregate and heated formwork
Aggregates required for the shotcrete are
delivered by truck to the construction site
and stored in steam-heated containers in
order to prevent the formation of ice in the
concrete batches which have been made
according to stringent quality standards.
The dry material for the shotcrete is prepared
using 80°C hot water. The truck
mixers must also be carefully freed from
any ice prior to loading in order to maintain
the correct temperature for the setting
of the concrete – even in biting frost.
About 70,000 m 3 of steel fibre reinforced shotcrete was
placed in the individual sections
(Fig.: Olaf Möller, FOSSKRAFT)
Total length of individual tunnel
sections
53 km
410 m
Last winter at the dam construction site,
another approach was taken: in exposed
areas, the concrete was placed into heated
plastic formwork to prevent the concrete
from cooling down too quickly. It was also
absolutely essential to be able to work
construction sections such as diversion
galleries during the winter months in order
to guarantee there would be additional
diversion capacity to accommodate the
enormous masses of water set free in the
snow melt in spring 2004.
Empire State Building
New York (443 m)
Title Story
The insulated mixer ensured the production of concrete
throughout the winter months
15 16
Shotcrete application using the Putzmeister WETCRETE WKM 103 at the portal of an access adit tunnel
(Fig.: Olaf Möller, FOSSKRAFT).
17 18
Systematic presentation of the 410 m pressure tunnels, turbine hall,
transformer hall and tailrace tunnels. In comparison; the 443 m high
Empire State Building.
(Fig.: LANDSVIRKJUN) A Putzmeister BSF 36.14 H carrying out minor
concrete placements on the dam abutments
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Title Story
Concrete guns and additives supplied by
Sika ® /Putzmeister alliance
When having to select concrete guns
and additives, both IMPREGILO and
FOSSKRAFT decided on machines and
materials from the Sika ® /Putzmeister
alliance. Sika ® therefore supplies in
addition to fluxing agents and aerating
agents, the alkali-free setting accelerating
agents. In order to ensure an uninterrupted
and efficient supply of the setting accelerator
(Singuit AF 53) during the four-year
construction period, Sika ® installed its own
mixer unit in the neighbouring town of
Egilsstadir. A local company receives the
raw materials for the accelerator in powder
form, mixes them under controlled temperatures
with water to produce a liquid
accelerator which is then transported to the
construction site in 1,000 l tanks by truck.
The accelerator must then be stored at the
individual Kárahnjúkar construction
sections at a temperature of plus 15°C.
Producing the accelerator locally and
according to demand avoids the problem of
de-mixing or segregation in the product.
The Sika ® /Putzmeister alliance supplied all
of the machinery required for shotcreting
operations in Kárahnjúkar, including
several large-scale shotcrete manipulators
which have been installed for wet spraying
operations in various galleries as well as in
the turbine hall and transformer hall deep
within the mountain. The wet spraying
devices are equipped with a smoothrunning
type BSA 1005 piston pump and
a spraying arm which allows work to be
carried out up to approximately 16 m
height. The telescopic spraying arm has a
3 m sliding arm and a nozzle spray head at
the top to provide optimum mobility and
efficiency in the interest of high-quality
shotcrete application. The top performance
of the Sika ® /PM wet spraying device is
very generously measured at 30 m 3 /h. For
example, in the tailrace tunnels built by
FOSSKRAFT approximately 120 m 3 wet
shotcrete is placed weekly on round
lengths of 55 m to provide an extremely
even spray pattern. The reason for these
relatively small quantities of shotcrete are
the favourable i.e. stable, geological
conditions so that shotcrete reinforcement
is only required in the roof between the
“ten hundred and fourteen hundred hours”
position. The wet shotcrete used in this
area also contains about 40 kg/m 3 steel
fibres.
Wet shotcrete device for small cross
sections
The prototype of the new wet spray device
Sika ® -PM400 P is also in operation at the
Kárahnjúkar site. This device was
developed especially for application in
tunnels with a small cross section, e.g. for
the 4 m x 4 m cable tunnel. It is equipped
with a Putzmeister piston pump from the
BSA 500 series, a Sika ® spray arm AL 302
and a dosing system Al 403. The AL 403 is
fitted with SPC and can be set so that on
site, the nozzle guide has very little influence
on the dosing of the accelerator
which means there is no risk of the quality
of the shotcrete being changed due to
improper and incorrect setting of the
dosing rate. Sika ® also supplied rotary
spray units which are suitable for use for
both dry and wet spraying operations.
