PM 3582 GB POST 60
Transcription
PM 3582 GB POST 60
The Magazine for our Customers and Friends 60 PM 3582 GB Contents Latest News 2 Latest News 3 M 32 fights major fire 4 M 32 fights major fire PM greetings cards support UNICEF projects Title Stor y 4 Extensive concreting for a complex bridge construction International 7 10 13 14 20 Afghanistan: Building a new university Great Britain: Service-directed for more than 30 years 8 22 23 4 3 7 9 20 8 Italy: No time for a coat of paint! Poland: Warsaw pump service concreting “Golden Terraces building complex” France: The land of the rotor fans Domestic Compact 4-section boom features numerous strong advantages 5 10 6 14 10 18 Formwork dismantled just three days following placement of high-strength concrete One-side support on narrow Neckar weir Applications 24 Universal pump for shotcrete job 7 Tunnel Construction 18 Sika®-PM wet spraying systems back up tunnel advance work along the Mediterranean Highway Practical Tip 19 2 PM 3582 GB Mess-free formwork 12 For three years now, the M 32 truckmounted concrete pump belonging to the ready-mix company BERDING-BETON (Steinfeld) has been a firmly integrated item in the resource planning of Vechta fire brigade for the Osnabrück region. And only just recently, the concrete boom was able to demonstrate its valuable features in fighting a major fire in Dinklage. 13 8 22 11 23 Although the 17 fire brigades from the Vechta area and the neighbouring Artland totalling 59 vehicles were quickly on the scene of the fire – an approximately 4,000 m2 hall complex – the working area of the two turntable ladders used was not sufficient to cope with the situation alone. The operation controllers therefore made a quick decision to send for the additional help of the Putzmeister BRF 32.16 H belonging to the BERDING-BETON company. Within a mere 15 minutes, the truck-mounted concrete pump was converted into a highly flexible fire-fighting boom as two firemen replaced a section of the delivery line downstream of the pressure pipe of the truck-mounted concrete pump with a delivery line bend fitted with an adaptor to the fire brigade’s coupling system. A collective connection to accommodate the two B-water hoses was also added. The end hose was removed from the tip of the boom and replaced with a socalled S8 foam pipe using a coupling. Concrete pump operator, Franz-Heinrich Ritterhof, then directed the articulated boom by radio remote control over the seat of the fire. During the fire-fighting operations, foam was used to extinguish the fire, instead of water. The foam was provided from a tank fire truck which fed up to 2,400 litres per minute to the delivery line of the truck-mounted concrete pump. As pump operator Ritterhof was controlling the boom from ground level and the view from above was restricted to the seat of the fire, his mates from the fire brigade had to improvise. From two higher observation posts (a tree and a retractable ladder), they actively and energetically helped to guide PM greetings cards support UNICEF projects Photo: Police Oldenburg 13 Photo: Holger Bokern the boom tip to where it was needed. Christian Katzer, a fitter at BERDINGBETON and fire chief of the Steinfeld fire brigade involved in the operations: “The boom of a concrete pump is well suited for fire-fighting operations. It is easily converted for the job without having the firemen standing in the real danger areas!” By the way – if a nozzle is connected to the boom tip instead of the S8 foam pipe and only fire-fighting water is sprayed, then the reach with this combination of fire truck and concrete pump boom is up to 70 m! Unlike in the past, Putzmeister AG will not be sending Christmas and New Year cards of its own design this year to its business partners but will be using UNICEF greetings cards instead. UNICEF has been selling the cards for many years and using the income to support numerous projects in countries where it is most needed. For example, the sale of 500 cards will finance the equipment required in a complete village hospital ward. Putzmeister hopes the change will meet with the approval of its customers and friends and would be happy to learn that they liked the cards. 3 PM 3582 GB Title Stor y Extensive concreting for a complex bridge construction 14 The new, 820 m Yahagigawa Bridge has a three-lane carriageway in each direction of travel. Its impressive architecture is visible from afar. 15 Currently under construction in Japan is the so-called Second Tomei Expressway, urgently needed to deal with the high volume of traffic between Tokio and Nagoya. The new motorway will take some of the pressure off the present Tomei Expressway which connects the two cities. 16 principals JAPAN HIGHWAY PUBLIC CORPORATION to two well-reputed construction companies KAJIMA KENSETSU Co. Ltd. who is building the Western side and ORIENTARU KENSETSU Co. Ltd. who is responsible for the Eastern side. Construction work commenced in October 2002 and work should be completed by the end of 2004. The new motorway project also involves the construction of an 820 m long motorway bridge to span the Yahagigawa River – a task which is worth several entries in the Guinness Book of Records! The most interesting aspect of the work is the methods of placing and distributing enormous quantities of mostly highstrength concrete into the piers of the bridge and on to the formwork for the road surface using stationary and mobile PM concrete pump units. The bridge across the Yahagigawa River is a cable-stayed bridge resting on two towers, which have a drop-shaped crosssection separating into two lattice-trussed halves at a height of about 11 and 16 m through which a six-lane road is spanned in the centre of the carriageway. The two structures meet in perfect harmony about 84 m above the ground, reaching a height of around 121 and 126 m above the foundations. The impressive construction height of the Yahagigawa bridge represents a record-breaking project for Japan. The contract for the works was awarded by the 4 PM 3582 GB Simultaneous concreting of separate towers A systematic diagram of the first phase of construction showing the PM high-pressure pumps BSA 2110 HP-D and BSF 2107 HP. Concrete placement in the towers was made using two RV 10 rotary distributors. Sub-contractors TYUOU KENSETSU Co. Ltd. (formerly TAKASAGO KENSETSU Co. Ltd.) were commissioned to concrete individual sections of the impressive motorway bridge. The company’s fleet includes more than 20 Putzmeister concrete pumps and is one of the largest concrete pump service providers in Japan. According to estimations made by the site management no locally-manufactured concrete pump would have been able to carry out the concrete installation on this construction site as almost all sections require concrete to be pumped to a height of about 120 m – and that demands a very high concrete pressure. All in all, the amount of concrete required for the towers and the carriageway deck of the Yahagigawa Bridge is estimated at about 24,000 m3. Pump service providers CHUO KENSETSU solved the problem by deploying two Putzmeister concrete pumps type BSF 2107 HP designed specially for high concrete pressures and a stationary pump type BSA 2110 HP-D. The BSF 2107 HP (MOLI) is a truck-mounted concrete pump 17 18 without a boom which PM has designed to deliver concrete through long pipelines (i.e. for high pump pressures). The MOLI, which stands for mobile line pump is frequently to be found in operation in