2006 - Putzmeister
2006 - Putzmeister
2006 - Putzmeister
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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 />
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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 />
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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 />
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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 />
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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