They have been installed on the shotcrete
platforms of the three 1,200 ton TBMs
about 30 m behind the drill head usually to
lay down wet shotcrete. Dry shotcrete is
Shotcrete work in tunnels with small cross sections, e.g. the cable tunnel where FOSSKRAFT deploys the
prototype of the new wet spraying device Sika ® -PM400 P
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Makes heavy demands on the machinery in operation:
Service Manager, Haraldur Ingthorsson
only sprayed when safety operations using
small quantities of concrete must be carried
out immediately behind the drill head.
The original plan was to stop outside work
on the dam during the three most severe
winter months but as the construction
schedule for the Káranjúkar Projekt of four
years is so tight, it has become necessary to
continue working in shifts throughout the
whole year.
The demands made on reliability of the
machines in operation and the skills of the
workshop personnel on the Kárahnjúkar
site are clearly assessed by Haraldur
Ingthorsson, Service Manager at
FOSSKRAFT: “We are working with a
fleet of machinery, all in good working
order. That means we do not have
machines in reserve standing by. We can
only work in this way because the equipment
is of such high standard and because
of the excellent work carried out in our
workshops where practically all of the
service and maintenance work necessary
here is dealt with. This illustrates well the
high standard of work in the workshop.”
Incidentally, in the meantime, deadline
pressures at the FOSSKRAFT sites are
viewed very casually because work is well
within schedule and in some sections –
for example the tailrace tunnel – is already
six to eight months in advance of
schedule…
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In Iceland, lots of things are different from elsewhere
With approximately 290,000 inhabitants
and a population density of fewer than
three persons per km 2 , Iceland is among the
most sparsely populated countries in
Europe. The island situated on the edge of
the northern Polar Circle still boasts today
around 30 active volcanoes and numerous
geysers. Some of the hot springs are now
being used to supply heating and warm
water to households, other hot water
springs feed large thermal power plants
with environmentally-friendly energy.
Although journeys to the hinterland over
rock debris and coarse gravel are only
possible in a four-wheel drive vehicle,
drivers of “normal cars” can now drive
around the island on a firm and asphaltsurfaced
peripheral road.
In spite of that, even today, there is no more
efficient means of transport close to nature
through the untouched highlands of the
island than by the sturdy little Iceland pony
which is totally adapted to the severe
environment. This stocky little pony is the
master of a variety of gaits (walk, trot and
gallop) including the running tölt, a fourbeat
gait ensuring the rider a smooth and
comfortable ride. The Iceland pony is
135 cm hh and is incidentally not a pony but
a member of the small horses which have
remained pure for more than 1,100 years on
the island thanks to a law passed in 982 AD
forbidding the import of other horses.
Public outdoor baths in Iceland are fed by the hot springs
The robust Iceland pony is still today one of the most
reliable and simple means of transport through the
hinterland
The island was discovered around 800 B.C.
by the Irish and approximately 75 years
later, the first Norwegian settlers arrived.
The Icelandic language of today is similar
to Old High German.
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Title Story
Spread over an area of 8,300 km 2 , the
Vatnajökull is not only the largest glacier in
Iceland but also in Europe and thus one of
the major tourist attractions in the country.
The continental ice cap occupies terrain
which lies 700 to 800 m above sea level and
is in some places 1,000 m thick. Its Icelandic
name translates to “waters glacier” and
refers to the numerous glacial rivers which
among other things will also feed the
Kárahnjúkar dam.
For reason of its geographical location,
much of public life and social activities in
Iceland takes place in the summer months
in the hours around midnight and the early
hours of the morning – when it is still light.
That is why the mayor of Reykjavík, the
capital city, sends out invitations to a
reception for midnight and why traffic jams
do not occur after work has finished but on
Saturdays and Sundays around two in the
morning when thousands of car drivers are
roaming the pub areas honking their horns
whilst looking out for a car park. And even
if Reykjavík has more daylight hours than
Miami or Rio de Janeiro during the year,
the winter months are characterised by long
periods of darkness. Around about the
winter solstice, daylight time amounts to
no more than three or four hours.
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Engineering
Flexible, five-sectioned M 47 and M 46 boom
Following its premiere at the BAUMA six
months ago, the first PM truck-mounted
concrete pumps in the M 47 /M 46-5
series have been delivered. And week for
week, the number of machines
demonstrating what a large-scale, yet
compact, “fiver” in the 40 m boom class
can achieve on building sites both at
home and abroad increases. Even in
Australia the newcomer has shown its
colours.
Regarding the boom’s vertical reach, the
new roll-and-fold Z boom M 47 / M 46-5
has replaced the former M 46 overhead
roll-and fold system. But that is where the
similarities between the two boom types
Easily recognizable: The unusually flexible arm assembly of the Z roll-and-fold
M 47 / M 46- 5 seen here in a typical site application
end as the earlier version of the M 46 was
really designed as a “four-section” type.