countries in South-East Asia. Already in rod side operation, the machines in this series achieve concrete pressures of 150 bar and pump flows of 68 m3/h, as does the “ordinary” stationary pump BSA 2110 HP-D which, by the way, is designed for concrete pressures up to 150 bar and outputs of up to 110 m3/h in rod side operation. CHUO KENSETSU have connected the concrete pumps at each of the two towers to two type RV 10 mechanical concrete rotary distributors via high pressure-proof ZX delivery lines. The concrete distributors can be slewed horizontally over a working radius of 10 m and in this phase of construction, one was installed to each of the tower halves to enable the concrete to be poured as rapidly as possible into the, in parts, very complex formwork sections. High-pressure pumps designed to deal with 220 bar concrete pressure The MOLI (mobile line pump) is a boom-less truckmounted concrete pump designed by Putzmeister especially for the delivery of high-pressure concrete through long delivery lines – the two operators are looking apparently well satisfied with its performance… When pressure rose to 130 bar in about 80 m height, operational mode was switched to piston side in both the MOLIs and the BSA 2110 HP-D. All of the pumps were now able to deliver concrete up to a pressure of 220 bar. This of course, for physical reasons, reduced the output. Nevertheless, around 170 m3 of concrete was placed each day, tantamount to a daily construction height of around 4.5 m. All that was then needed to concrete the upper As construction height increases, only one highpressure concrete pump and one concrete rotary distributor are required for concreting the towers areas of the towers was a concrete pump and a concrete rotary distributor type RV 10. At the end of the placing operations, the delivery lines were cleaned using a power-driven high-pressure water pump which had to be hoisted each time by a crane up to the site of the concrete placement. 5 PM 3582 GB Title Stor y International 24 19 High-strength concrete for the carriageway Concreting the carriageway deck was a totally different story for CHUO KENSETSU. The substructure of the bridge consists of pre-fabricated box girders on which a carriageway deck rests as a relatively lightweight composite construction. The tensile strength and flexural strength of the construction is provided by steel girders. The reinforcement on top is cast in concrete. With a width of 43.8 m for the main girder, the Yahagigawa River Bridge sets yet another construction record for Japan as does the distance of 235 m between the two towers – an impressive performance for the Japanese bridge builders. 22 In spite of occasional attacks, there is no more stopping the re-building of Afghanistan’s capital, Kabul. Following our report in the PM POST No. 58 regarding the delivery of a M 36 to the F.C.E.C. company and its building projects, we would now like to present a brief report on the construction of a new university complex. MOLI high-pressure pumps in combination with M 36 booms To begin with, two Putzmeister type BSF 52.15 H heavy-duty boom pumps – one of which was mounted on a semi-trailer – took on the job of concreting the deck formwork on the bridge. The five-arm folding booms reached as high as the carriageway where they were positioned at a right angle to concrete more than half of the carriageway width in one operation. As work progressed on the carriageway sections, the process was changed: The two M 52 heavy-duty booms at the foot of the towers were replaced by two MOLI highpressure pumps which delivered concrete via firmly installed pipelines first horizontally, then vertically to the M 36 truckmounted concrete pumps on the bridge decks. Efficient and powerful pumps were now required for casting the deck formwork because of the 60 N/mm3 concrete compressive strength. The M 36 by the way was used to distribute concrete and not as a relay pump. Kabul: Building a new university by simple means Concreting the bridge carriageway. In the centre is a BSF 36.15 H which is only used for distributing the concrete. The supply of concrete comes from a pipeline fixed on the spread. The line is connected to the riser pipe of the truckmounted concrete pump downstream from the reducer (please refer also to the title page of this issue). 20 21 TARHE SAKHTE AFGHAN TOOS – an Afghan-Iranian enterprise is currently constructing a modern university centre which has been commissioned by Ayatollah Mohseni. When work has been completed, up to 4,000 students will be accommodated on a campus of 36,000 m2. In addition to 50 classrooms, the area will boast a research centre, a mosque, a library, a cafeteria, a medical centre and residential accommodation for the students. In May 2004, by the way, Afghanistan’s President Hamid Karzai participated in laying the foundation stone for the mosque – which will be one of the largest in Kabul. In all, work is in progress on ten buildings varying in size, all of which are planned to be handed over in March 2006 after a two-year construction period. The construction site is providing a livelihood for more than 200 people. The concrete pour for the foundations and the construction of numerous floors was pushed to some extent by AFGHAN TOOS by using a new PM stationary pump type BSA 1005D and an RV 10 rotary distributor. The most important spares and wearing parts of the BSA concrete pump, the couplings and the rubber washers for the delivery line were safely stored in a container. There is also a Putzmeister mortar pump type S 5 EV on the construction site where it deals with all AFGHAN TOOS personnel make sure that the name on their company sign is clearly visible on one of the walls 25 The RV 10 can be slewed manually and is used to place concrete on the floors pumpable mortars up to 6 mm grain size, output can be set infinitely variable (1.5 – 40 l/min) and is used particularly for plastering jobs. During the initial phases of constructing the carcass, AFGHAN TOOS personnel were making the concrete required themselves with the help of a 1 m positiveaction mixer which had to be filled by hand. In this way, they produced about 4 – 5 m3/hour of concrete and daily performance averaged at around 45 m3. In the meantime, AFGHAN TOOS is supplied with concrete from a newly-built concrete ready-mix works (capacity 30 m3/h) operated by the 2 RC company along the road to Jalalabad. The distance to the AFGAHN TOOS construction site is covered by the truck mixer in about 20 to 30 minutes. That means that there is now a considerably greater volume of concrete available which inevitably can be pumped and distributed more quickly. A PM stationary pump BSA 1005 D is responsible for concrete delivery on the vast area covered by the university premises 26 Many of the tools and machines needed for the work by AFGHAN TOOS came packed in containers from Iran to Kabul. In the foreground, the Putzmeister BSA and the responsible operator 23 27 Number and types of concrete pumps, provided by CHUO KENSETSU for the construction work on the Yahagigawa Bridge: 1 x BSF 52.15 H 1 x BSS 52.15 H (semi-trailer) 6 x BSF 36.15 H 2 x MOLI BSF 2107 HP 1 x BSA 2110 HP-D 4 x RV 10 6 PM 3582 GB A systematic diagram of the concreting of the bridge carriageway. As long as the horizontal reach of the two M 52 is long enough, the concrete is installed from ground level exclusively by means of the long-reach boom pumps (top right), during later construction process supported by