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The Magazine for our Customers and Friends 67<br />

PM 3786 GB


2<br />

PM 3786 GB<br />

Contents Latest News<br />

3<br />

4<br />

Latest News<br />

<strong>Putzmeister</strong> bids farewell to board<br />

member Dr. Hartmut Benckert<br />

Title Story<br />

11<br />

Compact “four-arm”<br />

with multiple strengths<br />

Dam Construction<br />

10<br />

High-rise<br />

Between Madrid and Valencia –<br />

the M 42-5 has a full schedule<br />

Bridge Construction<br />

12<br />

20<br />

Practical Tip<br />

14<br />

24<br />

Background<br />

15 PM DAISY® tracks down a stolen M 24<br />

Application<br />

16<br />

Side anchoring with compact<br />

spray concrete pump<br />

Stationary booms on launching gantries<br />

Lapped or braided?<br />

Attractive niche markets for the<br />

TELEBELT ® telescopic conveyor<br />

Technology<br />

18<br />

23<br />

Brutal concrete mixture<br />

Small pin for great effect<br />

New long-reach boom pump serves<br />

historical exhibition halls<br />

M 38-4, the big allrounder<br />

4 10<br />

18<br />

23<br />

3 7<br />

12<br />

11<br />

2<br />

16 20<br />

4<br />

5<br />

8<br />

9<br />

6<br />

<strong>Putzmeister</strong> bids farewell to board<br />

member Dr. Hartmut Benckert<br />

At the end of June <strong>2006</strong>, <strong>Putzmeister</strong> AG<br />

said goodbye to its longstanding board<br />

member Dr. Hartmut Benckert. Whoever<br />

knows HB – as is his internal abbreviation<br />

– will know that retirement is a long<br />

way off yet. Instead, he is going to remain<br />

“unretired” and active.<br />

A multitude of <strong>Putzmeister</strong> innovations and<br />

major technical breakthroughs over the last<br />

25 years can be attributed to ideas and proposals<br />

of the engineer who was born in<br />

Husum, northern Germany, in 1946 and<br />

grew up in Bremen. These include the forward<br />

looking Free-Flow Hydraulics FFH<br />

(1982), the computer-controlled highly<br />

flexible handling system HFH (1986) and<br />

the computer-aided and sensor-monitored<br />

mobile SKYWASH robots. The know-how<br />

behind these highly complex systems<br />

would years later form the basis for the<br />

joystick-controlled EBC Electronic Boom<br />

Control and for the conception of other<br />

ERGONIC modules. With the establishment<br />

of the US PM subsidiary in the 80s<br />

and 90s, Dr. Benckert faced an altogether<br />

different challenge. The list of outstanding<br />

technical achievements would soon include<br />

the development of high-performance<br />

concrete pumps, to which <strong>Putzmeister</strong><br />

owes much of its world records in high-rise<br />

concrete pumping (most recently 532 m in<br />

1994), and the series manufacture of the<br />

largest PM truck-mounted concrete pump<br />

with a vertical reach of up to 63 m (2005).<br />

Following his studies (mechanical engineering,<br />

aerospace engineering) and completion<br />

of his dissertation at TU Stuttgart,<br />

Dr. Benckert spent the next six years<br />

working in turbine and power plant<br />

engineering. In April 1981, he moved to<br />

<strong>Putzmeister</strong> taking the role of assistant to<br />

the Managing Director and PM founder,<br />

Karl Schlecht. Some time later he became<br />

test manager and, in 1988, was appointed<br />

general manager of the Engineering division.<br />

Since then, he has been responsible<br />

for Engineering, Production, Quality<br />

Assurance and Technical Services.<br />

During the conversion in 1996 of the<br />

former <strong>Putzmeister</strong> GmbH into the legal<br />

form of public limited company, or<br />

Aktiengesellschaft (AG), Dr. Hartmut<br />

Benckert was offered an appointment to<br />

member of the board. As part of the<br />

establishment of the AG, it was also a<br />

condition that the contracts of all PM board<br />

members would expire in their 60th year.<br />

For HB, this time has now come.<br />

His colleagues have come to know him as<br />

a meticulous and single-minded worker. A<br />

large number of concrete pump operators<br />

at home and abroad, who have for years<br />

maintained close, personal contact with<br />

him, hold in high regard his readiness to<br />

think laterally and to resolutely implement<br />

even unconventional solutions. “Hurricane<br />

Harry” – as is his nickname in the USA –<br />

took on technical challenges with relish.<br />

And in ambitious developments he would<br />

often identify a benefit where others would<br />

only see the risks. Many of his ideas are<br />

now patent-protected.<br />

What did he enjoy most in all his years<br />

with <strong>Putzmeister</strong>? The answer came swiftly:<br />

“The freedom of expression that I had<br />

here!” In his opinion, one of the greatest<br />

challenges facing the company in the future<br />

is the development of mechydronics, i.e.<br />

the meshing, or symbiosis, of mechanics,<br />

hydraulics and electronics with the aim of<br />

being able to offer “intelligent” construction<br />

machinery. What pleases him – and this<br />

is also something in which he has personally<br />

played a not insignificant part – is the<br />

healthy growth of the company throughout<br />

the years and the expansion of sites.<br />

With his great commitment to PM AG, his<br />

participation in a variety of associations<br />

(more notably in several committees of the<br />

German Engineering Federation VDMA<br />

and as President of the Committee for<br />

European Construction Equipment) and<br />

voluntary activities in regional politics,<br />

the private interests in HB's life had been<br />

forced to take somewhat of a back seat.<br />

This has changed since July, with Dr.<br />

Hartmut Benckert finding more time for<br />

his hobbies of cycling, riding and mountain<br />

climbing. And he is looking to take on new<br />

responsibilities in this new chapter in his<br />

life, albeit in a different area to before:<br />

“I'd like to try lending my experience to<br />

economic policy!”<br />

As a source of valuable experience,<br />

PM AG also wants him to remain available<br />

as a consultant.<br />

He wishes his successor, Dr. Mehmet<br />

Varlik, the best of luck and the courage<br />

to meet the new challenges in a rapidly<br />

changing environment head on, even if<br />

the solutions happen to be unconventional.<br />

10<br />

3<br />

PM 3786 GB


4<br />

PM 3786 GB<br />

Title Story<br />

Compact “four-arm”<br />

with multiple strengths<br />

By the end of 2005, <strong>Putzmeister</strong> AG had<br />

announced the development of an<br />

extremely compact truck-mounted concrete<br />

pump with a 20-metre “four-arm”<br />

boom. Even in the project stage, the combination<br />

of minimal support width, lower<br />

unfolding height, short arm segments,<br />

flexible boom kinematics and a robust<br />

pump assembly promised a fascinating<br />

working machine.<br />

Many construction sites, which previously<br />

could only be supplied with concrete by<br />

means of crane-lifted buckets, goods lifts<br />

or wheelbarrows, were suddenly presented<br />

with an interesting alternative. In addition,<br />

the working range of this universal truckmounted<br />

concrete pump is extended by the<br />

delivery hoses and tubes carried in magazines.<br />

The delivery of the first machines<br />

began after the presentation at the trade fair<br />

INTERMAT in Paris in April <strong>2006</strong>. With<br />

the following examples of application,<br />

<strong>Putzmeister</strong> would like to take this<br />

opportunity to present the new M 20-4 ZR<br />

in typical construction site situations.<br />

Restoration with lightweight concrete<br />

In Heidelberg, buildings of up to 50 years<br />

old at the Max Planck Institute for nuclear<br />

physics are presently undergoing modernisation.<br />

Also benefiting from the restoration<br />

project is the adjoining Gentner laboratory.<br />

The technology and air-conditioning<br />

system of the building is located in a<br />

separate room on the flat roof and is being<br />

completely renovated along with the loadbearing<br />

substructure by Bauwerk-Sanierung<br />

Rhein-Neckar GmbH (BWS).<br />

Since the ceilings could only be subjected<br />

to low load for static reasons, it was only<br />

possible to use lightweight concrete with a<br />

specific weight of no more than 1,900 kg/m 3<br />

for the foundation of the new technology<br />

room. The BWS foreman said, “This<br />

means we have 500 kg less ceiling load per<br />

cubic metre concrete!” To deliver the lightweight<br />

concrete (grain size 0/8 mm,<br />

strength class LC 25/28) approximately<br />