Since about the middle of the Nineties, PM
offered to fit a delivered M 46 with an
additional joint in the end arm to provide
improved flexibility, an offer which
numerous customers gladly took up.
However, with a flex angle of 90°, the end
arm of the M 46 overhead roll-and-fold
boom did not have the flexibility which
characterizes a classical five-section, allround
boom.
The differences between the two
generations become very obvious when
comparing the arm assembly and the
respective extent of the supports. First of
all, it becomes apparent that the type of
fold is totally different: in the one, the
Z roll-and-fold system unfolds the indi-
23
vidual arms like a pocket rule immediately
on lifting the boom assembly and brings
them into the required position, in the
other, the overhead roll-and-fold system,
must first lift the second arm in order to
move the first arm before the other boom
segments can be placed into the required
position for concreting. The advantage of
the boom fold is its relatively low-weight
construction, a design which Putzmeister
also applies to the large-booms M 58-4
and M 58-5. The weight advantage in the
M 47 / 46-5 was “reversed” in favour of
the Z roll-and-fold system by directed
structural measures; the arm assembly is
now distinctly lighter than the preceding
model.
Whereas the unfolding height of the truckmounted
concrete pump M 46 with the
overhead roll-and-fold system was 12.3 m
prior to the BAUMA, the new M 47-5 RZ
roll-and-fold manages with just 9.5 m
because of the distinctly shorter boom
segments which can be placed up to an
angle of 245°. The new M 47-5 has a
clearly larger net horizontal reach (39.3 m)
than its predecessor (38.2 m) and can
excavate almost one meter more working
depth (32.2 m).
Another interesting aspect is manoeuvrability,
a factor which becomes more and
more important with increasing horizontal
reach of the boom. Manoeuvrability is
24
The distance between the front and rear support foot is a mere 8.2 m when fully supported
(in OSS operation a mere 7.2 m)
mainly determined by the total length of
the vehicle, the boom overhang and the
wheel base.
With regard to the dimensions, the total
length of the new M 47-5 on a standard
chassis is less than 13 m. The compact substructure
of the new M 47 / M 46-5 means
only a small support area is required even
for full support. The width to the front is
thus only 8.0 m, to the rear approximately
8,9 m. If the machine is supported in a
narrow OSS mode, these figures fall to
just 5.1 m and 6.6 m support width.
Optional M 46-5 variant
PM also offers a slightly shorter version of
the modern “Fiver”, the M 46-5, customized
and tailored to meet the permissible
conditions of special markets. Concrete
pump operators in Switzerland, for
example, this version remains within the
legal requirements (max. length of single
vehicles 12 m). Putzmeister has also kept
the wheel base in both versions within a
sensible limit of 4.40 m (distance between
the second and third axle).
Photos from the construction site show a
BSF 46-5 16 H owned by BETON-
PUMPENUNION (Ulm) during its initial
operation. Operator Jürgen Joner exchanged
the standard end hose for a hose which
tapers from 125 mm to 100 mm to place
concrete in very narrow wall formwork.
Incidentally, another novelty shown at the
BAUMA. Together with the Ergonomic
Boom Control, placing concrete in the wall
formwork becomes an almost pleasant task.
Reduced end hoses
for narrow formwork
In order to facilitate
insertion into narrow
formwork and densely
packed reinforcements,
Putzmeister AG has introduced
a reduced end hose
into its product range
since BAUMA 2004.
Reduction is gradual
from 125 mm to
100 mm over a
length of a good
3 m. Also under
development is
the version of
another end hose in
which the diameter
tapers from 125 mm
to 75 mm. For further
information, please
contact Phone
+49(0)7127/599352.
Ø 125 mm
Ø 100 mm
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26
Engineering
EBC enhances efficient installations
A construction site in Bubsheim near
Rottweil made quite other demands on the
quality of the BSF 46-5 16 H, where one of
the new “fivers” pumped and distributed
600 m 3 of concrete into the floor formwork
of the new training centre for the Häring
company (precision engineering) in just
one morning. From one single position, the
operator was able to fill the extensive
formwork by extending and folding the
Z roll-and-fold boom system. And as the
arrival times of the truck mixer had been
coordinated to perfection, there was practically
no idle time. In most cases, two
mixers charged the new BSF 46.16 H
simultaneously and Jürgen Joner “simply
let them get on with it”. “Output Step 9“
was set on the remote controls, i.e. allowing
90 % of maximum output to be pumped.