the BSA and MOLI high-pressure pumps. Time-consuming concrete production using a positive-action mixer. In the meantime, green concrete is brought to the construction site in truck mixers. AFGAHN TOOS has a good supply of the most important wearing parts in stock 7 PM 3582 GB Domestic 30 Compact 4-section boom features numerous strong advantages In the meantime, many pump service companies have supplemented their machine fleet with the compact and universally deployable Z-fold M 28-4. Our brief report in issue 59 of the PM Post on some of the features might have contributed to such a decision being made. The following report describes the typical advantages of this four-sectioned boom with its exemplary weight reserves and ing operations can really begin, operator Roland Bänfer and his mate, Heinrich Gräb – who is on site today as a reserve man – have calculated a 30 minute warm-up period to get their M 28-4 “Z-fold” ready for operation. Then for this job for the Weber company (turning – drilling – milling), it’s not enough just to support the machine quickly and unfold the boom, the boom must be extended to reach far into the hall in order to place concrete for a high-load bearing foundation for a new metal-working machine. decidedly site-compatible support in daily operations. Furthermore, the special version of the machine is also equipped with the new fuel-saving EOC engine speed control. The new BSF 28.14 H owned by the concrete pump service company HÄBEL (Siegen) arrives punctually at nine in the morning at the construction site in the Netphen industrial park. Before the pump- The M 28 four-section boom stands with its long side immediately in front of the entrance to the machine shop. The working range of the Z-fold boom can be used without too great a loss in lateral reach. The arm assembly is lifted, slewed sideways and placed a little to the rear. Now the boom can be unfolded – like a pocket rule – and then driven to its end position in the shop. It’s really quite amazing to watch how quickly a “Z-fold” boom is ready for work! 29 28 The M 28-4 belonging to pump service providers HÄBEL also has a wide range of accessories on board: 125 mm and 100 mm delivery hoses and pipes for a total of 60 m, 65 mm hoses with a reach of up to 50 m, reducers, a considerable number of couplings and rubber washers. Nothing is left lying around loose on the flatbed – everything has its place. Either in magazines, in a storage space, on holders or in drawers. In order to be able to reach into the furthermost corners of the floor formwork in the shop, the 28 m extended boom must be lengthened by approximately a further 25 m. The two HÄBEL experienced employees easily and quickly replace the end hose on the boom tip with a reducer which tapers the line diameter from 125 mm to 65 mm. In compliance with safety regulations, the boom tip is placed on the ground and the reducer connected. In just a few minutes, five 65 mm hoses have been connected – and pumping begins at 9.30, a.m.. The working range of the M 28 Z-fold boom can be used without too great a loss in lateral reach “With my M 28 pump, not only can I pump large quantities of concrete for floor slabs or floors, but I also frequently work on smaller construction sites where pumps with larger booms cause problems when setting up the machine. Not to mention renovation sites which of course, are not always at the roadside. That means in about every third job, it is necessary to extend the boom delivery line by attaching additional hoses”, estimates pump operator Bänfer. “Here in the Siegerland, we are confronted by conditions that are either narrow, steep or confined. But I am always able to find a space for our M 28; I can even set it up between the site trailer and the Dixi site toilets!” When he mentions needing less space, he is referring to the front diagonal support (support width 6.2 m) and the almost vertical support legs at the rear (where the support width is just 2.6 m). What he also likes is the manoeuvrability of the four-sectioned boom which is made possible by its short wheel base. 31 The special version of the BSF 28.14 H belonging to HÄBEL is also equipped with the new fuel-saving EOC engine speed control. The EOC – or Ergonic Output Control – is just one of the extras provided by PM in the “Power Kit”. Putzmeister has developed the Ergonic Output Control (EOC) module as a control system for Where smaller quantities of concrete are required – although the delivery distance might still be extensive – operator Bänfer often deploys the 65 mm hoses. “That 8 PM 3582 GB The pipelines and connected delivery hoses are “lubricated” at first using a few buckets of grout 32 makes it easier for the concreting team, there’s less concrete residue and it’s easier to clean up afterwards.” According to his observations, there are practically no natural deposits of 16 grain size in the Siegerland – in contrast, for example, to the neighbouring Ruhr District. “The 16-grain chippings we send through the narrow lines should contain ample fine particles, otherwise we will quickly have too much wear and tear.” In the meantime, most of the mix companies in his catchment area have changed over to using fine-grain concrete with 0/8 chippings for renovation work. “Before I begin to place any concrete, I send a few buckets of grout through the line and then I start the job!” The retro-fitted high-pressure water pump means that cleaning operations are dealt with quickly and thoroughly, even in the big delivery lines. Radio remote control allows pump operator Roland Bänfer to remain close to the placement site 65 mm hoses are easy to handle further optimising fuel-saving concrete pump operations. As soon as the operator has set a desired output via radio remote control, the EOC fuel management automatically regulates the required minimum r.p.m.. Using EOC not only reduces diesel consumption in concrete pumps but also noise level and, last but not least, wear and tear in the machines. When required, this value can be manually “overridden” to set a higher or lower r.p.m. However, fuel is also saved when in “normal operation” mode. 9 PM 3582 GB International 33 By Austin Quier, managing director Putzmeister Ltd., Chesterfield How PMUK performs is dependant on the entire team, and those behind the scenes are every bit as important in delivering quality to the customers. This culture has been reinforced in the systems and structure already developed to achieve certification for BS EN9001-2000. Thirty years of service Thirty years ago, PMUK consisted of just one office and one storeroom – the company moved into this new building in 1981 2004 marks thirty years of Putzmeister’s direct presence in the UK and Ireland, and it is a good moment to reflect on Strengths built on differences It can come as no surprise that, as in other aspects of life, the UK market for Putzmeister products does not always follow the European norm. As a consequence it has been necessary to innovate, look for alternative markets and new applications. The beginnings were certainly humble, just two small rented buildings one in which the first pumps were assembled, the other used as stores and offices. Chesterfield, where the current premises were built in 1981. Over a period of six years more buildings were rented to accommodate the growing demand. This may not have been a glamorous start, but it established the culture of financial strength and self-sufficiency that has become a hallmark of PMUK, and provided the resources to acquire the site in Whilst the buildings are important PMUK is about commitment to supplying quality products, and about people with a commitment to providing the best for their customers, not always succeeding, but willing to learn, and come back stronger for the experience. PMUK can take pride in an People matter the record of Putzmeister Ltd, known within the Putzmeister Group as PMUK. To assess how they have arrived where they are today, and how the company can continue to develop in the future. 