15 m high and up to 30 m wide, BWS<br />

ordered a truck-mounted concrete pump<br />

from Betonpumpendienst Rhein-Main<br />

(BRM, Lorsch). The precondition was that<br />

the machine would not only have to be<br />

suitable for pumping lightweight concrete<br />

but also be able to manage with the<br />

restricted space on the Institute grounds.<br />

BRM dispatcher, Walter Steiner, decided<br />

that the new M 20-4 should take on the<br />

task. With a maximum support width of<br />

3.4 m forward and 2.5 m aft (i.e. inside<br />

chassis width), there was still sufficient<br />

space around the construction site for the<br />

normal traffic of the Institute's members<br />

as well as for the vans and light-duty<br />

construction vehicles of the restoration<br />

company. However, the crucial factor in the<br />

decision to award the job to the compact<br />

11 12<br />

Once the machine is set up, BRM operator, Horst<br />

Sommer, regulates concrete output from immediately<br />

beside the placement site<br />

M 20 “four-arm” was the fact that it is<br />

equipped with EPS hydraulic control.<br />

The EPS module (Ergonic Pump System)<br />

is standard equipment on the M 20-4 and,<br />

unlike conventional hydraulic control<br />

systems, regulates the functions of the concrete<br />

pumps electronically. This makes it<br />

possible to optimise the pumping process<br />

in line with the prevailing conditions. The<br />

The EPS system supports adjustment of the maximum<br />

desired hydraulic pressure (and thus the concrete<br />

pressure too)<br />

changeover force of the transfer tubes, for<br />

example, is adjusted to suit the consistency<br />

of concrete. However, other important<br />

parameters were also optimally matched by<br />

the EPS computer, such as the slewing<br />

angle of the S transfer tube, the delivery<br />

rate of the hydraulic pump, the hydraulic<br />

pressure and much more.<br />

It was particularly helpful to limit the<br />

conveying pressure to the desired value<br />

given by the transmission ratio (i = 1 : 4.4)<br />

on the display itself. The setting is easily<br />

made using the rotary selection knob. For<br />

example, for a desired conveying pressure<br />

limit of 30 bar, a hydraulic limit of 132 bar<br />

must be set.<br />

132 bar<br />

30 bar conveying pressure x 4,4 =<br />

hydraulic pressure<br />

13<br />

The lightweight concrete flows at maximum rate from<br />

the ND 65 hoseline<br />

14<br />

15<br />

16<br />

Caution: lightweight concrete!<br />

The pumping of lightweight concrete demands<br />

the utmost attention of the machine<br />

operator. This is because most lightweight<br />

aggregates (swelling clay granulate) are<br />

porous and absorb water and concrete fines<br />

under pressure. As this causes discontinuity<br />

in the lubricating film on the inner wall<br />

of the tube or hose, the properties of segregation<br />

and therefore blockages are preprogrammed.<br />

An increase in the conveying<br />

pressure would result in the blockage being<br />

further compressed and it would remain<br />

blocked. The following tips should help to<br />

avoid problems in the pumping of lightweight<br />

concrete:<br />

■ Check whether the aggregates have been<br />

prewatered in the concrete factory<br />

■ Increase the mixing time. The duration<br />

depends on the type of admixture. It is<br />

two minutes for the addition of polycarboxylate<br />

ether (PCE), for example.<br />

■ Start pumping with considerably more<br />

grout than with standard concrete.<br />

There must be sufficient lubrication<br />

over the entire length of the line.<br />

■ Only pump at low output<br />

■ Specify the lowest possible maximum<br />

pressure using the EPS system<br />

Particularly favoured is, incidentally, the<br />

use of the rotor pump system for delivery<br />

of lightweight concrete that <strong>Putzmeister</strong><br />

offers not only for PUMI ® truck-mixer concrete<br />

pumps but also for truck-mounted<br />

concrete pumps with booms with a vertical<br />

reach of 28 m. The reason for this is the<br />

system's inherently low conveying pressure<br />

(max. 25 bar) and the highly uniform delivery<br />

of the rotor with only low pressure<br />

peaks.<br />

The advantage of lightweight concrete – in<br />

addition to its low deadweight – is also its<br />

low thermal conductivity. A disadvantage<br />

of this material is the elasticity module that<br />

decreases disproportionally with bulk<br />

density. Lightweight concretes with bulk<br />

densities of between 800 and 2,000 kg/m 3<br />

are the norm today. However, the bulk<br />

density of unhardened, pumpable lightweight<br />

concrete should not be below<br />

1,800 kg/m 3 (corresponds to bulk density<br />

class 1.6). The fines being of natural sand<br />

is also important to the pumpability of the<br />

concrete. The technically possible, lower<br />

weight threshold for lightweight concrete<br />

is currently around 350 kg/m 3 .<br />

5<br />

PM 3786 GB


6<br />

PM 3786 GB<br />

Title Story Title Story<br />

17<br />

Boom as pipe bridge<br />

In Zürich-Müllingen, the Swiss Post is<br />

having its distribution centre, built in 1985,<br />

converted in wide sections for around CHF<br />

110 million (approximately 70 million<br />

euros). Concrete was delivered into the<br />

lightweight false ceilings by a flexible<br />

M 20-4, firstly through the boom pipework<br />

and then a 130 m long hoseline.<br />

To increase the effective area, the extensive<br />

construction measures also include putting<br />

in large false ceilings in the high rooms.<br />

These photos were taken as one of the<br />

ceiling formworks measuring 1,600 m 2<br />

was being filled with 250 m 3 of concrete,<br />

strength class C35/45. A highly modern<br />

letter distribution centre will be commissioned<br />

here on completion of the work.<br />

The new M 20-4 of a 3 Betonpumpen AG<br />

(Affoltern) was deployed for this application<br />

for various reasons: on the one hand,<br />

the space available was perfectly adequate<br />

for setting up the machine; on the other<br />

hand, the “four-arm” boom could be fed<br />

through any of the desired window openings.<br />

Furthermore, the machine operator<br />

had a sufficient number of hoses on board<br />

to still be able to fill the ceiling formwork<br />

deep within the room. The total extension<br />

was eventually 130 m.<br />

18<br />

Narrow roadway, plenty of support<br />

On the outskirts of Munich, the municipality<br />

of Ottobrunn is having a new communal<br />

services industrial park, including extensive<br />

commercial premises, built on the grounds<br />

of a former airport for 2.7 million euros.<br />

In addition to the buildings, warehousing<br />

structures and workshops, the construction<br />

project also includes permanent spaces for<br />

the comprehensive fleet of vehicles. Due to<br />

the relatively high surface load – this area<br />

is used for the parking of HGVs, road<br />

sweepers, snow ploughs, etc. – a concrete<br />

of somewhat higher strength (C30/37) is<br />

required. The narrow yet long sections<br />

measuring 50 to 100 m 3 are being concreted<br />

by the new M 20-4 of BFM (Betonförderdienst<br />

München GmbH Co.KG). Since<br />

roadways with a width of more than just<br />

3.5 m for supporting the truck-mounted<br />

concrete pump are few and far between, the<br />

M 20-4 was a natural first choice.<br />

Space enough for oncoming traffic<br />

Even weeks after the event, machine<br />

operator Bernd Blöhe remembers well one<br />

of the first times his new M 20-4 was put<br />

to use. “Man, that time in Feldmoching<br />

was a close call…” says the Berlin-born,<br />

Betonförderdienst München (BFM) machine<br />

operator who has lived in Bavaria<br />

for over 15 years.<br />

The reason for this “lasting memory” was<br />

the search for a suitable set-up area for the<br />

BSF 20.09 H that was employed first a few<br />

days before. Now, this machine does not, in<br />

fact, require very much space at all, but<br />

even its minimum (support width front<br />

3.4 m, rear only 2.5 m within the vehicle's<br />

surface area) did not appear to be available.<br />

Before we go into more detail here, we<br />

should first get a general idea of the construction<br />

site conditions. The order of the<br />

Deutsche Bahn AG commissioned the<br />

restoration of an extremely busy railway<br />

bridge for regional and cross country traffic,<br />

including the two side wing caps. The<br />

bridge spans a similarly hectic through<br />

road, which has been closed off on one<br />

ca. 3.5 m<br />

The width of the roadway is enough for the M 20-4 to support itself Placement of concrete in the bottom formwork<br />