That corresponded to an actual output of
more than 140 m 3 /h. Unwanted vibrations
in the boom are caused, among other factors,
by the position of the boom, the consistency
of the concrete etc. and can frequently
lead to problems when the pump is
operating under full load. In this case, they
were actively absorbed by the Ergonomic
Boom Control system which had been
connected. In this way, the end hose can be
guided at a constant height and high
lay-down rate over the floor formwork.
This BSF 46.16 H is bound for Australia
This BSF 46.16 H was dispatched to
Australia at the beginning of August,
bound for the concrete pump service
company GEELONG CONCRETE
PUMPING (Melbourne). The Putzmeister
AG “two version policy” obviously pays
off in the market “down under”, too.
Because it would have been a problem to
have the M 47-5 approved for use under
the Australian approval regulations, so this
customer could be satisfied with a slightly
shorter version of the new “Fiver”.
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International International
The spirit of the gold-digger era in the Emirates
In the meantime, the United Arabic
Emirates (UAE) have generated a GDP of
almost 80 billion US dollar thus reaching
the economic power of Singapore. Whilst
in the past decades most of the revenues
and prosperity of the seven emirates in the
federation resulted from the crude oil and
natural gas business, in the meantime
continuous growth is increasingly due to
income from trade, tourism and financial
services. The up-and-coming economy is
based mainly on the boom in Abu Dhabi,
Dubai and, although to a lesser extent,
Sharjah.
A sound foundation
UNIMIX DUBAI used three of its
Putzmeister truck-mounted concrete pumps
to concrete the base slab of the Oil Trade
Centre in Dubai. After about 18 hours, a
total of 3,500 m 3 of concrete had been
poured. In the foreground, a BSF 42.14 H.
Three booms with one target…
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With spectacular construction projects,
Dubai especially has made a name for
itself since the Nineties as the “showcase”
of the United Arabic Emirates. With
approximately 4 million inhabitants and a
population growth rate of 8 %, this meant
that alone in 2003, 45,000 new homes were
built in this – in size - the smallest of the
emirates.
Investments are also being made in gigantic
hotel complexes and their required infrastructures.
The supply industry serving a
variety of sectors is also being encouraged
to locate business in the Gulf, not only
companies processing petrochemical
products but also suppliers to the major
4 different M 43s in Sharjah
In the emirate of Sharjah, four Putzmeister
concrete pumps with 43 m booms delivered
around 3,300 m 3 of concrete within 16 hours
to cast the foundations of the Residential
Project on Corniche Bay.
car manufacturers. For example, there are
plans for opening up three large industry
zones in Abu Dhabi in the near future.
Foreign workforces have contributed greatly
to economic growth in the emirates. They
make up almost 80 % of the population
with almost two-thirds of them coming
from India, Pakistan, Bangladesh, the
Philippines and Thailand. They are also
strongly represented in the building industry,
working too for concrete pump
operators. With the following pictures we
would like to give you an idea – without
too detailed an explanation – of the
manifold building activities in the United
Arabic Emirates, the concrete pumps and
booms in operation and the operators.
Incidentally, the four machines were
equipped with totally different types of
pump units designed for a maximum
output of 110, 120, 140 and 150 m 3 /h.
Even if the view from up here is pretty good:
personnel are not allowed to remain on a concrete pump during operation for safety reasons!
28
30
Drilled piles for the “drawing board”
town
Work on the drilled piles foundations for
the Jumeirah Beach residence Project in
Dubai is progressing well. Putzmeister
truck-mounted concrete pumps are being
used to backfill the drilled piles including
the recently delivered BSF 36.16 H.
The Jumeirah Beach Residence project is a
part of the Dubai Marina Development
Project – an artificially created city facing
the sea. The complex of new buildings
comprises luxuriously equipped apartments
in high-rise towers, detached villas and
hotels. A total of 40 high-rise buildings are
under construction. The "drawing board"
city is planned to house around 35,000
people.
As the ground is prone to subsidence, the
foundations of the buildings are being
constructed on drilled piles. Before work
was able to commence in December 2003,
meters of soil layers had to be removed
from some parts – in total more than
450,000 m 3 of sand.
The drilled holes reach down to 18 to 36 m
and are between 800 and 1000 mm in
diameter. The local provider of ready-mix
concrete Unimix was contracted to supply
and pump about 50 % of the concrete
required for the project. The company
owns, among other things, a fleet of 17
truck-mounted concrete pumps with
differing boom lengths - most of which are
Putzmeister machines. Several of these
High-strength concrete for new hotel
A large stationary pump type
BSA 14000 HP-D and a stationary
concrete boom MX 32 with an autoclimbing
installation made sure the
hotel Shangri-La in Dubai was completed
Have a break – concrete placing the carcass of the Shangri-La hotel
Thousands of drilled piles for the satellite town will be concreted into the sand
machines are being deployed in the largescale
pile foundations measures currently
being undertaken. Unimix uses a fleet of
up to 30 truck mixers to bring the concrete
to the construction site.