36 average length of service over twelve years, but without losing any of the enthusiasm. Mick Ferguson the Service Manager has been with Putzmeister from the beginning, and still finds new challenges, still gets excited by talking a customer through a problem, still looks for ways to improve the service his team provides and how it isdelivered. PMUK invest in training and forward planning to ensure this fund of knowledge and practical experience of the machines, applications and operations is secured for the future. This has helped to make PMUK more responsive to market requirements, and has resulted in a number of successes over the years. The City Pump concept of a small mobile concrete pump was conceived in 1986, and in 1987 the first units were assembled in Chesterfield with 16 m boom and 1005 pump mounted on a 13 t chassis. Initially this model attracted a number of new operators into the pumping market, and has evolved over the years until small concrete pumps now feature in most UK In compliance with the requirements of the British market, Putzmeister developed the City concrete pump series The team (well, almost all of them) of the English PM subsidiary 34 35 pump hire fleets. The BSA1005 D – Primera trailer mounted concrete pump is an example of responding to specific customer needs, and through co-operation developing a new model. This simple, robust unit was introduced in 1998, and has gone on to form the backbone of Putzmeister trailer pump sales in the UK. As with all Putzmeister products this model is subject to continuous development to take advantage of new technology and incorporate new customer led features. The hydraulic Mixokret – M3250HD was developed and assembled in the UK and introduced in 1997 when sales into this sector were somewhat erratic. This new model with hydraulic drive gained immediate market acceptance, and continued to perform strongly through to its replacement by the M760DH in 2001. 10 PM 3582 GB This stationary pump BSA 1005 D “Primera” differs in a few details from the series produced in Aichtal 11 PM 3582 GB International International 40 38 No time for a coat of paint! This philosophy of responding to the market continues to feature strongly, sometimes resulting in small modifications or additional features rather than new models, but still reflecting a focus on the customer, combined with experience, innovation and the determination to achieve a positive outcome. The Italian PM subsidiary was under time pressure to supply a new truck-mounted concrete pump. M 36-Z: The machine Accepted as competent partners which had been ordered at short notice by pump service operators COSSI Spa had to Another feature of the UK is the key role played by specialist hire companies who operate a high proportion concrete pumps and mortar machines in the market. For these companies the equipment is their primary business which means they are particularly focused on raising standards of productivity and price performance across the range. This creates a stimulating environment for PMUK, and one in which there is no room for complacency if they are to continue to feature strongly with hire fleets throughout the UK and Ireland. be in operation on Tuesday of the following week. That meant Putzmeister Italia did not even have time to give the new truck-mounted concrete pump a coat of paint, let alone the final finishing. Instead, the M 36 received just a priming coat – something on which the customer insisted! The reasons: the renovation work on a more than eighty year-old The strength of PMUK’s technical resources is evident in it’s ability to specify and manage in house, industrial pump installations. These include a number of complex waste water treatment projects for companies like Welsh Water and Severn Trent Water. The current major contract is for the supply of two HSP 25100 pumps to a mine infill project in Ireland. 37 12 PM 3582 GB PMUK delivered nine KOS high-density solids pumps and four silos with discharge equipment for a waste water treatment plant in Cardiff, Wales. On the right, two HSP high-density solids pumps in an Irish mine. The Dynajet range of high pressure cleaners are the latest Putzmeister products introduced by PMUK. Whilst these have some overlap with existing equipment and markets, there is a sharp learning curve to appreciate the full potential. This is a positive process in itself enabling them to identify new opportunities to support existing customers, with the 350 mg Plus, and build new markets across the range. For the first time PMUK are using a number of specialist distributors to support the direct sales effort for Dynajet to achieve maximum penetration in this broad-based market. In the meantime, the Cancano reservoir “I“ built in 1922 is in urgent need of renovation. The reservoir lies at an altitude of about 2,000 m and contains approximately 650,000 m3 of water. Work on the 91 m high and 965 m long dam comprises pumping and distributing around 30,000 m3 of concrete which the commissioners, AEM, have contracted to the pump service provider COSSI Spa in the north Italian town of Sondrio. Renovation work commenced in April 2004 (concrete pump was not used until July) and is planned for completion at the end of 2006. reservoir had to be carried out within a PMUK addresses concrete pump operators and new markets with the DYNAJET high-pressure cleaners These qualities are no less important with other users from major companies to small contractors. In all cases a key factor that gives confidence is PMUK’s commitment to a direct presence in the market underpinned by investment in people, parts and service to provide comprehensive support at all levels. Premadio and Braulio. Other hydro-power stations also provide the region and its industries with electricity. very tight schedule. Secure the future At many customer’s PMUK is now dealing with the second generation, and the next few years will see considerable change within the company as all those years of experience bring more people towards retirement. With the right planning in place this an opportunity to pass on the knowledge, enthusiasm and core values that have brought success over the past 30 years, and combine them with new vitality and skills to build the future. This has been a positive process for their customer’s and PMUK must emulate that success. Something which the Italian Alpine region around the small town of Bormio does not lack are rain and snow, which can sometimes be quite heavy. Precipitation in the dams San Giacomo and Cancano “I” and the melt from the neighbouring glacier are collected by the power company AZIENDA ENERGETICA MUNICIPALE DI MILANA (AEM) and used to generate electricity in the power stations at Fraele, The concrete being poured is a C30/37 with a 16 – 22 cm slump and, as a rule, a water/cement ratio of about 0.45. Aggregates consist of broken materials and are up to 50 mm in size. In spite of the addition