side for the duration of the construction<br />

work. Traffic lights control the traffic,<br />

which is only able to move along the single<br />

free lane. The other lane – the width of<br />

which is not even 2.8 m – is required for<br />

the erection of the construction site. At the<br />

same time, this happens to be the only setup<br />

site for a truck-mounted concrete pump<br />

in the entire surrounding area.<br />

Machine operator, Blöhe, parks the 2-axle<br />

vehicle in the closed lane in such a way<br />

that the foot of the right-hand forward<br />

support leg, with a support plate for an<br />

underlay, is positioned precisely on the<br />

white centre line marking, which is approximately<br />

10 cm wide. This may sound unbelievable,<br />

but every centimetre counts in<br />

these conditions. On the left-hand side of<br />

the truck, things get trickier: because the<br />

tyres of the machine are already in contact<br />

with the kerb, the support foot must find<br />

space to rest half on the narrow verge, half<br />

on the embankment. In addition to the<br />

support plate, adequately dimensioned timber<br />

blocks ensured the safe set-up of the<br />

machine. Bernd Blöhe: “Well, then I raised<br />

the arm assembly, unfolded the four-arm<br />

boom and it was then the mixers' turn!”<br />

19 22<br />

Oncoming traffic has free passage<br />

20 21<br />

23<br />

7<br />

PM 3786 GB


8<br />

PM 3786 GB<br />

Title Story Title Story<br />

M 20-4 as rotor pump<br />

On this construction site, too, it was only<br />

possible to work with truck-mounted concrete<br />

pumps that could find a support area<br />

between palettes, cranes, construction<br />

materials, skips, a pit across the way and<br />

craftsmen parking their vehicles. This is<br />

because the actual construction site road<br />

has to remain clear for construction<br />

vehicles and delivery traffic.<br />

The company responsible for the building<br />

carcass had ordered the BSF 20.09 H as a<br />

pure rotor pump to deliver two or three<br />

mixer loads of fine concrete for the floor<br />

into the basement of one of the new builds.<br />

To be able to reach all basement rooms of<br />

the house, the machine operator requires a<br />

hoseline of 80 m (ND 65) in total as an<br />

extension up to the placement site. To<br />

create the transition from the hopper outlet<br />

to the hoseline, the M 20-4 carries three<br />

reducers on-board: a relatively short<br />

adapter for the transition from the hinged/<br />

pivoting elbow to the standard delivery line<br />

cross section (Ø 150/125 mm); another for<br />

adapting to the smaller diameter of the<br />

3-metre extension tubes (Ø 125/100 mm)<br />

carried on-board; and a relatively long<br />

reducer for the transition to the ND 65<br />

hoses.<br />

Fitting the reducers only takes a matter of<br />

minutes. In the meantime, the co-workers<br />

on the construction site brought some of<br />

the 16 hoses into the basement and connected<br />

them together using quick-release<br />

couplers. The other delivery hoses run<br />

overground; these, too, are joined together<br />

with a small number of handles and connected<br />

to the final reducer. Then it's all<br />

hands to the pump!<br />

The construction site is blocked off in all directions, yet the M 20 “four-arm” still finds space<br />

Reducers for the ND 65 delivery hoses are connected to the hinged elbow pivoted through 180°<br />