Although Unimix has a concrete works not
far from Jumeirah, the company set up two
further mixing units in the immediate
vicinity of the construction site. The reason
for two more units is the enormous volume
of concrete required for the construction of
this large-scale project. Another reason is
in next to no time. The first 42 of a total of
48 storeys were cast in self-compacting
concrete with a compressive strength of
60 N/mm. In 15 months, Putzmeister
machines owned by UNIMIX pumped and
distributed approximately 65,000 m 3 for
this high-rise project.
32
the extreme density of traffic in the Gulf
state which meant that trouble-free
transport to the building site could not
always be guaranteed. In addition to this
problem, there are also restrictions on
trucks using the main roads. The problem
can be easily solved however by setting up
modern concrete mix units directly on site.
The Unimix Jumeirah beach residence site
depot is in operation around the clock and
has a current capacity of 280 m 3 /h.
UNIMIX uses these two high-performance pumps
type BSA 14000 HP-D for high-rise pumping of
concrete.
31
33
13
PM 3581 GB

14
PM 3581 GB
Domestic Domestic
BERGER concrete pumps
for new lock chamber con-
struction
A modern lock chamber is being planned
for the Teltow Canal south of Berlin
which on completion will replace a
considerably smaller chamber which has
been in operation for almost 65 years.
A new lock bridge is currently under
construction as a preparatory measure for
this construction project. The necessary
and extensive concrete works are being
carried out by BERGER BETON GmbH
using PM truck-mounted concrete pumps.
The new construction of the lock bridge
Kleinmachnow is part of the
„Verkehrsprojekt Deutsche Einheit Nr. 17“
(Traffic Project German Unity No 17)
which involves extensions to the Midland
Canal, the Elbe-Havel Canal, Lower Havel
Waterway and the Berlin Waterways. The
Kleinmachnow lock comprises a weir
outlet and three lock chambers. Two of the
chambers, each 67 m long, were built in
1905 in masonry, the third north chamber
in sheet piling in 1940 and up to now
allowed boats of up to maximum 85 m
long to pass. The north chamber is to be
rehabilitated to allow convoys of up to
185 m to pass through. As an historic
monument, the whole navigational lock
facility, including the bridge and the lock
stand, is under protection.
The new construction of the bridge is being
carried out by a Berlin company, PORR
TECNOBAU GmbH which is a subsidiary
of PORR TECHNOBAU und UMWELT
AG (Austria). Problematic soil conditions
first necessitated a test foundation be made
prior to rebuilding the bridge. Then work
commenced on building the north bridge
abutments, which, in the meantime, have
been completed. PORR commissioned
BERGER BETON GmbH to deliver and
pump a total of 2,000 m 3 of concrete.
Large horizontal reach combined with flexible boom system are characteristic features of the BERGER M 52 “Fiver”
34
The navigational lock at Kleinmachnow is an historic monument and thus under protection. Bottom left: part of the old lock bridge is still recognizable.
Operator Jörg Börner controls the boom movement and
regulates the pump flow using EBC and precise remote
controls
36
BERGER tackled the job using its
Putzmeister pumps BSF 36.16 H, BSF
42.16 H and BSF 52.20 H placing concrete
for the bridge substructures (granular subgrade
course and foundations), the bridge
abutments and the three bridge support
piles. Beforehand, piles made of concrete
mixed on site were made to form foundations
for the abutments and support piles.
The BERGER BSF 52.20 H has been in
operation since September 2003 and is
managed by pump operator Jörg Börner.
When these pictures were made, he was
just delivering (… between midday and
12 o’clock noon…) 110 m 3 concrete – a
water-impermeable concrete, strength
classification C 35/45 into the formwork
of the south abutment of the lock bridge.
The smooth-running pump unit (output
160 m 3 /h with just 21 piston strokes or
200 m 3 /h with 26 strokes) ensured the job
was finished in next to no time.
A specialist for all cases
With more than 50 truck-mounted
concrete pumps in its fleet,
BERGER BETON GmbH is among
the really big pump service providers
in Germany. The company can deal
with the most varied of requirements
in civil engineering using booms
with a vertical reach of between 21
and 52 m. BERGER BETON GmbH
has specialised in rehabilitation
projects in the old parts of cities and
towns and in concrete placement in
tunnels. Such sites are often difficult
to access for truck-mounted concrete
pumps so the concrete is delivered as
required through pipes and hoses of
up to 1,000 m in length.