of a plasticizer and an apparently softsticky consistency (F4), this concrete is not easily pumped. For example, the manometer shows an increase in hydraulic pressure of 260 – 280 bar each time the S-tube is connected. The reason is special additives which are put into the concrete batches in the mix unit. The hydro-electric power station Cancano “I” plays a considerable role in providing the area with a sure supply of electricity The M 36 truck-mounted concrete pump displaying its mere coat of priming in front of the 91 m retaining wall of the dam By the way: The missing coat of paint will be applied to the M 36 “Z” in the winter months, when construction ceases anyway due to the bad weather. So, the coming spring will see renewed and “colourful” activities on the Cancano site! 41 39 13 PM 3582 GB International International 42 Warsaw pump service concreting the “Golden Terraces” building complex Solid building components made of self-compacting concrete In the city of Warsaw next to the Centralna (main railway station) and right opposite the 231 m high-rise Palace of Culture and Science, ING REAL ESTATE is investing around e 250 million in the construction of a multi-functional building complex which goes by the name of “Zlote Tarasy“ which means “Golden Terraces“. Many of the supporting components are made of high-strength, self-compacting concrete – the wall thickness in some of them is up to 150 cm. Putzmeister pumps and booms have been commissioned to deliver and place the considerable quantities of concrete required for the project. 44 On completion, the underground car park will accommodate 1,800 vehicles on four levels. The three storeys above the car park will house numerous shops, restaurants, service providers and a state-of-the-art multiplex cinema. Additionally planned is a hotel with 450 beds. The upper storeys will be rented out as office premises and residential apartments. Sub-contractors bear a great responsibility SKANSKA Sp. z.o.o. as the main contractor is responsible for the mammoth project. As the “Golden Terraces“ are to be multi-functional, the carcass is being constructed as four separate zones differing in their architecture. Whilst SKANSKA is building all of the foundations and sectors 1 and 2 using its own personnel and fleet of machines, sub-contractors HYDROBUDOWER 6 (HB6) have been commissioned with the construction of zones 3 and 4. Both SKANSKA and HB6 are relying on the know-how and technical equipment of specialists in providing concrete pumps – i.e. on BOSTA Beton and WARBUD S.A. Both of these Warsaw pump service companies are deploying several of their PM machines in the construction of the “Golden Terraces“. For example, for work on the 1.5 – 2.5 meter thick floor slab and for placing concrete on floors in zones 1 and 2 at varying heights, BOSTA-Beton used in each case two M 28s and M 42s. Even throughout the night, concreting continues using the BSA 2110 HP-D The Putzmeister MX 32 T takes on the task of concreting in zone 4 from a central position 45 BSA pumps and concrete booms team up The WARBUD company also commenced work initially using their mobile Putzmeister truck-mounted concrete pumps M 36 and M 42. As the height of the building increased and delivery distances of more than 100 m were required, WARBUD switched over to just stationary concrete pumps and placement operations. Since January 2004, a Putzmeister BSA 1409 D and a mechanically slewable concrete boom in sector 3 have formed a concreting unit and in zone 4, a BSA 2110 HP-D has been working together as a team with a stationary concrete boom MX 32 T. 43 Mighty columns, girders and ceiling joists made of self-compacting concrete Building industry booms in Poland According to enquiries carried out by the Frankfurter Allgemeine Zeitung, Poland’s building industry is on a definite road to recovery; this can be attributed to the improved economic situation and resulting investments. In addition to privately financed construction projects, the future will see more and more funding from the EU funds to benefit especially civil engineering and road construction as well as special environmental construction projects. The increasing number of tenders for major projects has contributed to an improved climate in the building industry: alone in the first quarter of 2004, there was an increase of 20 % compared with the figures for the same period in the previous year. (FAZ, 7 June 2004) 14 PM 3582 GB 15 PM 3582 GB International 46 50 48 they are wrapped in an insulating foil for at least 72 hours to ensure the slow release of hydration heat. The result is high-strength building components which have a basic area of 150 x 150 cm on the “Golden Terraces” site and a very fine, smooth surface already prepared for painting. cleaning process and the BSA pump and gate valve are carefully serviced. Whereby operator Zdzieszynski is very particular: “Lubrication is on the agenda, at least once a day!” 52 Maintenance jobs are taken seriously Andrzej Zdziesznski is the operator responsible for the six-year old Putzmeister BSA 2110 HP-D. Before the first load of concrete is delivered, he pumps around 0.75 m3 trial batch through the line. “And then it runs on its own!” As output pressure is never high (e.g. only 150 bar hydraulic pressure at 40 m pump height), the rod side of machine is pressured, i.e. operates “according to quantity”. The delivery line The PM gate valve is hydraulically operated 53 Floor frames clamp the tubular column of the concrete boom taut into the building structure 47 Concrete pump BSA 2110 HP-D with cleaning “gallows” (blue) and gate valve (at the right of the picture) during the climb, supplementary tubes are installed as length adjustments. 49 The climbing process in detail: ■ Extending the climbing formcylinder (30 mm), extracting bolt 2 and complete extension ■ Placing bolt 2 on floor frames, removal of bolt 1 and retracting climbing cylinder ■ The process is repeated The MX boom is situated on a 20 m high tubular column led through small openings in the floor and supported in the storeys by three frames. The floor frames fulfil two functions: On the one hand, they clamp the tubular column taut and on the other hand, they absorb the introduction of vertical load moments in the structure of the 16 PM 3582 GB In the winter months, the two pump services can carry out pours using pre-heated aggregates up to a temperature of -12°C. The concrete is pumped up to the eighth storey whereby the delivery line is now almost 200 m long. In addition to WARBUD’s graduate engineer Adam Wleklak, the company has three other employees constantly on site for concrete jobs in zones 3 and 4. “Cooperation with our customer HYDROBUDOWA is simply excellent. Our colleagues from HB 6 give us every support when things begin to get tight and we understand when sometimes a piece of formwork isn’t ready according to schedule!” ■ Attaching the climbing cylinders and bolt 1 building. With the help of an hydraulic climbing device, the height of the concrete boom can be adjusted to building progress. The climbing process is easily and quickly carried out by using two lift cylinders which are connected with the hydraulic system of the MX boom. The delivery line remains attached to the tubular column transfers the concrete to the pumps, each batch is tested in their own mobile laboratory. In general, the concrete used for the project is of strength class C50/60 and C35/45. Furthermore, different components are