25<br />

26<br />

24<br />

Connection of the extension line to the boom tip<br />

Concrete placement in the 2nd row<br />

In the Munich district of Laim, the new<br />

M 20-4 of JUMBO pumping services is<br />

pumping concrete not only through the<br />

boom pipework, but also through an extension<br />

line connected to it. Around 200 m 3<br />

is to be placed from 10.30 am onwards.<br />

The construction site is situated more or<br />

less in the 2nd row: an unfavourable location<br />

set behind the actual road-side buildings<br />

that “normal” truck-mounted concrete<br />

pumps with placing boom would find<br />

difficult to reach.<br />

The grounds are home to the development<br />

of 46 private apartments, a retail outlet and<br />

underground parking levels. Being concreted<br />

today is the 40 cm-thick basement garage.<br />

Site manager: “We can't set up conventional<br />

boom pumps here without blocking the<br />

road or the pavement. And because our site<br />

is on Fürstenrieder Straße, a road with six<br />

lanes, we can't just move the pavement<br />

onto the other side of the road like that<br />

either!” Yet the M 20 four-arm does<br />

manage to find space for a set-up area<br />

measuring – with maximum support – just<br />

3.4 m by 8.8 m between the extremely<br />

busy road and the walkway. The support<br />

legs are lowered and the boom stretched<br />

out to the side in no time. The nine, 3-metre,<br />

ND 100 pipe sections and the three extension<br />

hoses (5 m) are routed and connected<br />

to the boom tip with the help of the site<br />

personnel within minutes. The machine<br />

operator exchanged the end hose for a<br />

normal 3-m delivery hose with spout beforehand.<br />

The machine operator fits a suitable<br />

reducer between this delivery hose<br />

(Ø 125 mm) and the first pipe section<br />

(Ø 100 mm), and between the delivery pipe<br />

(Ø 100 mm) and the hoseline (Ø 65 mm).<br />

In this way, the compact M 20 is able to<br />

achieve the horizontal working range of a<br />

long-reach boom pump in the 60-metre<br />

class. As the truck mixers arrive through<br />

the traffic without delay, concreting of the<br />

ceiling formwork is already complete by<br />

the early afternoon.<br />

27<br />

Concrete placement takes place far behind the front of the buildings<br />

29<br />

28<br />

9<br />

PM 3786 GB


10<br />

PM 3786 GB<br />

Dam Construction High-rise<br />

Side anchoring with compact<br />

spray concrete pump<br />

Small-scale construction machinery has<br />

authorised access even on the largest of<br />

construction sites. For even where ground<br />

conditions are difficult, they are mobile,<br />

easily repositioned and up and running in<br />

a short space of time. This is demonstrated<br />

by this application report from south<br />

east Asia on a <strong>Putzmeister</strong> spray concrete<br />

pump.<br />

In Laos, one of the poorest countries in the<br />

region, the harnessing of water power to<br />

generate electricity is playing an increasingly<br />

important role. The country needs<br />

the electricity not only to supply its own<br />

population and domestic industry on the<br />

one hand, but to export it for currency<br />

earnings on the other. The income earned<br />

will mainly be used to fund the expansion<br />

of the Laosian infrastructure. The main<br />

consumer of the power supply is neighbouring<br />

Thailand, which has been supplied<br />

with electricity from the Nam Ngum 1<br />

water power station since as early as 1971.<br />

More hydroelectric power stations have<br />

been built in the country in the meantime<br />

and work on the current major construction<br />

site of Nam Ngum 2 – also in the catchment<br />

basin of the Nam Ngum River – is<br />

making progress. The reservoir dam project<br />

essentially comprises a 169 m high arch, a<br />

hydroelectric power station with an output<br />

of 615 MW and two 1 km long head race<br />

tunnels each measuring 12 m in diameter.<br />

Nam Ngum 2 is being built under a contract<br />

awarded to Thai construction firm, Ch.<br />

Karnchang, as the principle contractor. The<br />

costs of the project run to around US $ 830<br />

million (approximately 654 million euros)<br />

and completion is scheduled for 2011.<br />

Uniform spray of concrete anchors the mountainside<br />

Before the valley is flooded, the loose<br />

rocks on the relatively steep mountain sides<br />

must be prevented from causing a possible<br />

landslide. These areas are anchored using<br />

spray concrete. For this purpose, Ch.<br />

Karnchang employs two small, hydraulically-controlled<br />

<strong>Putzmeister</strong> P 715 TD piston<br />

pumps, which regulate the synchronised<br />

addition of the hardening accelerator by<br />

means of separate metering devices. The<br />

P 715 TD model is essentially equivalent to<br />

the earlier BSA 702 D PM fine concrete<br />

pumps and achieves a pump output of up to<br />

18 m 3 /h.<br />

The P 715 TD concrete pumps have a<br />

piston stroke of over 700 mm, a delivery<br />

cylinder diameter of 100 mm and are<br />

driven by a 30 kW diesel engine (electric<br />

motor as an option). Of course, they can be<br />

used not only for concrete spraying but<br />

also for the delivery of concrete through<br />

piping and hoses. The maximum grain size<br />

in the concrete should not exceed 16 mm<br />

with this application. The solution for<br />

cleaning the actual core pump and hopper<br />

is exemplary: through the side-mounted<br />

flaps on the upper section of the hopper,<br />

there is access to all areas that have come<br />

into contact with concrete by the time<br />

pumping is over.<br />

Meanwhile, the Thai construction firm, Ch.<br />

Karnchang, based in Bangkok, operates a<br />

small fleet of PM machines: in addition to<br />

the two P 715 TD fine concrete pumps, the<br />

firm also works with three S 5 mortar<br />

pumps, a large BSA 2110 HP-D highpressure<br />

concrete pump and a MXR 32<br />

stationary boom.<br />

31 32<br />

Truck mixers fill up the small P 715 concrete<br />

spray pump<br />

30<br />

Between Madrid and Valencia – the M 42-5<br />

has a full schedule<br />

Even the Spanish pumping services – who<br />

in recent years have been known mainly<br />

as users of long-reach-boom concrete<br />

pumps in the 50 and 60-metre class – are<br />

showing an increasing interest in the new<br />

M 42 “five-arm”.<br />

The first machine of this model for Spain<br />

was delivered in May to Emipesa S.A., a<br />

company that, in addition to truck-mounted<br />

concrete pumps, also operates concrete,<br />

mortar and stone breaking works and a<br />

gravel pit. Emipesa's site is located in the<br />

Province of Teruel between Madrid and<br />

Valencia.<br />

After the machine operators had been given<br />

introductory instructions by engineers from<br />

the PM subsidiary, <strong>Putzmeister</strong> Iberica, two<br />

of the “right kind” of construction sites<br />

eagerly awaited the new M 42-5. One of<br />

these construction projects was an apartment<br />

block for 57 homes in Teruel (requiring<br />

around 1,800 m 3 of pumped concrete),<br />

the other a smaller, three-floor hotel in Mas<br />

de Andrés, not far from the Emipesa headquarters.<br />

In this case, the top floor had yet<br />

to be concreted. Even for weeks ahead, the<br />

dispatch office in Teruel had been inundated<br />

with orders for the new M 42-5.<br />

Machine operator, Raúl Jarque, appeared<br />

extremely satisfied with his new “five-arm”<br />

at the end of day one. It was the flexibility<br />

of the boom and the ease of use that<br />

appealed most.<br />

High and wide – a “five-arm” boom adapts to the most varied of building profiles with ease<br />

33<br />

34<br />

11<br />

PM 3786 GB


12<br />

PM 3786 GB<br />

Bridge Construction<br />

Stationary booms on launching gantries<br />

Since mid-2004, the Hungarian government<br />

has made the expansion of infrastructure<br />

its top priority. By the end of<br />

<strong>2006</strong>, the country's motorway network<br />

will have almost doubled in length from<br />

700 km to around 1,200 km. The projects<br />

of prime importance include the completion<br />

of the M7 motorway from Budapest to<br />

the Croatian border. Four stationary<br />

<strong>Putzmeister</strong> placing booms and two PM<br />

concrete pumps are also there to help with<br />

a demanding bridge construction en<br />

route.<br />

On the southern shore of Lake Balaton,<br />

construction of the spectacular Köröshegy<br />

bridge project along a section of the M7 is<br />

underway. On completion, this valley<br />

crossing will be the longest land bridge in<br />

Central Europe. The main contractor for<br />

the project is the Hungarian construction<br />

firm, Hidepito RT (Budapest).<br />

The new motorway viaduct is supported on<br />

16 conically tapered pillars reaching<br />

heights of up to 80 m. Wall thicknesses<br />

therefore decrease with increasing progress<br />

in the construction. Each of the pillars are<br />

topped with 6 m long, 23 m wide, 7 m high<br />

hammer heads that have been concreted in<br />

three sections. Several PM truck-mounted<br />

concrete pumps with vertical reaches of up<br />

to 36 m were present for months to participate<br />

in the concreting of the pillars, including<br />

foundations and heads. The machines<br />

were connected to risers for the maximum<br />

heights of delivery.<br />

The bridge superstructure is created in 11 m long sections using launching gantries<br />