35
15
PM 3581 GB

International International
Business success with multi-purpose
concrete pumps
In Italy, it is common to find smaller,
often family-run businesses operating
more often than not with not more than
three machines. As a rule, these are
truck-mounted concrete pumps with
booms which can be put to universal
use. The specialists among the truckmounted
concrete pumps includes for
example the M 24-4 “Multi-Z” concrete
pumps with special renovation equipment
which is unsurpassed when used in
enclosed buildings. Or the long-reach
pumps such as the M 52-5 which are
probably found more often in larger
machine fleets.
16
PM 3581 GB
38
A BSF 36.14 H owned by SO.CO.ME, seen here placing cellar foundations, has been kept in top working order
SO.CO.ME Srl. for example is one of
Italy’s largest concrete pump service providers
and with 16 concrete pumps is
deemed the largest pump service company
in Milan. The SO.CO.ME. fleet comprises
several machines which have been tailored
for use beyond that of the normal site
concreting. These specialists in the concrete
pump sector make their owners a
strong competitive partner when it comes
to demanding, large-scale projects.
SO.CO.ME. and its four to seven machines
is therefore constantly in demand, even
participating in the impressive new
construction of the Milan Fair Halls.
During our visit, two M 24-4 owned by
SO.CO.ME were in operation pumping
from the inside of one of the two-storey
halls into the upper storey. For this task,
not only the excellent slip characteristics of
the boom M 24-4 Hallenmeister were in
demand but also the extensive range of
accessories required for lengthening the
delivery line.
Incidentally, it is typical for most truckmounted
concrete pumps in Italy to carry a
substantial number of accessories with
them, as the machines do not as a rule
drive back to their pump service base
between operations due to the dense traffic
in the Lombardic city. This was also true
for the relatively new Putzmeister M 36
owned by SO.CO.ME which we saw near
the San Siro stadium. Here, three truck mix
batches were being used to concrete
sections of a cellar foundation. During this
operation, machine operator Marino
Zerbetto, who has been with SO.CO.ME
for a long time, was able to make full use
of the horizontal reach of his BSF 36.14 H
– which was painted all over in red and in
top condition.
Good work must be properly rewarded
The SO.CO.ME fleet does not comprise –
as is often observed – a mix of truck
mixers, PUMI ® s, stationary and truckmounted
concrete pumps. Instead, the
company’s managing directors Roberto
Greggio and Sandro Sgaburri focus
exclusively on truck-mounted concrete
pumps booms between 24 and 46 meters.
According to the company motto
“lavorare molto – dare un buon servizio –
guadagnare il guisto” (which in English
means roughly “work well – serve well –
reward well”) since 1977 business has been
successful and in Lombardy, they enjoy an
excellent reputation (just as important) as
concrete pump service providers. In the
meantime, the company which operates its
machines in a radius of about 100 km
around Milan is managed in the second
generation of the founders. When asked
why SO.CO.ME place their trust in
Putzmeister concrete pumps, the two
directors are not lost for an answer: “We
attach great importance to machines that
are reliable, robust and keep their value.
And if you take these requirements seriously,
a concrete pump from PM is like a
cheque which is valid worldwide.”
37
Milan’s new fair premises
Since the end of 2002, work has been
on-going on the outskirts of Milan on
a cost-intensive project worth about
500 million A commissioned by the
trade fair company FIERA MILANO
SpA and with the Italian bank consortium
ASTALDI-VIANIN PIZZAROTTI
acting as the general contractor.
In addition to an open-air area of
60,000 m 2 , the new Milan fair premises
will comprise a covered exhibition area
of more than 200,000 m 2 which will
accommodate among other things 80
congress halls, 20 restaurants and 25
bars. Plus the construction of a 5-storey
administration building with more than
4,000 m 2 office space for 400 of the total
of 450 fair employees. The original plan
was for 10 single storey fair halls but the
project has since been modified. The
current plan is for eight halls with modern
facades in glass and steel, six of them
single-storey and two halls each with
two storeys. The new fair halls are
arranged around a greened central axis
consisting of a 1 km long tree-lined
avenue and a lake.
Incidentally, the new fairgrounds are
being financed solely by the fair
company FIERA MILANO SpA. The
Lombardy region is taking over the
investments required for the infrastructure
together with provincial and
municipal administration for Milan.