made of self-compacting concrete (SCC) of the same strength. Of the total quantity of concrete (156,000 m3 for the building and 56,000 m3 for the foundation), about 4,800 m3 is SCC material. The degree of slump is about 17 cm. The concrete is supplied by two mixer plants outside of Warsaw, which together have a capacity of 140 m3/h. Before WARBUD 51 is emptied using a gate valve, which steers the concrete residue still in the line via a pipe bridge - a so-called „gallows“- into a truck mixer. The valve is connected to the hydraulic circle of the concrete pump agitator and can be controlled by means of remote control push button. As soon as the pipe line is empty, the whole of the concrete delivery system undergoes a thorough A construction piece wrapped around with foil releases hydration heat only slowly Diplom-Ingenieur Adam Wleklak Self-compacting concrete means less formwork Self-compacting concrete is used for example in sections where a vibrator cannot reach. Or because the high degree of early strength of SCC means the formwork can be removed sooner, for example, from the supporting piles where formwork may be removed in most cases already after 12 hours. Immediately after the removal of formwork from these building components, 54 PM representative – a strong partner Not only BOSTA and WARBUD but also many other Polish concrete pump companies and building contractors are provided with support from the PM representative ALLTECH, both on the purchase of a machine and its servicing. Already in the “Golden Terraces“ planning phase, ALLTECH specialists were able therefore to give the main contractor SKANSKA practical tips regarding optimum concrete pours for this complex construction site. ALLTECH, registered in Warsaw and Sopot (near Gdansk) has been representing Putzmeister AG in Poland since 1992. The 15 employees at ALLTECH – four of them exclusively responsible for service and maintenance – deal with consultation, sales, spares supply and customer service for the PM machines in Poland. The most important wearing parts are kept in stock in all three locations, or can be ordered at short notice. When required, the service team can be quickly on the spot to tend the machines. Trained ALLTECH employees also carried out the required customer service jobs at the “Golden Terraces“ site – to the total satisfaction of both the pump service companies and the responsible contractor. 17 PM 3582 GB Tunnel Construction Practical Tip ® 55 Sika -PM wet spraying systems back up tunnel advance work along the Mediterranean Highway Work is currently on-going on a further section of the Mediterranean Highway in the south of Spain, where three Sika®-PM500 P type concrete shotcrete spraying devices are being employed in backing up advance work in each of the three twin-bore tunnels (total length 5.04 km) along the total stretch of 9 km. The section under construction between La Herradura and Taramay (Almuñécar area) is part of the “Autovía del Mediterráneo” which will link up the cities of Cádiz and Gibraltar in the South of the Iberian Pensinsula and Barcelona in the North East. The 9.1 km long section which is being built by U.T.E. LA HERRADURA, a joint venture comprising the construction companies PLODER S.A., AZVI S.A. and OBRAS SUBTERRÁNEAS S.A. runs over a distance of 1.8 km joint, 4-lane carriageway and then over a distance of 7.3 km in each direction of traffic as a separate route through three twin-bore tunnels (in total 2.52 km long) and four bridges (in total 2.17 km long). The project commissioners, the Ministerio de Fomento, had initially calculated construction costs totalling A 180 million for the complex track routing; which meant the highest motorway costs in the whole of Europe – A 20 million for each kilometre. Construction costs are now put at A 157 million. Work commenced in March 2003 and completion is expected for September 2006. Whereas the bridges consist of two parallel girders each 350 m, 2 x 580 m and 630 m long, the tunnels in each direction of traffic 18 A newcomer to the Putzmeister AG product range is a pneumatic pinch valve for the end hose. The idea itself i.e. to „squash the ends of the hose together“ in order to avoid concrete leakage is known. This new squeeze valve is made completely of rubber and is simply pushed over the concrete end hose. It is opened and closed pneumatically via radio remote control automatically. With only a few seconds delay, the valve closes or opens the end hose as soon as the operator has given the command “Pump ON” or “Pump OFF” via radio remote control. The pinch valve can be completely switched off at any time via a toggle switch on the control cabinet. The Sika®-PM500 P have an extensive working reach and are therefore well suited for shotcreting jobs on high embankments as well as in underground chambers and tunnels. Dimensions range from 4.5 m to 17.5 m. The Putzmeister twin-piston pump installed lengthwise at the rear of the truck has over 1000 mm lift and 180 mm delivery cylinder diameter, as does the stationary pump BSA 1005. With a capacity of 30 m3/h and just 19 strokes/minute, this core pump is simply ideal for vibration-free shotcreting jobs. The horizontal automatic on the spraying arm has proven very helpful in shotcreting work in the six LA HERRADURA tunnel bores. This device enables the cradle to be extended by 3 m and held in a horizontal position. In conjunction with the highly manoeuvrable head of the spraying nozzle this results in an extraordinarily even spray pattern with little rebound. The pinch valve can be completely switched off at any time via a toggle switch on the control cabinet 58 56 All of the Sika®-PM500 used at the LA HERRADURA site are standardly equipped with a liquid metering device (Sika®Aliva-403.5) and one or two tanks for concrete accelerating agent (capacity in each case 1000 l). As the site already provided compressed air lines in the tunnels, the spraying devices were not supplied with their own compressors. A total volume of 75,000 m3 of shotcrete was placed in the six tunnels. The pumping of concrete for the tunnels – approximately 80,000 m3 in strength class C40/50, 180,000 m3 highstrength concrete C 60/75 and 100,000 m3 in strength class C25/30 – was placed using stationary concrete pumps, which had been previously used for building the bridge piers. Here, too, only Putzmeister machines were used. One of three Sika®-PM 500 P seen here placing concrete for the upper arches of a tunnel portal of ARGE “LA HERRADURA“ (Photo: José Luis Rivas, Sika®) PM 3582 GB 60 are designed as single structures. All of the six bores (2 x 2170 m, 2 x 278 m and 2 x 220 m) have a full section of approximately 110 m3 and advance work is progressing at 6 to 10 m per day – depending on whether supporting arches type THN 21 and THN 29 need to be installed or not. The three mobile shotcrete Sika®-PM500 P spraying devices have been operating on individual construction site sections since September. They were first used to secure the slope area around the portals and in the meantime are needed to quickly secure tunnel excavation work according to the new Austrian tunnel construction process. As the machines are equipped with fourwheel drive and four-wheel steering they are easily manoeuvrable even in difficult terrain. Mess-free formwork The horizontal automatic of the telescopic arm proved to be very helpful when securing excavation work with shotcrete (Photo: José Luis Rivas, Sika®) 57 As no metal collars or metal