60 m of concreted superstructure in each<br />

direction<br />

Hidepito is creating the 1,872 m long, 23 m<br />

wide and up to 7 m high superstructure<br />

section by section using two launching<br />

gantries. On each of the four service girders<br />

– there are two in each direction of travel –<br />

there is a formwork carriage and a stationary<br />

PM MX 28 concrete placing boom.<br />

The stationary booms are connected by<br />

cruciform base to the girders and are filled<br />

with concrete by two BSA 1409 D stationary<br />

concrete pumps through 150 m long<br />

delivery lines. The two stationary pumps<br />

generally operate in parallel and are relocated<br />

from one side of the valley to the<br />

other in unison. In segments approximately<br />

11 metres in length, the team of Hidepito<br />

concretes the substructure for 60 m in both<br />

directions emanating from the hammer<br />

head. Around 400 m 3 of concrete (C45/55)<br />

is demanded of the BSA pumps per section.<br />

The <strong>Putzmeister</strong> delivery lines (SK 125)<br />

have additional insulation to ensure<br />

trouble-free operation during the cold<br />

winter months and the hot summer.<br />

35<br />

The bridge builders concrete the segments<br />

of the superstructure in two steps: first the<br />

floor slab and footbridges are cast, then the<br />

viaduct floor slab and cut-outs are created.<br />

Around ten to twelve days are required to<br />

manufacture a segment.<br />

The valley crossing at Köröshegy is part of<br />

a 15 km long motorway section that includes<br />

three bridges, the construction costs<br />

of which are reported to be 258 million<br />

euros. The foundation work began in<br />

September 2004; completion is estimated<br />

for mid-2007.<br />

36<br />

38<br />

Bridge Construction<br />

The 150 m long delivery lines are well<br />

insulated against the heat and cold<br />

37<br />

13<br />

PM 3786 GB<br />

3


Practical Tip<br />

Lapped<br />

or braided?<br />

Delivery hoses must be flexible, must not<br />

wear too quickly, and yet they must still<br />

be able to satisfy the requirements of<br />

pressure and burst resistance. It goes<br />

without saying that the purchase price<br />

of the hoses should also represent good<br />

value. Careful though – like some car tyre<br />

bargains, cheap delivery hoses often end<br />

up being an expensive purchase.<br />

Car tyres and delivery hoses share common<br />

ground: both have a carcass (usually made<br />

of steel mesh) and a wear layer made of<br />

abrasionproof rubber. While the structure<br />

of the carcass is critical to driving<br />

characteristics (tyre) or pressure resistance<br />

(delivery hose), the thickness of the rubber<br />

layer, among other factors, is decisive to<br />

the service life of the tyre or concrete delivery<br />

hose. With car tyres, it is radial tyres<br />

(steel breaker tyres) that have long since<br />

found general acceptance due to the improvement<br />

in driving characteristics that<br />

they offer by comparison with diagonal<br />

tyres. With concrete delivery hoses, the<br />

more practical of operators will similarly<br />

opt for the high-quality design with braided<br />

steel wire reinforcement. What with the<br />

expensive costs of manufacture, these<br />

hoses naturally have their price.<br />

Supposed bargains are regularly turning<br />

up on the market. As part of its product<br />

monitoring, therefore, the <strong>Putzmeister</strong> Parts<br />

Service arranged for Contitec to carry out a<br />

closer examination of the concrete delivery<br />

hoses from what at first glance appeared to<br />

The braiding of fine steel wires around the inner hose is<br />

complex and is only possible with the right technologies<br />

14<br />

PM 3786 GB<br />

be a value-for-money manufacturer. As<br />

early as the pressure test, the naked eye<br />

could see that the third-party product<br />

deformed noticeably even before the manufacturer's<br />

specified concrete pressure had<br />

been reached. The material inspection then<br />

confirmed the first impression. We have<br />

listed the result of the material inspection<br />

in the table above. The inspected hoses<br />

were SK65, 5-metre hoses.<br />

The production of <strong>Putzmeister</strong> delivery<br />

hoses is highly complex and the fruit of<br />

long experience. While the hoselines consist<br />

entirely of rubber and the bushes on the<br />

outside, the internal structure is substantially<br />

more involved: with the PM hoses, a<br />

network of steel wire is braided around the<br />

inner hose, which is made of 6 – 7 mm<br />

Third-party product PM delivery hose<br />

Total wall thickness 10.5 mm 12.0 mm<br />

Inner rubber layer 4.5 bis 5 mm 6.5 mm<br />

Outer rubber layer 1.8 mm 2.5 mm<br />

Steel wire reinforcement lapped braided<br />

Tensile strength 14.5 MPA 24.0 MPA<br />

Bending radius 500 mm 350 mm<br />

Stretch at break 365 % 495 %<br />

40<br />

thick rubber material. The inspected hose<br />

of the competition, on the other hand, had<br />

only a lapped steel reinforcement. Hoses<br />

of this construction are indeed more costeffective<br />

to manufacture, but a lapped steel<br />

reinforcement needs considerably more<br />

space than a braided one. This is compensated<br />

for by a thinner rubber layer, which<br />

reduces the service life of the hose.<br />

The outer layer of a <strong>Putzmeister</strong> hose is<br />

usually a 2.5 mm thick sprayed-on jacket<br />

that protects the hose from external<br />

damage. There then follows the banding<br />

of the basic hoses and their vulcanisation.<br />

To prevent the formation of uneven areas<br />

when joining the galvanised and tempered<br />

bushes to the inner wall of the hose, the<br />

PM hoses are stripped of their casing in<br />

these areas as this serves to drastically<br />

reduce the risk of blockages. As a consequence<br />

of the thinner inner and outer layer<br />

alone, the alternative hose would have to<br />

be approximately 30 % cheaper, which was<br />

not the case.<br />

41<br />

42<br />

The theft of truck-mounted concrete pumps<br />

was even easier at one time… This is what<br />

one – or several, we still don't know –<br />

sticky-fingered individual must have learned<br />

at the beginning of June when he gained<br />

access to the secured premises of the TBG<br />

concrete mixing plant in Tagewerben<br />

(Halle/Leipzig area) in the middle of the<br />

night, broke into a BSF 24.11 H truckmounted<br />

concrete pump and drove it away.<br />

Background<br />

PM DAISY ® tracks down a stolen M 24<br />

The theft was noticed the next morning<br />

when driver, Falk Berger, wanted to drive<br />

his truck to the first pumping operation of<br />

the day. The police were called, the theft<br />

reported and a search called out for the<br />

missing M 24-4. Meanwhile, the<br />

Tagewerben concrete works informed the<br />

dispatch office of TBG Betonpumpendienst<br />

Berlin of the theft of the concrete pump<br />

stationed with them. From central dispatch<br />

in Berlin-Hoppegarten, all TBG concrete<br />

pumps in Brandenburg, Mecklenburg-<br />

Western Pomerania, Berlin, Saxony,<br />

Saxony-Anhalt and Thuringia received<br />

their orders. Back-up also came in the form<br />

of the PM DAISY ® XP fleet management<br />

system.<br />

The data and information system (DAISY ® )<br />

was developed by <strong>Putzmeister</strong> back in the<br />

90s for the management accounting of concrete<br />

pumps. It networks important information<br />

and operational data between the<br />

dispatch office, the truck-mounted concrete<br />

pumps and their operators. PM DAISY ®<br />

offers such functions as the complete re-<br />

cording and processing of orders for the<br />

truck-mounted concrete pumps, on-time<br />

billing and driver payroll bonus accounting.<br />

In addition, an integrated map system in<br />

connection with GPS (Global Positioning<br />

System) makes it possible for itineraries to<br />

be planned and visually displayed. Even<br />

hundreds of miles away, the headquarters<br />

therefore has precise information about the<br />

present site or set-up location of its trucks.<br />

Since this time, the bulk of the 1,700<br />

registered truck-mounted concrete pumps<br />

in Germany are managed using PM<br />

DAISY ® XP. Furthermore, approximately<br />

15 % of all concrete pumps are linked to<br />

their central dispatch via the on-board<br />

computer.<br />

43<br />

The stolen BSF 24.11 H<br />

truck-mounted<br />

concrete pump<br />

Satellite-supported data exchange<br />

The M 24 thieves really ought to have<br />

planned their job better – they obviously<br />

hadn't reckoned with the GPS location<br />

capabilities of the dispatch office of TBG<br />

Betonpumpendienst Berlin (all the<br />

company's pumps happen to be equipped<br />

with GPS). Thanks to the satellite-supported<br />

data exchange between the PM DAISY ®<br />

XP on-board computer and the dispatch<br />

office of the pumping service, the location<br />

of the truck-mounted concrete pump would<br />

soon be clear. The accuracy is comparable<br />

with that of a navigation system. Andreas<br />