The “Hallenmeister” M 24-4 – unsurpassed in indoor applications – seen here doing credit once more to its
name placing concrete in one of the new fair halls in Milan
40
39
40/1
17
PM 3581 GB

PM 3581 GB
Tunnel Construction
Safeguarding with wet shotcrete
on 175 m 2 tunnel cross-section
In the most north-eastern part of the
Rhineland-Palatinate, a 378 m long
tunnel is currently under construction in
Betzdorf. On completion, it will noticeably
reduce the amount of through traffic in
the town. The large tunnel cross-section
at the south portal is unusually large but
as work progresses it becomes smaller. To
secure the excavation and to stabilise the
working face, the working group is using
a concrete wet spraying device type
Sika ® -PM500 P.
Work on the Siegkreisel Tunnel is being
carried out by a working group comprising
HOCHTIEF Construction AG, ALPINE
Bau Deutschland and KIRCHNER GmbH.
The tunnel cuts through a mountain
protusion between the two small rivers the
Sieg and the Heller and in future will
create the required space to allow traffic to
flow unhindered at the junction B 62 with
the B-roads L 280 and L 288. The working
group commenced advance work at the
beginning of July 2004.
The south portal is located on the immediate
outskirts of Betzdorf and presents the
site logistics with particular challenges
because of the extremely cramped conditions.
On commencing the tunnel
opening, work was complicated by the
fact that a house a mere 18 m away on the
side of the mountain was not to be
damaged by vibrations resulting from
blasting.
The south portal was first driven with a
cross-section of 175 m 2 to accommodate
three traffic carriageways of which about
100 m 2 made up the excavation of the
crown, and 75 m 2 the bench advance. After
a distance of approximately 63 m, the
tunnel cross-section was reduced like the
shape of a trumpet. In this area, the three
carriageways will merge into two so that
only a normal cross-section of around 80 m 2
is required (crown 50 m 2 , bench 30 m 2 ).
The mountain which has been driven
through is compact clay slate, which allows
1 m lengths of rounds (in the area of the
175 m 2 section) and later 1.50 m. To secure
the excavation, a shotcrete manipulator
Sika ® -PM 500 P is used to wet spray a
concrete shell of at first 30 cm and later
15 cm. The work can be carried out up to
a height of around 6 meters. Furthermore,
the device secures the working face after
each excavation with a layer of shotcrete
(as prescribed by the building owners and
for additional occupational safety). The
working group reckons about 6,500 m 3 of
wet shotcrete will be required for the
Siegkreisel Tunnel. It will be supplied by
After the wet spraying work in the portal area, the Sika ® -PM500 P takes over securing the excavation of the almost 400 m long tunnel tubes
The Sika ® -PM500 P and a well-rehearsed team will
ensure a speedy shotcrete application.
several mix stations in the region. After the
whole length of the tunnel has been
secured with shotcrete, the internal leaf
is applied using on-site mix.
Incidentally, the Sika ® -PM 500 P is
operated by a three-man team of Polish
miners. When the newly delivered machine
was taken into operation, the men were
instructed by Sika ® service personnel in the
operation, maintenance and cleaning of the
wet spraying device. The men have already
worked together before on large-scale sites
e.g. in the Augustaburg Tunnel along the
new stretch of ICE railtrack between Erfurt
and Nuremberg. The construction supervisor
of the working group reckons that
such a well-rehearsed team and the new
shotcrete manipulator promise rapid
progress in the construction work. The
scheduled building time is only 12 months.
42
41
Rotor-
PUMI ®
pumps crushed aggregates
We attempted to refute the preconception
that “the rotor hose doesn’t last long” in
an article in our PM Post No. 55. In the
meantime, we receive further information
which allow interesting conclusions to be
made regarding the durability of the rotor
pump almost daily.
Manuel has been working for three years as
a PUMI ® 21.67 Q operator for the major
French pump service company DELTA
POMPAGE from his base in Toulon.
44
Although chippings are used as aggregates, operator
Manuel has achieved amazingly long operating times
with his rotor hose
According to his observations, several
factors influence the wearing
characteristics of the rotor hose:
■ the quality of the concrete (especially
grain size, amount of fine-grained
material, cement contents)
■ the type of aggregate used (broken
material or round grain) as well as
■ “the experienced hand” of the operator.
Is he pumping an even output? Is he
pumping under average power? Or does
he repeatedly pump “at full throttle”?
On our small building site in Saint Cyr sur
Mèr, 11 m 3 of concrete are required for
casting a prefabricated floor, 6 m 3 of which
are transported by the 21 meter PUMI ®
owned by DELTA POMPAGE in their own
mixer drum, the rest is brought in a
separate truck mixer to the site. The
building project comprises several dozen
holiday and weekend houses which are
being constructed a few hundred meters
away from the Mediterranean coast.