rollers have been used, it is, on the one hand, irrelevant at what height the rubber collar is attached to the hose. On the other hand, the new switch-off valve is so light, that when fitted to the standard boom end hose, stability is not impacted. That means that the end hose need not be shortened by one meter, as is usually the case. The pinch valve is placed over the end hose like a collar and is activated pneumatically 61 59 An inside view of the closed pinch valve 19 PM 3582 GB International International 64 France – the land of the rotor fans For years now, the demand for Putzmeister rotor PUMI s among our ® neighbours in France has been considerably higher than that for PUMI®s with a piston pump. The rotor system – in France it is also known as “ROMIX” – is so well-known and successful that some customers would like to install the rotor onto a “normal” truck-mounted concrete pump with boom. Putzmeister is only too pleased to put this request into practice. We came across one of these truck-mounted concrete pumps from the BQF series on a typical construction site south of is part of the large fleet of vehicles belonging to BETON DE FRANCE, a pump service company operating all over France. Operator Alain Meroy has been working on the rotor pump for three years delivering a whole range of different materials. In the evening, he does not go back to his depot, but takes his ROMIX home with him! “That’s better for me because I save myself the trip to the depot and in the morning, I can drive straight to the construction site. All the many traffic jams in and out of Paris mean you need to calculate extra time to get to the site punctually”, he explained. As the operator and the machine are practically left to their own devices, the BQF is equipped with all the accessories needed for “an emergency”. Paris. The machine is a BQF 24.08, built in 1999. The rotor pump with a 24 m Z-fold boom 67 62 This morning, Alain Morey is on his way to his first job in the what used to be rural landscape around Paris to place concrete 63 foundations in the garden of a 300 year-old farmhouse, 20 m3 normal concrete, boom tip extended with a 15 m hose, lots of time spent just waiting – the usual situation. The large hopper on the rotor pump is easy to charge 65 Waiting for concrete At 7.15 a.m., the rotor pump arrives at the construction site. In half an hour, the pump is ready for operation. The boom has been placed over the wall in position and the 100 mm pipe and delivery line have been connected with a reducer. It’s late – and around 9.00 a.m. the first of three truck mixers turns up. So there is enough time for a chat at the vehicle and then for an espresso with the PM visitor in the café next door. Along the way, we are told that Alain Meroy pumps using a 4,000 m3 rotor hose, a wearing part, which is replaced about 3 or 4 times a year. “No – we don’t just turn the hose around in order to lengthen its service life”, states operator Meroy clearly, and he goes on to tell us all about the different materials his rotor delivers, with never a word of complaint! “I pump everything the pinch valve can cope with – whatever happens to come along: lean concrete, lean mortar, steel fibre reinforced concrete, light-weight concrete, that means materials which would not be so suitable for a piston pump. So, I am never at a loss for work!“ The hose is placed around the side of the building The 24 m boom serves as a “pipe bridge” taking the garden wall in its stride 66 Even a pump hose has only one life It doesn’t happen too often but occasionally it has been observed that after the rotor hose has dealt with a certain quantity it is not replaced, but simply turned around. This attempt assumes saving costs and extending the service life of the wearing part. Jörg Herrmann, head of the Central Service Station at PM AG in Aichtal doesn’t think much of such reputedly economizing measures: “It takes more time to turn the pump hose around than it does to replace it with a new one because the hose spout must be removed from the ends and then pushed on again after the hose has been turned. And afterwards, the operator still has a worn rotor hose, in which the fabric lining has been subjected to great stress. The risk of the hose bursting is therefore very high, And all that just to save A 840 for a new rotor hose? There is nothing to be gained from it, you only lose out!” No need to dispose of concrete residues – saving detours and time This job also reveals other strengths of the rotor system. The whole of the concrete can be pumped forward into the formwork - an important feature - as otherwise there would be no way of cleaning the pump system and the delivery line on the construction site. This speciality is also an important reason that the M 24 rotor concrete pump earns its keep on average at two sites each day in spite of frequent traffic congestions. It would have cost operator Meroy a lot of time in those traffic conditions to drive off to the next disposal site. 20 PM 3582 GB When the truck gets stuck in a jam, there’s time for a chat for the operators Without holding up the flow of traffic, the BFQ 24.08 can be set up along the road 21 PM 3582 GB Domestic Domestic 69 Formwork dismantled just 16 hours day following placement of high-strength concrete One-side support on Neckar weir Well-conceived site logistics, modern The walls of the Neckar weir in formwork methods and a reliable fleet of machines are today’s essentials when it stationary PM concrete pump type BSA 1408 E took over the delivery of concrete via a high-pressure pipeline to the stationary boom MX 32 T. Mittelstadt were renovated in the summer months using a Putzmeister BSF 42.16 H. comes to saving time and money on highrise projects. The latest example of rapid project completion are the 91 m high RWE towers in Dortmund where a stationary Putzmeister concrete pump and a concrete boom climbing up with the formwork platform played a decisive role. In the early stages the construction company responsible for carrying out the work OEVERMANN GmbH & Co. KG (Münster, branch in Dortmund) rented truck-mounted concrete pumps with longreach booms from local pump service companies for placing concrete for the floor slab, the ceilings in the ground floor and the first four upper storeys. Afterwards, a The narrow banks provided very little The RWE tower is built on a lens-shaped foundation in the middle of which is the central core of the building. Whilst OEVERMANN installed MEVA formwork for the ceilings, the stationary concrete boom was anchored to a DOKA formwork platform which was supported in the elevator shaft. Half of the ceiling area and the walls of the building’s core were to be reinforced and simultaneously concreted wet on wet in a five-day rhythm. Using hydraulic cylinders, the formwork platform climbed upwards together with the MX boom. One storey every five days (3.45 m). The concrete used was of strength class C 50/60 of which 120 m3 went into the two ceiling sections in each storey and around 49 m3 into each half of the shaft. space for setting up the machine. The wall runs from the Cloister Mill about 200 m upstream, separating the Neckar from its old natural river bed. The surface of the sloping shoulder of the weir had been increasingly washed away over the years. The work immediately next to and in the Neckar had been planned to take place at low water. After placing an improved sub-base, a BSF 42.16. H belonging to BNA Betonpumpendienst (Reutlingen) delivered about 100 m3 of C 20/25 concrete to the masonry. Pump operator Achim Baierl needed not only sure instincts when setting up the machine but also OSS – one-sided supports as only a very narrow pedestrian or cycle path – in former times a towpath – could be considered as a possible location which could also be reached by the truck mixers. Achim Baierl is a fully qualified, trained and tested concrete pump operator and was therefore very much aware of the risks of setting up the machine so close to the river banks and of the need to comply with safety regulations. 