Keiser, authorised signatory at TBG<br />

Betonpumpendienst Berlin: “We were able<br />

to zoom right down onto the truck to a<br />

scale of just 15 m!”<br />

The GPS data led to a large outbuilding<br />

on a farm near Salzwedel, approximately<br />

250 km from the operating site of the<br />

M 24. Within around eight hours of the<br />

theft being discovered, machine operator,<br />

Falk Berger, and his colleague, Frank<br />

Thiem, had tracked down the stolen truck<br />

and contacted the police. And of the<br />

thieves? Not a trace. The only evidence<br />

they had left behind was yet a second –<br />

also stolen – truck-mounted concrete pump<br />

on the farmstead, and the assemblies of a<br />

third. The investigating authorities meanwhile<br />

assume that the stolen property was<br />

to be shipped out of the country from<br />

Hamburg at an opportune moment.<br />

44<br />

15<br />

PM 3786 GB


16<br />

PM 3786 GB<br />

Application<br />

Attractive niche markets for the<br />

TELEBELT ® telescopic conveyors<br />

The Swiss have always been technically<br />

sophisticated, and not only when it comes<br />

to the accuracy of precision mechanical<br />

timepieces. Construction machine operators,<br />

too, have concrete ideas of what their<br />

machinery and equipment must be<br />

capable of delivering when used on construction<br />

sites between Basel and Lugano.<br />

The criteria, for example, are versatility,<br />

minimal space requirements due to the<br />

chronic restrictions in Swiss inner cities,<br />

and safety and simplicity in operation.<br />

The TELEBELT ® TB 110 with a horizontal reach of 32 m<br />

46<br />

a 3 Betonpumpen AG is one of the companies<br />

that closely examines the potential<br />

of a new acquisition before committing to<br />

an investment. With around 30 employees,<br />

the company domiciled in Affoltern<br />

operates 13 PM truck-mounted concrete<br />

pumps with boom vertical reaches of up to<br />

46 m as well as several stationary concrete<br />

pumps and MX placing booms. “In construction,<br />

there are still plenty of materials<br />

other than concrete that often cannot be<br />

pumped,” says Gery Schär, the managing<br />

director of a 3 .<br />

Pneumatic conveyor as forerunner for<br />

bulk material transport<br />

This is why, for some years, the company's<br />

fleet has included three pneumatic conveyors.<br />

With compressed-air assistance,<br />

these machines serve to transport a variety<br />

of materials including lightweight and lean<br />

concrete and all sorts of bulk materials,<br />

such as sand, grit, gravel, crushed stone,<br />

granulate, etc. The pneumatic conveyors<br />

are manufactured in small-volume production<br />

by Swiss PM representative, Pumex<br />

(Winterthur). Acting as the machines'<br />

working arm is the boom of a truckmounted<br />

concrete pump. The conveying<br />

technology is based partly on the knowhow<br />

that <strong>Putzmeister</strong> gained from the<br />

MOCOPCO system (Mobile Concrete<br />

Pneumatic Conveyor) in the 90s.<br />

45<br />

However, the output of the pneumatic conveyors<br />

is – depending on the material –<br />

limited to no more than around 30 m 3 /h.<br />

And, due to the line cross section, it is only<br />

possible to deliver grain sizes of up to<br />

32 mm in diameter. With the desire to<br />

notch up the capacity of these “carry-alls”,<br />

a 3 Betonpumpen AG had for a long time<br />

shown a keen interest in the TELEBELT ®<br />

telescopic conveyors. The machines are<br />

built by the PM subsidiary, <strong>Putzmeister</strong><br />

America. The specialists of a 3 gained their<br />

first experience with a hired machine. In<br />

June <strong>2006</strong>, the company put their very<br />

own, first TELEBELT ® into service; a<br />

second would be delivered in August.<br />

High-capacity telescopic conveyor belts<br />

TELEBELT ® is a multiple-telescoping conveyor<br />

belt system onto which the conveyed<br />

material is transferred by a feed conveyor –<br />

there is one on-board. Three models are<br />

available (TB 80, TB 110 and TB 130)<br />

with a horizontal reach of 24 m, 32 m and<br />

38 m respectively. The telescopic conveyors<br />

are built on a 3 or 4-axled truck<br />

chassis. The near 45 cm wide conveyor belt<br />

of a TELEBELT ® can – as with the pneumatic<br />

conveyors – transport every conceivable<br />

type of bulk material, horizontally or<br />

vertically, – be it sand, grit, gravel, crushed<br />

stone, compost, substrate for roofscaping,<br />

or relatively dry or lean concrete mixtures.<br />

But these machines are significantly more<br />

powerful (capacity max./theor. 275 m 3 /h)<br />

and are even able to convey grain sizes of<br />

100 mm. Their favoured applications are<br />

therefore to be found in civil engineering,<br />

dam construction, railway construction and<br />

horticulture and landscaping.<br />

Incidentally, with the new TELEBELT ®<br />

generation, the feed conveyor on the work<br />

site can be raised, swung to the side and<br />

lowered hydraulically by radio remote control<br />

(“active feeder”). With the older<br />

machines, the feed conveyor was “piggybacked”<br />

by the main belt and set down to<br />

one side. In addition, the reversing function<br />

of a 3 's TB 110 is an interesting item of<br />

optional equipment: it allows the conveyor<br />

belt to be reversed, making it also possible<br />

to use the TELEBELT ® for tasks such as<br />

clearing away old gravel or substrate<br />

materials.<br />

Access all areas<br />

One of the first times the new TB 110 of a 3<br />

Betonpumpen AG was put to work, things,<br />

as expected, had become crowded. The<br />

machine had to be set up in the middle of a<br />

residential area not far from the centre of<br />

Dump trucks load the feed conveyor of the TELEBELT ®<br />

with gravel the size of a fist<br />

The telescopic conveyor fills the cavity between slope<br />

and basement wall with pin-point precision<br />

Zürich. Cars would come to park on both<br />

sides of the busy street. Right in front of<br />

the construction site, a couple of metres of<br />

space was left free for the TELEBELT ® and<br />

its “out and down” supports, which – in an<br />

extraordinarily space-saving manner – are<br />

only extended and lowered perpendicular<br />

to the direction of travel. As soon as the<br />

feed conveyor is lowered and the main conveyor<br />

brought into position, tippers begin<br />

to load the gravel - sometimes as big as a<br />

fist - onto the feed conveyor. A hopper<br />

mounting prevents the material from<br />

dropping onto the road during the transfer.<br />

The purpose of the gravel (approximately<br />

60 m 3 ) is to fill a cavity between the outside<br />

wall of a new build's basement and<br />

the hillside at the back. The architect res-<br />

47<br />

Application<br />

ponsible insists on it as an effective drainage<br />

layer. The gravel will then be topped<br />

with a pouring of recycled concrete granulate<br />

(10 m 3 ). How else would they have<br />

brought the gravel (size approximately<br />

30 x 50 mm, but often with particle oversize<br />

too) and the subsequent broken recycling<br />

material to the back of the construction<br />

site? With the wheel loader? This<br />

would have been impractical given the lack<br />

of approach. With the concrete pump?<br />

Impossible... the bulk materials were loose<br />

and dry. By crane-lifted buckets or wheelbarrow?<br />

This would have taken too long. In<br />

the opinion of the construction team, there<br />

could simply be no option more viable than<br />

delivering and placing the material with<br />

pin-point precision by TELEBELT ® .<br />

During the course of the morning, the<br />

TELEBELT ® operator receives a message<br />

from headquarters on the DAISY ® onboard<br />

computer. For not only are all of a 3 's<br />

truck-mounted concrete pumps and compressed-air<br />

conveyors managed using the<br />

data and information system, but so too the<br />

new telescopic conveyor. The machine is<br />

ordered on to the next construction site,<br />

which is located in Bremgarten, approximately<br />

20 km west of Zürich. Here it is<br />

needed to deliver concrete with a high<br />

steel fibre content (40 kg/m 3 , length of pins<br />

65 mm) for a warehouse floor. Under ideal<br />

conditions, i.e. feasible grading curve,<br />

matching cement percentile (additionally<br />

around 30 kg/m 3 ), not too low a w/c value<br />

etc., it would normally have been possible<br />

to have had this steel fibre concrete<br />

pumped. But conditions are not always<br />

exactly ideal. Gery Schär: “With the aggregates<br />

that we have in the concrete here, the<br />

maximum we can pump is a steel fibre<br />

content of 35 kg/m 3 !” To the TELEBELT ® ,<br />

the high steel fibre content, the long pins,<br />

the type of aggregates and a low w/c value<br />

are completely inconsequential.<br />

48<br />

17<br />

PM 3786 GB


18<br />

PM 3786 GB<br />

Technology<br />

New long-reach boom<br />

pump serves historical<br />

exhibition halls<br />

In Köln-Deutz, Hochtief Construction AG<br />