Casting a prefabricated floor – one of the typical PUMI ® construction sites on the French Mediterranean coast
International
Operator Manuel obviously works with a
great deal of feeling and experience. What
he cannot influence is the granulate used
here in the region around Toulon as an
aggregate – and an extremely abrasive one
at that! Nevertheless, his rotor PUMI ® and
his colleagues handle 3,500 to 5,000 m 3
before the rotor hose is replaced.
In Avignon, 180 km away, things look
different as the concrete works use almost
exclusively round grain. Operators at
TRANSBETON another leading French
pump service provider tell of 7,000 m 3
concrete which have been delivered with
just one rotor hose.
45
43
46
19
PM 3581 GB

Engineering
Less is
definitely more
Putzmeister AG has been registering in
the past few months a growing customer
interest in truck-mounted concrete pumps
with four-fold separated booms M 28 in
Z roll-and-fold – both at home and abroad.
The main feature of the 3-axle version is
the short wheel base which is, as a rule,
only 3.9 m (depending on the pumps
aggregate, 3.6 m is also possible).
Furthermore, the intrinsic weight is around
21 t which means the high weight reserves
of around 5 tons virtually invite the set up
of complete rehabilitation equipment or the
carrying of a comprehensive range of
Impressum:
Herausgeber
Putzmeister AG
Max-Eyth-Str. 10 · D-72631 Aichtal
Tel. (0 71 27) 599-0 · Fax 599-520
Internet: http://www.putzmeister.de
E-mail: pmw@pmw.de
■ Redaktion: Jürgen Kronenberg
■ Grafik: Friedrich Pippich
Your fax for further information
accessories such as delivery lines and hoses
in various diameters, reducing pieces,
couplings etc. We will be telling you more
about this in our next edition of PM Post.
Our picture shows the Z-fold BSF 28.14 H
owned by the pump service company
BOSTA Beton at a construction site on the
outskirts of Warsaw. For some months now,
it has been possible to observe brisk
Putzmeister AG, Max-Eyth-Str. 10, D-72631 Aichtal
PSdg, Deutsche Post AG, Entgelt bezahlt, E 60458
building activities here in the south east of
the Polish capital where a new estate of
single occupancy housing is going up.
Because of the high ground water level –
the site is very near the banks of the Vistula
– the building owners are dispensing with
cellars and are building their houses on
strip footings.
The BSF 28.14 H owned by BOSTA-Beton seen here placing concrete for strip foundation Pump operator Janusz Szymanski appreciates the
weight reserves in his M 28-4
■ Would you like more information on certain topics in this edition of Putzmeister Post?
If so, just copy this page, make a cross next to the topics you are interested in and fax
the form to us. We will then send you detailed information immediately.
❏ Truck-mounted concrete pump M 24-4 „Multi-Z“ ..............................MT 1085
❏ Truck-mounted concrete pump M 28-4 „Z“ ........................................MT 3512
❏ Truck-mounted concrete pump M 36-4 „Z“ ........................................BP 3180
❏ Truck-mounted concrete pump M 42-4 „R“ ........................................MT 2391
❏ Truck-mounted concrete pump M 46-5 „Roll-Z“ ................................BP 3552
❏ Truck-mounted concrete pump M 47-5 „Roll-Z“ ................................MT 3540
❏ Truck-mounted concrete pump M 52-5 „Multi-Z“ ..............................MT 3231
❏ Reduced end hose ..............................................................................BP 3559
❏ Stationary concrete pumps ..................................................................BP 2632
❏ Stationary placing booms ..................................................................MT 2059
❏ Concrete spraying system Sika ® -PM500 ..............................................TS 3573
❏ Rotor-PUMI ® ........................................................................BP 2047, BP 3536
47 48
Name .........................................................................................................
Company ...................................................................................................
Position .....................................................................................................
Street .........................................................................................................
Post Code/City ..........................................................................................
Tel. No. ......................................................................................................
E-mail ........................................................................................................
Putzmeister AG
Max-Eyth-Str. 10 · D-72631 Aichtal
P.O.Box 21 52 · D-72629 Aichtal
Tel. +49 (71 27) 599-0
Fax +49 (71 27) 599-520
Internet: http://www.putzmeister.de
E-mail: pmw@pmw.de
PM 3581 GB All rights reserved. Subject to technical amendments without notice. The illustrations in some cases show special-purpose machine designs and snapshots of site
practice which do not always comply with the regulations determined by professional bodies.© 2004 by Putzmeister Printed in Germany (30410 RR)