70 71 The BSA 1408 E being charged from a truck mixer Delivering concrete through high-pressure line Half of the ceiling area and the walls of the building’s core were to be reinforced and simultaneously concreted wet on wet 68 Concrete was delivered from the BSA stationary pump as far as the boom through a high-pressure pump line, totalling 120 m in length. It comprised for the most part ZX pipes which were supplemented on two short sections by high-pressure SK lines (130 bar operational pressure). At the interface between riser pipe and stationary boom pipework, a delivery hose – likewise able to withstand 130 bar – ensures flexible transition. Concrete was installed up to a maximum of 30 m3/h. During the whole period of installation, the piston side of the BSA 1408 E was under pressure. At a height of 91 m (max. height of the facade), hydraulic pressure was about 220 bar which equals concrete pressure of 67 bar (i = 3.3). To facilitate cleaning, a gate valve was installed into the delivery line about 12 m downstream of the BSA stationary pump. From Spring 2005, the 91 m RWE office high-rise will provide the Ruhr metropolis with yet another point of orientation, visible for miles around. The RWE tower in Dortmund is in the immediate vicinity of the railway station and on completion, will boast a 3-storey underground car park as well as 25,000 m3 of modern office space. The project costs amount to about A 50 million. A construction time of just 18 months has been scheduled (from November 2003 to May 2005) for the 22-storey high-rise until it is handed over as turnkey premises to the tenants. 22 PM 3582 GB Concrete pump and end hose in view – operator Achim Baierl can control concrete placement using the EBC radio remote controls down to the last millimetre 23 PM 3582 GB Applications Shotcrete job using universal pump Telford football stadium, about 80 kilometres north west of Birmingham was renovated and converted at a considerable financial cost. The building measures Putzmeister AG, Max-Eyth-Str. 10, D-72631 Aichtal PSdg, Deutsche Post AG, Entgelt bezahlt, E 60458 Imprint: Publisher Putzmeister AG Max-Eyth-Str. 10 · D-72631 Aichtal Tel. +49 (71 27) 599-0 · Fax 599-520 Internet: http://www.putzmeister.de E-mail: pmw@pmw.de ■ Editor: Jürgen Kronenberg ■ Design: Friedrich Pippich 73 comprised a new leisure centre complete with swimming pool. The construction company BUCKINGHAM POOLS used a small concrete pump BSA 702 D which had been rented from machine rentals CBL PLANT HIRE at short notice for lining the reinforced pool basin with shotcrete. 72 Placing 12 m3 of schotcrete per hour by hand The BSA 702 D is excellently suited for shotcrete jobs The shotcreting job began at the lower end of the pool and was followed by evenly shotcreting the walls. A 70 mm slump material was used for the first shotcrete layer, later the vertical areas were layered with a 50 mm slump concrete. A separate compressor provided the compressed air required for the shotcreting process where- by the compressed air was fed into the delivery stream just in front of the nozzle. Effective spray performance was 12 m3/h concrete, an astonishingly high quantity for the little universal concrete pump with manually operated nozzle. Putzmeister designed the compact BSA 702 D as a multi-functional concrete pump with a maximum output of 20 m3/h to de- Your fax for further information ■ Would you like more information on certain topics in this edition of Putzmeister Post? If so, just copy this page, make a cross next to the topics you are interested in and fax the form to us. We will then send you detailed information immediately. ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ Truck-mounted concrete pump M 52-5 „Multi-Z“ ..............................MT 3231 Truck-mounted concrete pump M 42-4 „R“ ........................................MT 2391 Truck-mounted concrete pump M 36.4 „Z“..........................................BP 3180 Truck-mounted concrete pump M 28-4 „Z“ ........................................MT 3512 Truck-mounted concrete pump BQF....................................MT 1085, BP 3536 Truck-mounted concrete pump MOLI ..................................................BP 3530 City-pump............................................................................................BP 2844 Pneumatic squeeze valve ....................................................................BP 3551 Stationary concrete pumps ..................................................................BP 2632 Fine concrete pump BSA 702 D ........................................................MM 3541 Stationary placing booms ..................................................................MT 2059 Mechanical distributors RV 10 and RV 12 ..........................................MT 3534 Delivery line systems..........................................................................PM 2300 Concrete spraying system Sika®-PM500 P..........................................TS 3573 DYNAJET high pressure cleaner ........................................................MM 3474 KOS-sludge pump ................................................................................IP 1082 HSP-sludge pump ................................................................................IP 1971 liver shotcrete, mortar and self-levelling screed. Just like the larger models in the BSA series, the 702 D is equipped with hard chromium-plated delivery cylinders, pressure-proof S-transfer tubes and infinitely variable output adjustments. The horizontally dual-division pump hopper can be folded down sideways and makes for easier cleaning. Name ......................................................................................................... Company ................................................................................................... Position ..................................................................................................... Street ......................................................................................................... Post Code/City .......................................................................................... Tel. No. ...................................................................................................... E-mail ........................................................................................................ Putzmeister AG Max-Eyth-Str. 10 · D-72631 Aichtal P.O.Box 21 52 · D-72629 Aichtal Tel. +49 (71 27) 599-0 Fax +49 (71 27) 599-520 Internet: http://www.putzmeister.de E-mail: pmw@pmw.de PM 3582 GB All rights reserved. Subject to technical amendments without notice. The illustrations in some cases show special-purpose machine designs and snapshots of site practice which do not always comply with the regulations determined by professional bodies.© 2004 by Putzmeister Printed in Germany (2.50412 RR)