is converting the old exhibition halls on<br />

the banks of the Rhine into a modern<br />

office and media centre. While the<br />

historical brick façades have been retained,<br />

Cologne's largest office project<br />

makes progress behind the outer walls.<br />

Both the coring of the old building and<br />

the excavation work require a combination<br />

of experience and instinct.<br />

The concreting of the expansive, up to<br />

1.5 metres deep foundations, walls and<br />

floors requires truck-mounted concrete<br />

pumps with a long working reach. Of the<br />

concrete's 140,000 m 3 total volume, around<br />

one third is being placed by machines of<br />

BEKA-Betonförderdienst GmbH (Kerpen).<br />

BEKA is favouring the use of its new<br />

<strong>Putzmeister</strong> M 62 “six-arm” in the<br />

former exhibition halls. The machine is<br />

equipped with a large 200 m 3 /h core pump,<br />

making the concreting of the formwork<br />

sections, which on this site have a typical<br />

volume of up to 1,800 m 3 , a speedy process.<br />

An older M 52-5 offers occasional<br />

assistance.<br />

Around a half of the gross floor space<br />

measuring over 200,000 m 2 has already<br />

been let to RTL, Europe's largest commercial<br />

television broadcaster. The reason<br />

behind this is that the TV company would<br />

like to relocate the German headquarters of<br />

the holding company to the historical halls<br />

and gather under one roof its businesses<br />

scattered across several locations in<br />

Cologne.<br />

The listed Rheinhallen 1 – 5 with their<br />

expressionist façades were built between<br />

1924 and 1928 on the order of Cologne's<br />

mayor of the time, Konrad Adenauer.<br />

Additional annexes were built in the<br />

1970's, but these have since been torn<br />

down as part of the modernisation work.<br />

The 200 m 3 unit of the BEKA M 62-6 pumps just the<br />

right amount<br />

After swinging out briefly, the forward telescopic support of the<br />

PM long-reach boom pump extends directly to the support point<br />

49<br />

50<br />

The floor slab is up to 1.5 m deep<br />

Technology<br />

51 52<br />

Concentrating on the task at hand, machine operator,<br />

Joachim Böhme, controls the placing boom of his<br />

M 62-6 into position over the formwork<br />

53<br />

19<br />

PM 3786 GB


20<br />

PM 3786 GB<br />

Bridge Construction<br />

Brutal concrete mixture<br />

Following the completion of the Three<br />

Gorges Dam and commissioning of the<br />

5,000 m high railway to Tibet, China<br />

now has everyone talking about another<br />

spectacular construction project.<br />

The Sutong bridge across the Yangtzekiang<br />

(also known as Yangtze) inspires so many<br />

superlatives that only the key facts need be<br />

listed here: its span makes it the longest<br />

cable-stayed bridge in the world. It has an<br />

overhead clearance of 62 m and is flanked<br />

by enormous pylons. Together with the<br />

approaches and departures, the 8,206 m<br />

long bridge construction, which rests on<br />

more than 140 pillars and was created<br />

using launching gantries, spans the<br />

Yangtzekiang River, which can swell to a<br />

width of 14 km in places depending on the<br />

time of year. But to get to the point: the<br />

concrete placed here forces the concrete<br />

pumps to the very limits of their performance.<br />

A boat ferries site personnel to one of the two pylons far out on the Yangtze<br />

To allow the passage of container ships, a<br />

bridge section with a span of 1,088 m is<br />

freely suspended by two 306 m high<br />

pylons. The new bridge is located approximately<br />

280 km to the east of Nanjing and<br />

around 100 km to the west of the Yangtze<br />

estuary. In the highly industrial province<br />

of Jiangsu (approximately 74 million inhabitants),<br />

the 6-lane water crossing establishes<br />

a link between Nantong City and<br />

Changshu. The bridge construction was<br />

deemed a necessary investment given the<br />

annual 15 % increase in the volume of<br />

traffic across the mighty river.<br />

The pylons stand on sturdy concrete foundations,<br />

which are anchored in the bedrock<br />

122 m below the river bed. Pontoons acting<br />

as working platforms are anchored around<br />

foundations for the duration of the construction<br />

phase. They are also home to the<br />

mixers and stationary concrete pumps.<br />

54<br />

Model of the enormous Sutong cable-stayed bridge<br />

Grit, granite and a low w/c value<br />

The pylons are made of an extremely dense<br />

reinforcement and high-strength concrete<br />

(C80). A great deal is expected of the concrete<br />

pumps in the task of delivering the<br />

concrete through the risers: the grading<br />

curve is unbalanced; the fines currently<br />

consist of open-pored, ground slag; a sharp<br />

grit is used for a grain size of 4 mm; the<br />

largest aggregates (5–25 mm) are made<br />

exclusively from extremely wear-promoting<br />

granite; and the w/c content even<br />

reaches the value of 0.34. Then mix in the<br />

various chemical additives and…<br />

The reinforcement is exceptionally dense<br />

56<br />

The high-pressure concrete delivery line is secured to the<br />

outer wall of the pylon towering to a height of 300 m<br />

57<br />

1.088 m<br />

8.206 m<br />

306 m<br />

Before delivery of the BSA 14000 HP-D<br />

high-pressure concrete pump, <strong>Putzmeister</strong><br />

had promised that, with a delivery height<br />

of 310 m, the machine would still deliver<br />

30 m 3 /h through a 125 mm pump line. To<br />

this end, the BSA had been designed for<br />

concrete pressures of up to 260 bar. When<br />

a disproportional increase in hydraulic<br />

pressure at the concrete pumps was observed<br />

on reaching the 150 m mark, <strong>Putzmeister</strong><br />

AG After Sales department and the<br />

Technical Management were called upon to<br />

intervene. After a minor modification to the<br />

concrete recipe, a reinforcement of certain<br />

concrete pump components under the most<br />

load, and the use of new generation hard<br />

metal wear parts, it was possible to resume<br />

the vertical delivery of the concrete.<br />

The total costs of the Sutong bridge building<br />

project are estimated at around 6.45<br />

billion yuan (approximately US $ 726<br />

million). The work began in June 2003;<br />

completion is scheduled for 2009.<br />

A totally unbalanced grain size was typical at first of<br />

the concrete used at the Sutong bridge<br />

59<br />

A BSA 14000 HP-D PM high-pressure pump under the mixer. You're observing the concrete pouring…<br />

58<br />

55<br />

21<br />

PM 3786 GB


22<br />

PM 3786 GB<br />

Bridge Construction<br />

Info on the Yangtze<br />

After the Nile and Amazon, the<br />

Yangtzekiang ranks as the third longest<br />

river on Earth. Its entire length of 6,380 km<br />

flows through the People's Republic of<br />

China, 2,800 km of which are navigable.<br />

A population of around 350 million live in<br />

its catchment area. More than 40 % of the<br />

country's industrial production and more<br />

than half of its agricultural production is<br />

output from this region. On the upper course<br />

of the Yangtze, meanwhile, the controversial<br />

Three Gorges Dam and its massive<br />

power station dominate the skyline.<br />

According to unconfirmed information, the<br />

concrete aggregates used for the Sutong<br />

bridge originated from the rubble blasted<br />

from the granite during construction of the<br />

hydroelectric power station and the head<br />

race tunnels at the Three Gorges Dam.<br />

Several sections of the gigantic river are so<br />

dirty today that the drinking water supply<br />

of a number of major cities along the<br />

Yangtze is suffering the consequences. The<br />

mighty river flows into the Yellow Sea<br />

north of Shanghai at a rate of 35,000 m 3<br />

every second.<br />

Its official name in China is Changjiang<br />

(long river). The name by which it is<br />

known in Europe, the Yangtzekiang, comes<br />

from the word Yangzijiang, which is used<br />

in Chinese only when actually referring to<br />

the estuary region of the Yangtze.<br />

Info on the cable-stayed bridge design<br />

Construction engineer, Bernd Nebel, a<br />

recognised bridge building expert,<br />

explains the advantages of the cablestayed<br />

design over other bridge building<br />

methods on his website: “The advantage<br />

of cable-stayed bridges over suspension<br />

bridges is that it is possible to do without<br />

cost-intensive back-anchoring by means<br />

of anchor blocks. With the cable-stayed<br />

bridge, the restraint cables outside the<br />

main span are simply secured directly to<br />

the deck. The mass of the deck at the<br />

shore span provides the counterweight for<br />

the main span...A cable-stayed bridge…<br />

can be built on the open sea as the main<br />

gateway to a substantially longer multispan<br />

bridge… The absence of an anchor<br />

block and the simpler construction are the<br />

reasons why cable-stayed bridges are,<br />

The catchment area of the Yangtze with the Three Gorges Dam on the upper course,<br />

and the Sutong bridge not far from the estuary to the Yellow Sea<br />

generally speaking, less expensive than<br />

suspension bridges… The largest cablestayed<br />

bridge in the world constructed to<br />

date is the Tatara bridge in Japan with a<br />

main span of 890 m. The constraining<br />

factor in the development of even longer<br />

spans and the crucial disadvantage of the<br />

cable-stayed bridge are the difficult, static<br />

conditions during the construction phase…<br />

Cable-stayed bridges are the world over<br />

constructed using the cantilever method...<br />

If the load-bearing framework consists of<br />

two pylons, the construction teams work<br />

from both sides simultaneously until the<br />

unsupported ends of the deck meet in the<br />

middle. The greater the main span of the<br />

60<br />

bridge and the more the freely projecting<br />

deck has been completed, the more<br />

susceptible the superstructure is to cross<br />

wind… Even a moderate wind can agitate<br />

the unsupported end into vibrations<br />

putting it at serious risk.”<br />

(www.bernd-nebel.de)<br />

61<br />

62<br />

M 38-4, the big allrounder<br />

Longer reach and more construction sites<br />

– these are the decisive plus points<br />

characterising the M 38-4 “Z fold boom”<br />

that <strong>Putzmeister</strong> has developed for special<br />

markets. Construction firms mainly in<br />

Eastern European countries, but also in<br />

France and Switzerland, have expressed a<br />

keen interest in the 30-metre class.<br />

The machine is fundamentally based on<br />

the boom design and base structure of the<br />

M 36-4 “Z”, which has been manufactured<br />

in large-scale production at PM for many<br />

years. Depending on the make-up of the<br />

vehicle fleet of a concrete pumping service<br />

and the content of the competition's vehicle<br />

pool, the M 38 assumes the position of<br />

flagship in a number of markets. The M 38<br />

“Z fold boom” is built on a 3-axled chassis<br />

Placing concrete in the floor of an old building<br />

as standard. In the 4-axled version (optional),<br />

the machine has considerable weight<br />

reserves for carrying extra pipes and delivery<br />

hoses. At the same time, the shorter wheelbase<br />

helps to improve the manoeuvrability<br />

of the truck-mounted concrete pump.<br />

The 4-axle version was chosen, for example,<br />

by the French pumping service, Atlantique<br />

Pompe à Béton (APB). From the corporate<br />

seat in Lorient, owner Patrick Boisbunon<br />

counts the whole of Brittany within his<br />

catchment area. In this region with a surface<br />

area of approximately 27,000 km 2 and<br />

almost 3 million inhabitants, APB uses a<br />

total of six truck-mounted concrete pumps<br />

in the 20 and 30-metres class as well as a<br />

PUMI ® truck mixer concrete pump.<br />

Concrete placement in the back yard<br />

Monsieur Boisbunon drives the new M 38-4<br />

himself. For this afternoon, he has been<br />

summoned to the centre of the town of<br />

Quimperlé. He is already familiar with the<br />

construction site from previous visits. In<br />

the busy traffic, he sets up the machine in<br />

front of the house and is relieved once<br />

more that his M 38 is equipped with oneside-support<br />

(OSS). The truck-mounted<br />

concrete pump is needed in the restoration<br />

of an annexed building in the rear courtyard,<br />

the roofs of which – spread over three<br />

floors – had to be removed first and are<br />

now going to be replaced with new ones.<br />

Today, the floor on the top level is being<br />

poured out with fine concrete (grain size<br />

0/5 mm).<br />

From the main road, Patrick Boisbunon<br />

controls the quadruple-jointed “Z fold<br />

boom” past the chimney of the streetfacing<br />

house and over the ridge of the roof<br />

Technology<br />

at a height of approximately 11 m. He then<br />

angles the “C” and “D” arms downwards<br />

towards the courtyard and, by gently<br />

slewing the boom sideways to and fro,<br />

manoeuvres the end hose into a position in<br />

which it can be pulled through the window<br />

opening by the members of the construction<br />

team. Within a few minutes, the 4.5 m 3<br />

of fine concrete is distributed on the floor<br />

surface measuring barely 50 m 2 . To make it<br />

easier for the concrete hose to be swung by<br />

hand, Monsieur Boisbunon had exchanged<br />

the ND 125 end hose for an ND 100 hose<br />

in advance and connected it using a reducer<br />

on the boom delivery line. As efficiently as<br />

the M 38 was set up and made ready for<br />

use, the pipeline was cleaned with a sponge<br />

ball and the boom brought into the transport<br />

position. It was already time to depart<br />

for the next construction site of the day.<br />

63 64<br />

Above and beyond the roof of the main building on the<br />

street, Monsieur Boisbunon controls the placing boom<br />

of his M 38-4 through the window of the adjoining<br />

building<br />

65<br />

23<br />

PM 3786 GB


Practical Tip<br />

Small pin<br />

for great<br />

effect<br />

The fact that concrete is often, or<br />

frequently has to be, pumped through<br />

extended hose and pipelines was demonstrated<br />

by a few examples in this edition<br />

of PM Post. <strong>Putzmeister</strong> AG expressly<br />

points out that the use of lever couplings,<br />

e.g. with the SK standard coupling system<br />

and the PX hoseline system, demands that<br />

the tension levers be additionally secured<br />

against inadvertent release by means of a<br />

spring pin (cotter pin).<br />

Only with a spring pin are lever couplings really secure!<br />

Imprint:<br />

Publisher<br />

<strong>Putzmeister</strong> AG<br />

Max-Eyth-Str. 10<br />

D-72631 Aichtal<br />

Tel.+49 (71 27) 599-0<br />

Fax 599-520<br />

■ Editor:<br />

Jürgen Kronenberg<br />

■ Design:<br />

Friedrich Pippich<br />

It is not that this precaution is a<br />

necessary to prevent couplings<br />

from being released unintentionally<br />

as a consequence of<br />

the concrete pressure that<br />

builds up in the line. This risk<br />

is practically eliminated as<br />

soon as the coupling lever is<br />

forced beyond the dead point.<br />

The machine operator is not able,<br />

however, to prevent the hoseline<br />

from moving during operation and,<br />

for example, being caught on reinforcements.<br />

An unwanted counter-<br />

Your fax for further information<br />

■ Would you like more information on certain topics in this edition of <strong>Putzmeister</strong> Post?<br />

If so, just copy this page, make a cross next to the topics you are interested in and fax<br />

the form to us. We will then send you detailed information immediately.<br />

❏ Truck-mounted concrete pump BSF 20.09 H ......................................BP 3697<br />

❏ Shotcrete pump P 715 TD ................................................................MM 3541<br />

❏ Truck-mounted concrete pump M 42-5 „RZ“ ......................................BP 3756<br />

❏ Stationary concrete pumps ..................................................................BP 2632<br />

❏ Stationary delivery booms ..................................................................BP 2059<br />

❏ TELEBELT ® TB 110 ..............................................................................TB 3637<br />

❏ <strong>Putzmeister</strong> Delivery line systems ......................................................PM 2300<br />

❏ Truck-mounted concrete pump M 6X ..................................................BP 3621<br />

❏ Truck-mounted concrete pump BSF 38.14 H, 16 H, 16 HLS ..............BP 3698<br />

<strong>Putzmeister</strong> AG, Max-Eyth-Str. 10, D-72631 Aichtal<br />

PSdg, Deutsche Post AG, Entgelt bezahlt, E 60458<br />

movement, and the tension lever opens.<br />

The consequence is an uncontrolled concrete<br />

stream that gushes out of the line<br />

with a pressure of 85 bar and that may<br />

cause disastrous damage to property and<br />

devastating personal injuries.<br />

For safety reasons, therefore, experienced<br />

machine operators will carry a few more<br />

spring pins on-board as spares than are<br />

actually needed. For not only do the spring<br />

pins secure the couplings of the extension<br />

lines, they are also a requirement for the<br />

couplings of the boom pipework. Fitting<br />

the cotter pin only takes a matter of<br />

seconds. In the interests of risk-free<br />

operation, any safety-conscious machine<br />

operator would take the time to ensure<br />

this is done.<br />

Name ........................................................................................................<br />

Company ..................................................................................................<br />

Position ....................................................................................................<br />

Street ........................................................................................................<br />

Post code/City ..........................................................................................<br />

Tel. no. ......................................................................................................<br />

E-Mail........................................................................................................<br />

<strong>Putzmeister</strong> AG<br />

Max-Eyth-Str. 10 · D-72631 Aichtal<br />

P.O.Box 21 52 · D-72629 Aichtal<br />

Tel. +49 (71 27) 599-0<br />

Fax +49 (71 27) 599-520<br />

Internet: http://www.putzmeister.de<br />

E-mail: pmw@pmw.de<br />

PM 3786 GB All rights reserved. Subject to technical amendments without notice. The illustrations in some cases show special-purpose machine designs and snapshots of site<br />

practice which do not always comply with the regulations determined by professional bodies. © <strong>2006</strong> by <strong>Putzmeister</strong> AG · Printed in Germany (3.50609RR)<br />

66

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